Decorative sheet and decorative member

Abstract

To provide a decorative sheet and a decorative member having texture close to texture of a surface of wood or stone used in a housing material and having excellent designability.SOLUTION: A decorative sheet 1 comprises: a pattern layer 3, a transparent thermoplastic resin layer 4 and a surface protective layer 5 laminated in order on one surface of a colored thermoplastic resin layer 2; a gloss-matte expression pattern portion 6 laminated on the other surface of the colored thermoplastic resin layer 2, arranged in sync with the pattern of the pattern layer 3, and made of a material that has light absorption properties with respect to light of a predetermined wavelength; and an embossed portion 5a formed in the portion of the surface protective layer 5 overlapping the gloss-matte expression pattern portion 6 in a plan view. The surface of the surface protective layer 5, including the embossed portion 5a, has a load of 1000 g or more at which scratches occur during the Hoffmann scratch test and a load of 2 kg or more at which scratches occur during the coin scratch test, and a hardness of 2B or more in the pencil hardness test according to JIS K 5600.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a decorative sheet and a decorative member. [Background technology]

[0002] Conventionally, decorative materials in which a decorative sheet is bonded to a wooden substrate such as plywood, MDF (medium density fiberboard), or particle board, a resin substrate, an inorganic non-combustible substrate, or a metal substrate have been widely used (see, for example, Patent Document 1). Furthermore, the design of the decorative sheet is often imitated to resemble the surface of wood, stone, or the like. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5045180 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, decorative sheets tend to have a flat surface texture compared to real wood or stone. Actual wood and stone have different textures due to differences in the surface material and structure, resulting in unevenness in different locations. Areas with different textures often also have different colors, but this is not expressed in decorative sheets, and in terms of design, more expensive real ones are superior.

[0005] The present invention has been made in consideration of these points, and aims to provide decorative sheets and decorative members that have a texture similar to the surface texture of wood, stone, etc. used in building materials, and that have excellent durability and design properties. [Means for solving the problem]

[0006] According to one aspect of the present invention, there is provided a decorative sheet comprising a pattern layer, a transparent resin layer, and a surface protective layer laminated in this order on one side of a colored resin layer; a matte gloss pattern portion laminated on the other side of the colored resin layer, arranged in sync with the pattern of the pattern layer and formed of a material that is light-absorbent for light of a predetermined wavelength; and an embossed portion formed on the surface protective layer in a portion that overlaps with the matte gloss pattern portion in a planar view, wherein the surface protective layer including the embossed portion is scratched at a load of 1000 g or more when a Hoffman scratch test is conducted in which the surface of the surface protective layer including the embossed portion is scratched with a load gradually increased from 200 g to 2000 g; the surface protective layer including the embossed portion is scratched at a load of 2 kg or more when a coin scratch test is conducted in which a 10-yen coin is brought into contact with the surface of the surface protective layer including the embossed portion and scratched while increasing the load by 1 kg increments within a range of 1 kg to 5 kg; and the hardness of the decorative sheet is 2B or more when measured by a pencil hardness test in accordance with JIS K 5600.

[0007] According to another aspect of the present invention, there is provided a decorative member comprising a substrate and the decorative sheet provided on at least one surface of the substrate, wherein the substrate is any one of a wood substrate, a resin substrate, a non-flammable substrate, and a metal substrate. [Effects of the Invention]

[0008] According to one embodiment of the present invention, decorative sheets and decorative members can be easily obtained that have a texture similar to the surface texture of wood, stone, and other building materials, and that have excellent durability and design. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a cross-sectional view schematically illustrating an example of a decorative sheet according to one embodiment of the present invention. [Figure 2] 1 is a process diagram showing an example of a manufacturing process for a decorative sheet according to one embodiment of the present invention. [Figure 3] 1 is a cross-sectional view schematically illustrating an example of a decorative member according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present technology will be described with reference to the drawings. The drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, etc., differ from the actual ones. The layers do not necessarily have to be stacked in the order shown in the drawings, as long as they are within the scope of the present disclosure. Layers not shown in the drawings may also be added. Furthermore, the embodiments shown below are illustrative of configurations that embody the technical ideas of the present disclosure, and the materials, shapes, structures, etc. of the components of the present disclosure are not limited to those described below. The technical ideas of the present disclosure may be modified in various ways within the technical scope defined by the claims.

[0011] Furthermore, the directions of "left and right" and "up and down" in the following explanation are merely definitions for the convenience of explanation and do not limit the technical idea of the present disclosure. Therefore, for example, if the page is rotated 90 degrees, "left and right" and "up and down" are read interchangeably, and if the page is rotated 180 degrees, "left" becomes "right" and "right" becomes "left."

[0012] [Configuration of decorative sheet] 1, a decorative sheet 1 according to one embodiment of the present invention is formed by laminating, in this order, a colored thermoplastic resin layer (colored resin layer) 2, a pattern layer 3, a transparent thermoplastic resin layer (transparent resin layer) 4, and a surface protective layer 5, and an embossed portion (embossed shape) 5a is formed in the surface protective layer 5. In addition, a matte gloss pattern portion 6 is formed on the surface of the colored thermoplastic resin layer 2 opposite the pattern layer 3, and a primer layer 7 is formed so as to cover the matte gloss pattern portion 6 and the colored thermoplastic resin layer 2.

[0013] [Colored thermoplastic resin layer] Examples of materials for the colored thermoplastic resin layer 2 include polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, acrylic acid ester, and methacrylic acid ester. Among these, polyolefin-based resins are preferred in terms of environmental compatibility, processability, and cost. The grade and composition of the resin can also be selected taking into consideration ease of sheeting, printability, and suitability for bending.

[0014] The hue of the colored thermoplastic resin layer 2 can be appropriately selected as the base color of the picture layer 3. The colored thermoplastic resin layer 2 can be colored, for example, by mixing or kneading a colorant such as a pigment into the thermoplastic resin during sheeting. Alternatively, the colored thermoplastic resin layer can be provided as a solid ink layer using a coating or printing method before providing the matte gloss pattern portion 6. The thickness of the colored thermoplastic resin layer 2 is not particularly limited.

[0015] [Picture layer] The design layer 3 is a printed layer on which a design pattern is printed to impart design to the decorative sheet 1. Known printing methods can be used to form the design layer 3. The printing method is not particularly limited, but gravure printing is preferred considering productivity and design quality. For example, if the colored thermoplastic resin layer 2 is available in a rolled state, printing to form the design layer 3 can be performed using a roll-to-roll printing device. Other printing methods include offset printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, and transfer printing from a transfer sheet. When using such printing methods, the design pattern of the design layer 3 can be formed by multicolor printing using the usual process colors of yellow, red, blue, and black, or by multicolor printing using special colors, in which plates of the individual colors that make up the design pattern are prepared.

[0016] Furthermore, the pattern of the pattern layer 3 may be any pattern, taking into consideration the design of the flooring or fittings. For example, a marble grain pattern can be used to evoke the image of a stone floor such as marble. For example, various wood grains or cork can be used as the pattern for a wood-based design. In addition to patterns of natural materials, artificial patterns based on these motifs or geometric patterns can also be used. Other examples of patterns include wood grain patterns composed of spring wood and autumn wood regions and vessels in the cross section of tree rings, leather (grain) patterns, stone grain patterns on the surface of stone such as marble, granite, and sandstone, sand grain patterns, tile patterns, brickwork patterns, fabric patterns, geometric shapes, letters, symbols, abstract patterns, floral patterns, landscapes, characters, and the like.

[0017] Printing ink is a mixture of a solvent and solid components such as a colorant and a binder resin. Examples of solvents include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water. The solvents may be used alone or in combination of two or more.

[0018] Examples of binder resins include chlorine-based resins, urethane resins, acrylic urethane resins, acrylic resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins (nitrocellulose), and cellulose acetate resins. Examples of chlorine-based resins include polyvinyl chloride resins such as polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, ethylene-vinyl chloride copolymers, vinyl chloride-vinyl acetate copolymers, and vinyl chloride-vinyl acetate-(meth)acrylic copolymers, as well as polypropylene chloride and chlorinated polypropylene. Here, (meth)acrylic means acrylic or methacrylic. The binder resin may be a single type or a combination of two or more types.

[0019] Examples of colorants include inorganic pigments such as carbon black, iron black, titanium white (titanium oxide), antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. The colorants may be used alone or in combination of two or more.

[0020] Here, the solvent contained in the printing ink will eventually volatilize, so the design layer 3 is formed mainly from solid components such as colorants and binder resins.

[0021] The printing ink may also contain other components such as stabilizers, plasticizers, catalysts, and curing agents. The printing ink may be selected based on the printing method. It is preferable to select the printing ink taking into consideration adhesion to the colored thermoplastic resin layer 2, printability, and weather resistance as a flooring material or fitting. The thickness of the design layer 3 can be adjusted appropriately, taking into consideration the decorative properties required of the design layer 3, the three-dimensional formability of the decorative sheet 1, and the like. The thickness of the design layer 3 is typically 1 μm or more and 1 mm or less, preferably 2 μm or more and 0.1 mm or less, and more preferably 2 μm or more and 50 μm or less.

[0022] To improve the adhesion between the design layer 3 and the transparent thermoplastic resin layer 4, an adhesive layer (not shown) may be provided on the surface of the design layer 3 that comes into contact with the transparent thermoplastic resin layer 4. By strengthening this adhesion, the decorative sheet 1 can be given the ability to be bent to conform to curved surfaces and right-angled surfaces. The resin used in the adhesive layer (not shown) is not particularly limited, and for example, a two-component curing urethane resin can be used. The adhesive resin may also be adhered to the design layer 3 with a urethane adhesive. For example, a coating device or a gravure printing device can be used to apply the resin used in the adhesive layer (not shown).

[0023] Furthermore, a glittering layer (not shown) may be provided between the picture layer 3 and the transparent thermoplastic resin layer 4 in order to suitably impart design effects such as a sense of depth and brightness to the decorative sheet 1. The glittering layer (not shown) preferably contains a glittering pigment and a binder resin. Examples of glittering pigments include pearlescent pigments and metallic pigments. Pearlescent pigments are particularly preferred because they can prevent a decrease in the light transmittance of the glittering layer and therefore do not impair the visibility of the picture layer 3.

[0024] Pearl pigments are pigments that can impart pearlescent luster. Examples include base particles whose surfaces are coated with a metal oxide. The base particles are preferably scaly particles such as mica. Examples of metal oxides include oxides of metals such as titanium, iron, zirconium, silicon, aluminum, and cerium. The metal oxides may be used alone or in combination. Specific examples include oxide-coated mica such as titanium mica, iron oxide-coated mica, iron oxide-coated mica titanium, Prussian blue-coated mica titanium, Prussian blue-iron oxide-coated mica titanium, chromium oxide-coated mica titanium, carmine-coated mica titanium, organic pigment-coated mica titanium, titanium oxide-coated mica, and titanium oxide-coated synthetic mica; oxide-coated glass powder such as titanium oxide-coated glass powder and iron oxide-coated glass powder; oxide-coated metal particles such as titanium oxide-coated aluminum powder; scaly flakes such as basic lead carbonate, lead hydrogen arsenate, and bismuth oxide chloride; fish scale powder, shell fragments, and pearl fragments.

[0025] Examples of metallic pigments include pigments made of metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, gold powder, and silver, and alloys of these metals. The metallic pigments may be used alone or in combination of two or more.

[0026] From the viewpoint of providing excellent design effects, for example, when forming the glittering layer using gravure printing, the average particle diameter of the glittering pigment is preferably 40 μm or less, and more preferably 30 μm or less. From the same viewpoint, the ratio of [average particle diameter of glittering pigment / thickness of glittering layer] is preferably 0.01 or more and 15 or less, and more preferably 0.5 or more and 10 or less. In this specification, "average particle diameter" refers to the value that can be determined as the mass average value D50 in particle size distribution measurement using laser light diffraction method.

[0027] Examples of binder resins include thermoplastic resins and cured products of curable resin compositions, with the cured products of curable resin compositions being preferred from the viewpoint of durability. Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation curable resin compositions. From the viewpoint of interlayer adhesion, the cured products of thermosetting resin compositions are preferred.

[0028] Examples of thermosetting resin compositions used in the glossy layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, aminoalkyd resin compositions, melamine resin compositions, guanamine resin compositions, urea resin compositions, and thermosetting acrylic resin compositions. These thermosetting resin compositions include monomers and / or prepolymers constituting each resin, and a curing agent added as needed. The ionizing radiation-curable resin composition used in the glossy layer can be the same as the ionizing radiation-curable resin composition of the surface protective layer 5 described below.

[0029] The content of the glittering pigment in the glittering layer is preferably 10 parts by mass or more and 90 parts by mass or less, and more preferably 50 parts by mass or more and 80 parts by mass or less, relative to 100 parts by mass of the binder resin. By setting the content of the glittering pigment to 10 parts by mass or more, it is possible to impart a sufficient glossy appearance, and by setting it to 90 parts by mass or less, it is possible to prevent impairment of the visibility of the picture layer 3. From the same viewpoint, the thickness of the glittering layer is preferably 1 μm or more and 30 μm or less, and more preferably 5 μm or more and 20 μm or less.

[0030] The glittering layer can be formed into any pattern depending on the design desired. Examples include wood grain, leather, stone, sand, tile, brickwork, fabric, geometric shapes, letters, symbols, abstract patterns, floral patterns, landscapes, and characters. It is preferable that the arbitrary pattern have shading to further enhance the design effect. Shading may be formed by varying the size or thickness of the halftone dots, but it is preferable to form it by varying the density of the halftone dots (i.e., the size of the halftone dots is uniform and the shading is formed by the density of the halftone dots).

[0031] The glittering layer can be formed, for example, by applying a coating liquid containing a glittering pigment and a binder resin using a general-purpose printing method such as gravure printing. When the shade of the glittering layer is formed by the density of halftone dots, the halftone dots on the printing plate can be formed using an FM (frequency modulation) screen.

[0032] [Transparent thermoplastic resin layer] The transparent thermoplastic resin layer 4 is a resin layer that provides thickness and depth for design purposes, as well as protecting the design layer 3 and imparting good surface properties to improve the weather resistance and abrasion resistance of the decorative sheet 1. The material for the transparent thermoplastic resin layer 4 is not particularly limited, and examples include vinyl chloride resin, acrylic resin, and polyolefin resin (polypropylene resin, polyethylene resin). Polyolefin resins are particularly preferred in terms of environmental compatibility, processability, and price. The grade and composition of the resin can be selected taking into consideration not only environmental compatibility, processability, and price, but also ease of sheeting, printability, and suitability for bending. When selecting a material for bending, it is important to consider the prevention of whitening or cracking at the bent portion.

[0033] A lamination method can be used as a method for forming the transparent thermoplastic resin layer 4. Furthermore, for example, when the transparent thermoplastic resin layer 4 and an adhesive layer (not shown) are formed simultaneously, a method can be used in which they are formed by co-extrusion. The thickness of the transparent thermoplastic resin layer 4 is not particularly limited.

[0034] [Surface protective layer] The surface protective layer 5 is a layer that imparts surface properties such as abrasion resistance to the decorative sheet 1. The surface protective layer 5 also adjusts the surface gloss of the decorative sheet 1. The surface protective layer 5 may be a single layer or multiple layers. For example, the surface protective layer 5 may be formed by providing two layers, a first surface protective layer (not shown) and a second surface protective layer (not shown), in this order on the transparent thermoplastic resin layer 4. When providing a surface protective layer 5 consisting of a first surface protective layer (not shown) and a second surface protective layer (not shown), each layer may be applied and the coating cured using a known coating device, heat drying device, or ionizing radiation irradiation device depending on the type of curable resin.

[0035] The surface protective layer 5 is primarily composed of a curable resin. That is, it is preferable that the resin component of the surface protective layer 5 is substantially composed of a curable resin. "Substantially" refers to, for example, 80 parts by mass or more when the total resin is 100 parts by mass. The surface protective layer 5 may contain weathering agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, etc., as needed.

[0036] The material for the surface protective layer 5 is not particularly limited, and examples thereof include ionizing radiation-curable resins and two-component curable urethane-based resins. The ionizing radiation-curable resin is not particularly limited. For example, a transparent resin primarily composed of a prepolymer (including oligomers) and / or monomer containing a radically polymerizable double bond in the molecule that can undergo polymerization and crosslinking upon exposure to ionizing radiation such as infrared, ultraviolet, or electron beams can be used. These prepolymers or monomers can be used alone or in combination. Specific examples of prepolymers or monomers include compounds containing radically polymerizable unsaturated groups such as (meth)acryloyl groups and (meth)acryloyloxy groups, and cationically polymerizable functional groups such as epoxy groups in the molecule. Polyene / thiol-based prepolymers, which are a combination of polyene and polythiol, are also preferred. Here, the term "(meth)acryloyl group" refers to an acryloyl group or a methacryloyl group.

[0037] Examples of prepolymers having a radically polymerizable unsaturated group include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, silicone (meth)acrylate, etc. The molecular weight of these is preferably about 250 to 100,000.

[0038] Furthermore, examples of the monomer having a radically polymerizable unsaturated group include monofunctional monomers such as methyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, and phenoxyethyl(meth)acrylate. Examples of the polyfunctional monomer include diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0039] Examples of prepolymers having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol-type epoxy resins and novolac-type epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Examples of polyene-based prepolymers include those obtained by adding allyl alcohol to both ends of polyurethanes made from diols and diisocyanates, and examples of thiol-based prepolymers include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

[0040] The ionizing radiation may be, for example, electromagnetic waves or charged particles having energy sufficient to cause a curing reaction of molecules in an ionizing radiation-curable resin (composition). Examples of the curing reaction include crosslinking and curing reactions. The ultraviolet light source may be, for example, an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, or a metal halide lamp. The wavelength of the ultraviolet light is preferably, for example, 190 nm or more and 380 nm or less. The electron beam source may be, for example, an electron beam accelerator such as a Cockcroft-Walton type, a Van de Graaf type, a resonant transformer type, an insulating core transformer type, a linear type, a dynamitron type, or a high-frequency type. In particular, those capable of irradiating electrons having an energy of 100 keV or more and 1000 keV or less (more preferably, an electron having an energy of 100 keV or more and 300 keV or less) are preferred.

[0041] The two-component curing urethane resin is not particularly limited. For example, a resin containing a polyol component having OH groups as a base component and an isocyanate component as a curing agent component can be used. Examples of the polyol component having OH groups include acrylic polyol, polyester polyol, polyether polyol, and epoxy polyol. Examples of the isocyanate component include tolylene diisocyanate, hexamethylene diisocyanate, and metaxylene diisocyanate.

[0042] Furthermore, the surface protection layer 5 may be formed mainly from an acrylic resin composition, or may be formed mainly from both an ionizing radiation curable resin and an acrylic resin composition, or may be formed mainly from an ionizing radiation curable resin. The thickness of the surface protection layer 5 is not particularly limited.

[0043] [Embossed part] An embossed portion 5a having a concave-convex pattern is formed on the surface of the surface protection layer 5 to impart a given design. Examples of the concave-convex pattern include the vessel grooves of a wood grain board, the concave-convex surface of a stone slab (such as the cleavage plane of granite), the texture of a cloth surface, a matte finish, a sand grain, a hairline, and a linear groove. The concave-convex pattern of the embossed portion 5a is provided so that it matches the design of the design layer 3.

[0044] The uneven pattern can be formed, for example, by embossing. The embossing method is not particularly limited. For example, a known sheet-fed embossing machine or rotary embossing machine can be used. This allows the decorative sheet 1 to be given a good texture that is close to that of real wood or stone.

[0045] It is preferable that the surface protection layer 5 including the embossed portion 5a has a load of 1000 g or more at which scratches occur when a Hoffman scratch test is performed in which the surface of the surface protection layer 5 including the embossed portion 5a is scratched by gradually increasing the load within a range of 200 g to 2000 g, and a coin scratch test in which a 10 yen coin is brought into contact with the surface of the surface protection layer 5 including the embossed portion 5a and scratched while increasing the load by 1 kg increments within a range of 1 kg to 5 kg, and the load at which scratches occur is 2 kg or more, and that the hardness in a pencil hardness test in accordance with JIS K 5600 is 2B or more.

[0046] Preferably, the region of the embossed portions 5a has an arithmetic mean roughness Ra of 5 μm or more and a maximum depth of the recesses of 25 μm or more, and the region of the surface protective layer 5 excluding the embossed portions 5a has an arithmetic mean roughness Ra of 3 μm or more and a maximum depth of the recesses of 20 μm or more. More preferably, the region of the embossed portions 5a has an arithmetic mean roughness Ra of 8 μm or more and a maximum depth of the recesses of 50 μm or more, and the region of the surface protective layer 5 excluding the embossed portions 5a has an arithmetic mean roughness Ra of 4 μm or more and a maximum depth of the recesses of 25 μm or more. Preferably, the arithmetic mean roughness Ra and the maximum depth of the recesses of the region of the surface protective layer 5 excluding the embossed portions 5a are smaller than the arithmetic mean roughness Ra and the maximum depth of the recesses of the region of the embossed portions 5a, respectively.

[0047] [Gloss matte pattern] The matt gloss pattern portion 6 is formed of a material that is light-absorbent for light of a predetermined wavelength, for example, a material that has infrared absorption properties. That is, a material with low infrared transmittance is used for the matt gloss pattern portion 6, and a material with significantly lower infrared transmittance than other layers is used. The matt gloss pattern portion 6 is formed of a material containing black ink containing carbon black, for example, a urethane-based printing ink, etc.

[0048] The matt gloss developing pattern portion 6 is arranged on the opposite side of the colored thermoplastic resin layer 2 from the pattern layer 3, in a position that is in harmony with the pattern of the pattern layer 3. For example, if the pattern layer 3 has a wood grain pattern, the matt gloss developing pattern portion 6 is formed in a position that overlaps with the wood grain board conduit grooves of the pattern layer 3 in a planar view. Note that "in harmony" here means that the matt gloss developing pattern portion 6 is formed in a position that overlaps with the pattern of the pattern layer 3 in a planar view.

[0049] The thickness of the matte gloss developing pattern portion 6 may be such that the transparent thermoplastic resin layer 4 and the surface protective layer 5 can be softened to an extent that the uneven shape can be sufficiently formed in the surface protective layer 5 during the embossing process described below. In order to obtain a sufficient matte gloss effect, it is preferable that the difference in gloss level between the area where the matte gloss developing pattern portion 6 is formed and the area where it is not formed is 5 or more in plan view, i.e., the image density level is preferably 60% or more.

[0050] [Primer layer] The primer layer 7 is a base layer that improves adhesion and corrosion resistance with a substrate (not shown) to which the decorative sheet 1 is attached. The primer layer 7 is formed on the surface of the colored thermoplastic resin layer 2 opposite the pattern layer 3 so as to cover the pattern portion 6 for expressing the gloss matte finish.

[0051] The primer layer 7 is formed using, for example, a polyester resin, an organic additive, a pigment, etc. An anti-rust pigment may be blended into the primer layer 7 to improve corrosion resistance. The thickness of the primer layer 7 is, for example, in the range of 1 μm to 10 μm.

[0052] [Method for manufacturing decorative sheet] Next, an example of a method for producing a decorative sheet according to this embodiment will be described with reference to FIG. First, a colored thermoplastic resin layer 2 is formed. For example, a PE (polyethylene) resin is used to form the colored thermoplastic resin layer 2 to a thickness of, for example, 55 μm (FIG. 2(a)).

[0053] Next, the design layer 3 is printed on one surface of the colored thermoplastic resin layer 2 using, for example, a urethane-based printing ink. Next, a pattern portion 6 for producing a matte gloss finish is formed on the surface of the colored thermoplastic resin layer 2 opposite to the pattern layer 3. For example, the pattern portion 6 for producing a matte gloss finish is formed at a predetermined position in harmony with the pattern of the pattern layer 3 using a urethane-based printing ink containing black ink containing carbon black (FIG. 2(b)).

[0054] Next, a primer layer 7 made of, for example, a polyester resin is formed on the colored thermoplastic resin layer 2 including the pattern portion 6 for expressing gloss matte, filling the gaps between the pattern portions 6 for expressing gloss matte and covering the upper surface thereof (Figure 2(c)). Next, a transparent thermoplastic resin layer 4 made of, for example, 80 μm thick PP (polypropylene) resin is laminated on the surface of the design layer 3 opposite the colored thermoplastic resin layer 2. Then, a surface protection layer 5 containing, for example, an acrylic resin composition and a UV resin as main components is laminated on the transparent thermoplastic resin layer 4. As a result, the design layer 3, the transparent thermoplastic resin layer 4, and the surface protection layer 5 are laminated in this order on one surface of the colored thermoplastic resin layer 2 (FIG. 2(d)).

[0055] An adhesive resin containing a urethane adhesive may be provided as an adhesive layer between the design layer 3 and the transparent thermoplastic resin layer 4.

[0056] Next, the entire laminate in which these layers are stacked, as shown in Figure 2(d), is irradiated with infrared rays from the side of the surface protective layer 5 (Figure 2(e)), and immediately after this irradiation, an embossing plate such as an embossing roll is pressed onto the surface of the surface protective layer 5 (Figure 2(f)). This forms embossed portions 5a, and the decorative sheet 1 is formed.

[0057] Here, the matte gloss pattern portion 6 is formed with black ink having infrared absorption properties. Furthermore, the matte gloss pattern portion 6 is made of a material with significantly lower infrared transmittance than the other layers. Therefore, compared to the infrared transmittance of the area where the matte gloss pattern portion 6 is formed in a plan view, the infrared transmittance of the area where the matte gloss pattern portion 6 is not formed is higher, resulting in a difference in infrared transmittance in the laminate shown in FIG. 2(d) in a plan view. Therefore, when the laminate is irradiated with infrared rays, the transparent thermoplastic resin layer 4 and the surface protective layer 5 are more likely to soften in the area of the surface protective layer 5 that overlaps with the matte gloss pattern portion 6 in a plan view, i.e., the area with high infrared absorptivity, compared to the area not overlapping with the matte gloss pattern portion 6. In other words, after infrared irradiation, the transparent thermoplastic resin layer 4 and the surface protective layer 5 have areas that are more likely to soften and areas that are less likely to soften. Therefore, when an embossing plate is pressed against the surface protective layer 5 in this state, unevenness is more likely to form in the softened areas, and unevenness is less likely to form in the less softened areas. That is, unevenness is likely to be formed in the softened portions of the transparent thermoplastic resin layer 4 and the surface protective layer 5, i.e., in the portions that overlap with the matt gloss developing pattern portion 6 in a planar view. As a result, embossed portions 5a having an uneven shape that is in harmony with the matt gloss developing pattern portion 6 are likely to be formed only in the positions of the transparent thermoplastic resin layer 4 and the surface protective layer 5 that overlap with the matt gloss developing pattern portion 6 in a planar view.

[0058] This allows the embossed portions 5a to be formed in positions synchronized with the picture layer 3, that is, the embossed portions 5a synchronized with the picture layer 3 can be easily formed without performing highly accurate positioning operations. Then, since the surface protective layer 5 has areas where the embossed portions 5a are formed and areas where the embossed portions 5a are not formed, a gloss matte finish is achieved.

[0059] It is considered that the heat energy retained by the gloss matte developing pattern portion 6 upon infrared irradiation is affected by the infrared transmittance and reflectance of each layer constituting the laminate, but the heat energy retained by the other layers is uniform regardless of whether the gloss matte developing pattern portion 6 is formed or not. Furthermore, the heat energy retained by each layer upon infrared irradiation is minute compared to the energy absorbed in the gloss matte developing pattern portion 6, and is negligible. Therefore, the influence of the infrared transmittance and reflectance of the other layers on the development of gloss matte can be considered to be negligible, and the gloss matte can be considered to be developed by the relative difference between the heat energy retained by the area where the gloss matte developing pattern portion 6 is formed and the heat energy retained by the area where the gloss matte developing pattern portion 6 is not formed.

[0060] The timing for pressing the embossing plate onto the transparent thermoplastic resin layer 4 and the surface protective layer 5 after infrared irradiation is not limited to immediately after infrared irradiation, but may be any timing that allows the plate to be pressed onto the surfaces of the transparent thermoplastic resin layer 4 and the surface protective layer 5 to selectively form an uneven shape in the parts softened by infrared irradiation.

[0061] In addition, other processes may be included between the process of creating the surface protection layer 5 and the process of performing infrared irradiation, and the key point is that the infrared irradiation should be performed in a state where the transparent thermoplastic resin layer 4 and the surface protection layer 5 have been formed.

[0062] [Effects of this embodiment] (1) According to the manufacturing method of the decorative sheet 1 of this embodiment, by irradiating a laminate in which each layer is stacked with infrared rays and then pressing an embossing plate, it is possible to strongly emboss the area that overlaps with the gloss matte-exhibiting pattern portion 6 in a plan view. In other words, it is possible to easily form an embossed portion in the desired position without having to perform high-precision positioning of the area where the embossing plate is pressed. As a result, it is possible to easily obtain a decorative sheet with excellent design properties.

[0063] (2) Because the matte gloss developing pattern portion 6 is provided as a layer below the colored thermoplastic resin layer 2, the visibility of the matte gloss developing pattern portion 6 is reduced when the decorative sheet 1 is viewed from the surface protective layer 5 side. As a result, although a high-concentration black ink with infrared absorption properties is used for the matte gloss developing pattern portion 6, the matte gloss developing pattern portion 6 can be prevented from being visible when the decorative sheet 1 is viewed from the surface protective layer 5 side. Therefore, even without using a dark color pattern for the picture layer 3, the matte gloss developing pattern portion 6 containing black ink can be prevented from being visible, and as a result, a light-colored pattern can be used for the picture layer 3, and the restrictions on pattern expression caused by the provision of the matte gloss developing pattern portion 6 can be reduced.

[0064] Furthermore, a colored thermoplastic resin layer 2 and a picture layer 3, as well as a transparent thermoplastic resin layer 4 and a surface protective layer 5, are laminated on top of a matte gloss developing pattern portion 6 made with a high-concentration black ink that has infrared absorption properties, and an embossed portion 5a is formed in a position that overlaps the matte gloss developing pattern portion 6 in a plan view of the surface protective layer 5. This makes it possible to reduce the visibility of the matte gloss developing pattern portion 6 made with black ink, and to suppress the impact that the matte gloss developing pattern portion 6, which is useful in the manufacturing process of the decorative sheet 1, has on the appearance of the decorative sheet 1, thereby making it possible to obtain a decorative sheet 1 with a highly designed appearance in which the picture of the picture layer 3 and the embossed portion 5a are in harmony.

[0065] (3) Since the pattern portion 6 for producing the gloss matte effect is arranged in harmony with the pattern of the pattern layer 3, it is possible to form an uneven portion in harmony with the pattern of the pattern layer 3, that is, it is possible to easily produce a gloss matte effect in harmony with the pattern.

[0066] (4) By providing the unevenness, the gloss matte expression is achieved, which can prevent the gloss matte pattern from coming off, etc. In other words, for example, when a gloss matte design is expressed by providing a gloss adjustment layer, the gloss adjustment layer may peel off due to wear, etc., and the gloss matte design may be deteriorated.

[0067] In contrast, the unevenness creates a glossy matte finish. Furthermore, the surface protective layer is irradiated with infrared light to apply heat when the embossing is formed, thereby improving the surface properties of the transparent thermoplastic resin layer 4 and, therefore, the surface strength of the decorative sheet. As a result, the surface of the surface protective layer exhibits a scratch load of 1000 g or more in a Hoffman scratch test, a scratch load of 2 kg or more in a coin scratch test, and a pencil hardness of 2B or more. This further improves abrasion resistance and scratch resistance, preventing degradation of the glossy matte design even when applied to floors, exteriors, etc. This, in turn, extends the life of the decorative sheet.

[0068] [Modification] (1) In the above embodiment, a case has been described in which a material containing black ink is used as the matte gloss pattern portion 6, and infrared radiation is applied to partially soften the transparent thermoplastic resin layer 4 and the surface protective layer 5, but this is not limited thereto. Alternatively, a material containing any ink made of a component that is light-absorbent for light of a predetermined wavelength may be used as the matte gloss pattern portion 6, and the transparent thermoplastic resin layer 4 and the surface protective layer 5 may be partially softened by using a light source that irradiates light of the predetermined wavelength.

[0069] (2) In the above embodiment, the pattern layer 3 is laminated on one surface of the colored thermoplastic resin layer 2, then the matt gloss pattern portion 6 and the primer layer 7 are formed on the other surface of the colored thermoplastic resin layer 2, and then the transparent thermoplastic resin layer 4 and the surface protective layer 5 are formed on the surface of the pattern layer 3 opposite the colored thermoplastic resin layer 2, but this is not limited to this. For example, the pattern layer 3, the transparent thermoplastic resin layer 4, and the surface protective layer 5 may be formed in this order on one surface of the colored thermoplastic resin layer 2, and then the matt gloss pattern portion 6 and the primer layer 7 may be formed in this order on the other surface.

[0070] (3) Furthermore, as shown in Fig. 3, the decorative sheet 1 according to the above embodiment may be attached to a base material 9, which is a base material for a decorative member, to form a decorative member 10. In the decorative member 10, the decorative sheet 1 may be provided on at least one side of the base material 9, or may be provided on both sides.

[0071] [Base material] The substrate 9 can be any of a wood substrate, a resin substrate, a non-combustible substrate, and a metal substrate. Examples of wood substrates include wood veneer, wood plywood, laminated lumber, particle board, medium-density fiberboard, and hard fiberboard. Examples of resin substrates include plastic and other resins, or composite materials thereof. Examples of non-combustible substrates include non-combustible steel plates or substrates made of non-combustible materials specified in Ministry of Construction Notification No. 1400. Examples of metal substrates include steel plates and aluminum plates. The substrate 9 can also be made of plastic and other resins, or composite materials thereof. That is, the substrate 9 can be a resin substrate. The substrate 9 can also be made of non-combustible steel plates or non-combustible materials specified in Ministry of Construction Notification No. 1400.

[0072] Thus, the decorative member 10 comprises a base material 9 and a decorative sheet 1 provided on at least one surface of the base material 9. The base material 9 can be any of a wood base material, a resin base material, a non-flammable base material, and a metal base material.

[0073] As described above, the decorative sheet 1 has a primer layer 7, which ensures adhesion to the substrate 9, thereby preventing the decorative member 10 from peeling off between the decorative sheet 1 side and the substrate 9 side. Furthermore, when the embossed portions 5a are formed, heat is applied to improve the surface strength of the decorative sheet 1, so by using this decorative sheet 1, a decorative member 10 can be obtained that has good bending suitability while maintaining surface strength. [Example]

[0074] The present invention will be described in detail below with reference to examples and comparative examples, but the present invention is not limited to the following examples.

[0075] (Preparation of decorative sheets in examples and comparative examples) Example 1 A wood grain pattern was printed on one surface of a colored thermoplastic resin layer 2 made of a 55 μm thick PE layer using a urethane-based printing ink to form a pattern layer 3 .

[0076] Next, on the other surface of the colored thermoplastic resin layer 2, a pattern portion 6 for expressing gloss and matte was printed using black ink made of urethane ink at a position corresponding to the pattern of the design layer 3. Next, a PP resin was laminated by extrusion lamination onto the surface of the colored thermoplastic resin layer 2 on which the pattern layer 3 was formed, thereby forming a transparent thermoplastic resin layer 4 having a thickness of 80 μm.

[0077] A surface protective layer 5 was formed on this transparent thermoplastic resin layer 4 using a resin mainly composed of an acrylic resin composition and a UV resin, and then an after-embossing process was carried out. Specifically, a laminate in which a gloss / matt pattern portion 6 was formed on one side of the colored thermoplastic resin layer 2 and a picture layer 3, a transparent thermoplastic resin layer 4, and a surface protective layer 5 were formed on the other side of the colored thermoplastic resin layer 2 was subjected to the after-embossing process to obtain a decorative sheet 1 that matched the picture of the picture layer 3. That is, this laminate was heated with an infrared heater, and then an embossing roll was pressed against it to form an embossed portion 5a (after-embossing process), and the decorative sheet of Example 1 having an embossed portion 5a that matched the picture of the picture layer 3, as shown in Figure 1, was obtained.

[0078] Here, the surface protection layer 5 is formed using a resin whose main components are an acrylic resin composition and a UV resin. However, as mentioned above, the material of the surface protection layer 5 is not particularly limited, and the layer may be formed using a resin whose main component is a urethane resin composition, or a resin whose main component is an acrylic resin composition.

[0079] (Comparative Example 1) The decorative sheet of Comparative Example 1 is the same as the decorative sheet of Example 1 except that a gloss-adjusting layer is provided instead of the embossed portions 5a. That is, as with the decorative sheet of Example 1 above, a pattern layer 3 consisting of a wood grain pattern was formed using a urethane-based printing ink on one side of a colored thermoplastic resin layer 2 consisting of a 55 μm thick PE layer. A transparent thermoplastic resin layer 4 having a thickness of 80 μm was formed on top of this by extrusion lamination of PP resin, and a surface protective layer 5 was then formed using a resin whose main components were an acrylic resin composition and a UV resin. A gloss-adjusting layer capable of expressing a gloss / matt design was then formed in a position that matched the pattern of the pattern layer 3, thereby obtaining the decorative sheet of Comparative Example 1 capable of expressing a gloss / matt design. The gloss-adjusting layer was formed using a urethane resin containing silica.

[0080] [Rating 1] For the decorative sheet of Example 1, the arithmetic mean roughness Ra and maximum depth were measured for the embossed area and the area of the surface protective layer excluding the embossed area, which affect the appearance of the gloss matte appearance. The arithmetic mean roughness Ra of the embossed area was 11.21 μm, and the maximum depth of the recesses in the embossed area was 68.73 μm. The arithmetic mean roughness Ra of the surface protective layer excluding the embossed area was 4.65 μm, and the maximum depth of the recesses in the surface protective layer excluding the embossed area was 30.221 μm.

[0081] [Rating 2] The decorative sheets of Example 1 and Comparative Example 1 were subjected to gloss measurement and evaluation of gloss-matt design based on the measurement, and further subjected to an abrasion test (steel wool test), a coin scratch test, a Hoffman scratch test, and a pencil hardness test. The evaluation and test methods are as follows.

[0082] (Gloss measurement) For the decorative sheets of Example 1 and Comparative Example 1, after forming an embossed portion or a gloss-adjusting layer, 85° gloss measurements were performed. For Example 1, the gloss of the embossed portion of the surface protective layer and the gloss of the area excluding the embossed portion of the surface protective layer were measured, and the difference in gloss between them was obtained. For Comparative Example 1, the gloss of the gloss-adjusting layer area and the gloss of the area excluding the gloss-adjusting layer of the surface protective layer were measured, and the difference in gloss between them was obtained. These 85° gloss measurements were performed using a specular gloss meter (micro-TRI-gloss, manufactured by BYK).

[0083] (Evaluation of gloss matte design) The evaluation was based on whether the difference in gloss between the embossed area of the surface protective layer and the area other than the embossed area of the surface protective layer was greater than "3," which is the level at which a gloss-matt appearance can be achieved. The evaluation criteria are as follows:

[0084] ◎: The gloss difference is greater than "3", and a stable gloss matte is achieved even when variations in production are taken into account. ◯: The gloss difference is greater than "3" and the gloss-matt appearance is visible. △: The gloss difference is smaller than "3", but the gloss matte expression is visible. ×: The gloss matte expression is not visible.

[0085] (Abrasion test (steel wool test) method) The surface of the surface protective layer side of the decorative sheets of Example 1 and Comparative Example 1 was rubbed back and forth 20 times with steel wool (Bonstar, manufactured by Nippon Steel Wool Co., Ltd.) under a load of 200 g / cm 2 When a load of 500g / cm is applied, 2 The test was carried out for both cases where a load of 10 ... Thereafter, the glossiness was measured and the gloss / matt design was evaluated in the same manner as above.

[0086] (Hoffman scratch test) The decorative sheets of Example 1 and Comparative Example 1 were tested using a Hoffman scratch tester manufactured by BYK-GARDNER, USA. Specifically, a scratch blade (a cylindrical blade with a diameter of 7 mm) was set so that it contacted the surface of the surface protection layer side of the decorative sheet at a 45° angle, and the tester was moved over the decorative sheet. Scratching was performed with a load ranging from 200 g to 2000 g, gradually increasing in 200 g increments, and the surface condition was observed, and the load at which continuous scratches appeared was recorded.

[0087] (Coin scratch test) For the decorative sheets of Example 1 and Comparative Example 1, a 10 yen coin was placed in contact with the surface of the surface protection layer side, and scratched while applying a load ranging from 1 kg to 5 kg, increasing the load by 1 kg each time. The surface condition was observed, and the load at which continuous scratches occurred was recorded.

[0088] (Pencil hardness test) For the decorative sheets of Example 1 and Comparative Example 1, a pencil hardness test in accordance with JIS K 5600 was carried out on the surface on the surface protective layer side. The evaluation and test results are shown in Table 1.

[0089] [Table 1]

[0090] As shown in Table 1, even when the decorative sheet of Example 1 was subjected to an abrasion test, there was no change in the difference in gloss before and after the abrasion test, confirming that it was able to exhibit a good gloss matte design. On the other hand, in the decorative sheet of Comparative Example 1, the hardness of the surface on the surface protection layer side of the decorative sheet was lower than that of the decorative sheet of Example 1 in the Hoffman scratch test, coin scratch test, and pencil hardness test, and therefore although it was able to exhibit a good gloss matte design before the abrasion test, after the abrasion test, a sufficient difference in gloss could not be obtained and the gloss matte expression was not visible.

[0091] The present invention can have the following configurations, for example. (1) a pattern layer, a transparent resin layer, and a surface protective layer laminated in this order on one surface of the colored resin layer; A gloss matte pattern portion laminated on the other surface of the colored resin layer, arranged in synchronization with the pattern of the pattern layer, and formed of a material having light absorption properties for light of a predetermined wavelength; An embossed portion is formed in a portion of the surface protective layer that overlaps with the gloss matte developing pattern portion in a plan view, The surface protection layer including the embossed portion is When a Hoffman scratch test is performed in which the surface of the surface protection layer including the embossed portion is scratched with a load gradually increased within a range of 200 g to 2000 g, the load at which scratches occur is 1000 g or more, and When a coin scratch test is performed in which a 10 yen coin is brought into contact with the surface of the surface protection layer including the embossed portion and scratched while applying a load that is increased by 1 kg increments within a range of 1 kg to 5 kg, the load at which scratches occur is 2 kg or more, and A decorative sheet characterized by having a hardness of 2B or more in a pencil hardness test in accordance with JIS K 5600. (2) The decorative sheet according to (1) above, wherein the pattern portion for producing gloss and matte finish is formed by containing black ink containing carbon black. (3) The decorative sheet according to (1) or (2) above, characterized in that the embossed area has an arithmetic mean roughness Ra of 5 μm or more and a maximum depth of the recesses of 25 μm or more, and the area of the surface protective layer excluding the embossed area has an arithmetic mean roughness Ra of 3 μm or more and a maximum depth of the recesses of 20 μm or more. (4) A substrate; and a decorative sheet according to any one of (1) to (3) above, provided on at least one surface of the substrate, The decorative member is characterized in that the substrate is any one of a wood substrate, a resin substrate, a non-flammable substrate, and a metal substrate. [Explanation of symbols]

[0092] 1 decorative sheet 2 Colored thermoplastic resin layer 3. Picture layer 4 Transparent thermoplastic resin layer 5 Surface protective layer 6 Gloss Matte Pattern 7 Primer layer 9 Base material 10 Decorative materials

Claims

1. a pattern layer, a transparent resin layer, and a surface protective layer laminated in this order on one surface of the colored resin layer; A gloss matte pattern portion laminated on the other surface of the colored resin layer, arranged in synchronization with the pattern of the pattern layer, and formed of a material having light absorption properties for light of a predetermined wavelength; An embossed portion is formed in a portion of the surface protective layer that overlaps with the gloss matte developing pattern portion in a plan view, The surface protection layer including the embossed portion is When a Hoffman scratch test is performed in which the surface of the surface protection layer including the embossed portion is scratched with a load gradually increased within a range of 200 g to 2000 g, the load at which scratches occur is 1000 g or more, and When a coin scratch test is performed in which a 10-yen coin is brought into contact with the surface of the surface protection layer including the embossed portion and scratched while applying a load that is increased by 1 kg increments within a range of 1 kg to 5 kg, the load at which scratches occur is 2 kg or more, and A decorative sheet characterized in that the hardness in a pencil hardness test in accordance with JIS K 5600 is 2B or more.

2. 2. The decorative sheet according to claim 1, wherein the pattern portion for producing gloss and matte finish is formed by using a black ink containing carbon black.

3. 3. The decorative sheet according to claim 1, wherein the embossed area has an arithmetic mean roughness Ra of 5 μm or more and a maximum depth of the recesses of 25 μm or more, and the area of the surface protective layer excluding the embossed area has an arithmetic mean roughness Ra of 3 μm or more and a maximum depth of the recesses of 20 μm or more.

4. A substrate; The decorative sheet according to claim 1 or 2 is provided on at least one surface of the substrate, The decorative member is characterized in that the substrate is any one of a wood substrate, a resin substrate, a non-flammable substrate, and a metal substrate.

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