Ink for pattern part formation for gloss / mat expression and method for producing decorative sheet

Abstract

To provide ink for pattern part formation for gloss / mat expression which is used in a process of producing a decorative sheet having close texture to texture of a surface of wood and stone materials used in a building material.SOLUTION: A pattern layer 3, a transparent thermoplastic resin layer 4 and a surface protective layer 5 are stacked in this order on one surface of a colored thermoplastic resin layer 2, and a pattern part 6 for gloss / mat expression is formed by using ink for pattern part formation for gloss / mat expression having such characteristics as to absorb more light of a wavelength from 800 nm or more and 2,500 nm or less than light of other wavelengths, at a position synchronized with a pattern of the pattern layer 3 on the other surface. Then, light of a wavelength with power of the light of the wavelength from 800 nm or more and 2,500 nm or less greater than power of light of the other wavelength is emitted, an embossing plate is plate impressed, and an embossing part 5a is formed. Light of a wavelength having high absorption characteristics in the pattern part 6 for gloss / mat expression is emitted, which suppresses emission of light of an unnecessary wavelength, and can suppress wasteful use of energy.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an ink for forming a pattern portion for expressing gloss and matte finish, and a method for producing a decorative sheet. [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 an ink for forming a pattern portion that exhibits a gloss matte finish and is used in the manufacturing process of decorative sheets that have a texture similar to the surface texture of wood, stone, etc. used in building materials and have excellent design properties, as well as a manufacturing method for decorative sheets. [Means for solving the problem]

[0006] According to one aspect of the present invention, there is provided a method for manufacturing a decorative sheet comprising the steps of: laminating a colored resin layer, a pattern layer, a transparent resin layer, and a surface protective layer in this order; forming a pattern portion for developing a gloss matte on the other side of the colored resin layer in a position synchronized with the pattern of the pattern layer; irradiating light with a wavelength in the range of 800 nm or more and 2500 nm or less, in which the power of the light is greater than the power of light of other wavelengths, after the laminating step and the step of forming the pattern portion for developing a gloss matte; and, after the step of irradiating light, pressing an embossing plate into the surface protective layer to form an embossed portion. The method provides an ink for forming a pattern portion for developing a gloss matte, which ink has the property of absorbing light with a wavelength in the range of 800 nm or more and 2500 nm or less more than light of other wavelengths.

[0007] According to another aspect of the present invention, there is provided a method for manufacturing a decorative sheet, comprising the steps of: laminating a colored resin layer, a pattern layer, a transparent resin layer, and a surface protective layer in this order; forming a pattern portion for expressing gloss matte on the other side of the colored resin layer at a position synchronized with the pattern of the pattern layer using a material that has the property of absorbing light with a wavelength in the range of 800 nm or more and 2500 nm or less more than light of other wavelengths; after the laminating step and the step of forming the pattern portion for expressing gloss matte, irradiating with light of a wavelength in the range of 800 nm or more and 2500 nm or less, the power of which is greater than the power of light of other wavelengths; and after the step of irradiating with light, stamping an embossing plate onto the surface protective layer to form an embossed portion. [Effects of the Invention]

[0008] According to one embodiment of the present invention, a decorative sheet having a texture similar to the surface texture of wood, stone, and other materials used in building construction and having excellent design properties can be easily obtained. [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.

[0015] The thickness of the colored thermoplastic resin layer 2 may be a thickness generally used for colored thermoplastic resin layers 2 in decorative sheets (50 μm or more and 70 μm or less), for example, about 50 μm.

[0016] [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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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 usually 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.

[0023] 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. For example, a two-component curing urethane resin can be used. Alternatively, the adhesive resin may 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).

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] 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).

[0032] 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.

[0033] [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.

[0034] 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 may be a thickness generally used for the transparent thermoplastic resin layer 4 in a decorative sheet (30 μm or more and 120 μm or less), for example, about 80 μm.

[0035] [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.

[0036] 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.

[0037] Examples of materials that can be used for the surface protective layer 5 include ionizing radiation-curable resins and two-component curable urethane-based resins. The ionizing radiation-curable resins are not particularly limited. For example, transparent resins primarily composed of prepolymers (including oligomers) and / or monomers containing radically polymerizable double bonds in the molecule that can undergo polymerization and crosslinking reactions upon exposure to ionizing radiation such as infrared rays, ultraviolet rays, 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 combinations of polyene and polythiol, are also preferred. Here, the term "(meth)acryloyl group" refers to an acryloyl group or a methacryloyl group.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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 protective layer 5 may be any thickness that is generally used as the thickness of the surface protective layer 5 in a decorative sheet.

[0044] [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.

[0045] 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 similar to that of real wood or stone.

[0046] [Gloss matte pattern] The matt gloss pattern portion 6 is formed using ink that absorbs all light in the infrared wavelength range but absorbs light with wavelengths between 800 nm and 2500 nm more than light with other wavelengths. This ink is formed, for example, from a urethane-based printing ink, including black ink containing carbon black. The ink forming the matt gloss pattern portion 6 may be any material that absorbs all light in the infrared wavelength range but absorbs light with wavelengths between 800 nm and 2500 nm more than light with other wavelengths, and may be, for example, at least one inorganic material selected from the group consisting of tin-doped indium oxide, antimony-doped tin oxide, lanthanum hexaboride, and cesium-doped tungsten oxide.

[0047] 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.

[0048] The thickness of the matt gloss pattern portion 6 may be any thickness that can soften the transparent thermoplastic resin layer 4 and the surface protective layer 5 to an extent that the unevenness can be sufficiently formed in the surface protective layer 5 during the embossing process described below. Specifically, the thickness of the matt gloss pattern portion 6 is 1 μm or more and 1 mm or less, preferably 1 μm or more and 0.1 mm or less, and more preferably 1 μm or more and 50 μm or less.

[0049] In order to obtain a sufficient gloss matte effect, it is preferable that the difference in gloss level between the area where the gloss matte-producing pattern portion 6 is formed and the area where it is not formed is 3 or more when viewed in a plane, i.e., the image density level is preferably 60% or more.

[0050] The gloss matte developing pattern portion 6 is formed using an ink that absorbs all light in the infrared wavelength range, but has the property of absorbing light with a wavelength in the range of 800 nm or more and 2500 nm or less more than light of other wavelengths.By forming the gloss matte developing pattern portion 6 using an ink that absorbs all light in the infrared wavelength range, but has the property of absorbing light with a wavelength in the range of 800 nm or more and 2500 nm or less, when the gloss matte developing pattern portion 6, the colored thermoplastic resin layer 2, the picture layer 3, the transparent thermoplastic resin layer 4 and the surface protective layer 5 are laminated together, the infrared transmittance for light of the same wavelength in the range of 800 nm or more and 2500 nm or less is smaller in the portion that overlaps with the gloss matte developing pattern portion 6 in a planar view than in the portion that does not overlap with the gloss matte developing pattern portion 6.More specifically, the infrared transmittance for light with a wavelength of 2500 nm in the portion that overlaps with the gloss matte developing pattern portion 6 in a planar view is 23.6% or less, the infrared transmittance for light with a wavelength of 2000 nm is 16.5% or less, and the infrared transmittance for light with a wavelength of 800 nm is 1.4% or less. Therefore, the portion overlapping with the matte gloss developing pattern portion 6 in plan view can more selectively absorb light in the range of 800 nm or more and 2500 nm or less than the portion not overlapping.

[0051] [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.

[0052] 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.

[0053] [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.

[0054] 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)).

[0055] 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)).

[0056] 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, a 90 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)).

[0057] 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.

[0058] Next, the entire laminate of these layers shown in Fig. 2(d) is irradiated from the surface protection layer 5 side with light having a wavelength in the range of 800 nm to 2500 nm inclusive, the power of which is stronger than the power of other wavelengths (Fig. 2(e)), and immediately after this light irradiation, an embossing plate such as an embossing roll is pressed against the surface of the surface protection layer 5 (Fig. 2(f)). This forms embossed portions 5a, and the decorative sheet 1 is formed.

[0059] Here, the matte gloss pattern portion 6 is formed of black ink that absorbs all light in the infrared wavelength range but absorbs light with a wavelength in the range of 800 nm to 2500 nm more than light with other wavelengths. Therefore, when the laminate is irradiated with light having a wavelength in the range of 800 nm to 2500 nm that is stronger than the power of other wavelengths, the transparent thermoplastic resin layer 4 and the surface protective layer 5 are more likely to soften in the portions of the surface protective layer 5 that overlap with the matte gloss pattern portion 6 in a planar view than in the portions 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 portions that are more likely to soften and portions 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 portions, and less likely to form in the less-softened portions. In other words, unevenness is more likely to form in the softened portions of the transparent thermoplastic resin layer 4 and the surface protective layer 5, i.e., the portions that overlap with the matte gloss pattern portion 6 in a planar view. As a result, an embossed portion 5a having an uneven shape that is in harmony with the pattern portion 6 for expressing gloss matte is easily formed only at positions that overlap with the pattern portion 6 for expressing gloss matte of the transparent thermoplastic resin layer 4 and the surface protective layer 5 when viewed in a plane.

[0060] 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. In this way, the surface protective layer 5 has areas where the embossed portions 5a are formed and areas where the embossed portions 5a are not formed, resulting in the development of a gloss matte finish.

[0061] 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.

[0062] 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. 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.

[0063] [Effects of this embodiment] (1) According to the decorative sheet 1 of this embodiment, the matt gloss developing pattern portion 6 is formed of black ink that absorbs all light in the infrared wavelength region, but has the property of absorbing light with a wavelength in the range of 800 nm or more and 2500 nm or less more than light with other wavelengths. Therefore, when the matt gloss developing pattern portion 6, the colored thermoplastic resin layer 2, the design layer 3, the transparent thermoplastic resin layer 4, and the surface protective layer 5 are laminated together, if light having a wavelength in the range of 800 nm or more and 2500 nm or less that is stronger than the power of other wavelengths is irradiated onto this laminate, the matt gloss developing pattern portion 6 will absorb the light, and the portion that overlaps with the matt gloss developing pattern portion 6 in a planar view will become softer than the portion that does not overlap with the matt gloss developing pattern portion 6.

[0064] Therefore, by pressing an embossing plate after irradiating the surface with this light, 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 precisely position the area where the embossing plate is pressed. As a result, a decorative sheet with excellent design properties can be easily obtained.

[0065] For example, in the wood grain patterned pattern layer 3, by forming a pattern portion 6 for expressing a gloss matte finish at a position that overlaps with the vessel grooves of the wood grain board when viewed in a plane, it is possible to obtain a tactile sensation that is in tune with the vessel portions of the wood grain as seen with the naked eye, i.e., a tactile sensation at a position that coincides with the vessel portions, thereby further improving the design.

[0066] The gloss matte developing pattern portion 6 absorbs all light in the infrared wavelength range, but has the property of absorbing light with wavelengths in the range of 800 nm to 2500 nm more than light of other wavelengths, so it is sufficient to irradiate light with a wavelength in the range of at least 800 nm to 2500 nm that is stronger than the power of other wavelengths, and light with wavelengths lower than 800 nm or higher than 2500 nm is unnecessary, so irradiation of light with unnecessary wavelengths can be suppressed accordingly, which means that wasted energy can be suppressed. In particular, the infrared transmittance for light with a wavelength of 2500 nm of the portion overlapping with the pattern portion 6 for expressing gloss matte in a planar view is 23.6% or less, the infrared transmittance for light with a wavelength of 2000 nm is 16.5% or less, and the infrared transmittance for light with a wavelength of 800 nm is 1.4% or less. Therefore, in a laminate in which the pattern portion 6 for expressing gloss matte, the colored thermoplastic resin layer 2, the picture layer 3, the transparent thermoplastic resin layer 4, and the surface protective layer 5 are laminated, the surface protective layer 5 and the transparent thermoplastic resin layer 4 in the portion overlapping with the pattern portion 6 for expressing gloss matte in a planar view can be softened more selectively, and an embossed portion of sufficient depth can be formed.

[0067] (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.

[0068] (3) A colored thermoplastic resin layer 2 and a design 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 design of the design layer 3 and the embossed portion 5a are in harmony.

[0069] (4) 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.

[0070] (5) By providing the unevenness, the gloss matte expression is achieved, which can prevent the gloss matte pattern from coming off. Therefore, for example, a synchronized gloss matte expression can be achieved even in flooring materials.

[0071] [Modification] (1) In the above embodiment, a material containing black ink is used as the gloss matte developing pattern portion 6, and infrared radiation is applied to partially soften the transparent thermoplastic resin layer 4 and the surface protection layer 5, but the present invention is not limited to this. Any material that has the property of absorbing light with a wavelength in the range of 800 nm to 2500 nm more than light with other wavelengths can be used as the material for the gloss matte developing pattern portion 6, and can provide the same effects as when black ink is used.

[0072] (2) In the above embodiment, the pattern layer 3 is laminated on one side of the colored thermoplastic resin layer 2, then the gloss matte-producing pattern portion 6 and the primer layer 7 are formed on the other side 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 side of the pattern layer 3 opposite the colored thermoplastic resin layer 2, but this is not limiting. For example, the steps of forming the pattern layer 3, the transparent thermoplastic resin layer 4, and the surface protective layer 5 on one side of the colored thermoplastic resin layer 2 may be carried out consecutively.

[0073] (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.

[0074] [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.

[0075] 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. 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 between the decorative sheet 1 side and the substrate 9 side. In addition, because heat is applied when the embossed portions 5a are formed, the surface strength of the decorative sheet 1 can be improved, and by using this decorative sheet 1, a decorative member 10 can be obtained that has good bending suitability while maintaining surface strength. [Example]

[0076] 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.

[0077] (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 .

[0078] Next, a gloss matte pattern 6 was printed on the other surface of the colored thermoplastic resin layer 2 using a urethane-based printing ink containing black ink with carbon black as an infrared absorbing material. This black ink has the property of absorbing light with wavelengths in the range of 800 nm to 2500 nm more than light with other wavelengths. Next, a PP resin was laminated by extrusion lamination onto the surface of the colored thermoplastic resin layer 2 on which the design layer 3 was formed, thereby forming a transparent thermoplastic resin layer 4 having a thickness of 90 μm.

[0079] A surface protective layer 5 was formed on this transparent thermoplastic resin layer 4 using a resin primarily composed of an acrylic resin composition and a UV resin, followed by an after-embossing process. Specifically, a laminate having a colored thermoplastic resin layer on one side with a pattern portion for developing a gloss / matt finish formed thereon, a design layer, a transparent thermoplastic resin layer, and a surface protective layer formed on the other side thereof, was subjected to an after-embossing process to obtain a decorative sheet that matched the design of the design layer. Specifically, the laminate was heated with an infrared heater, and then an embossing roll was pressed against it to form embossed portions 5a, thereby obtaining the decorative sheet of Example 1 having embossed portions 5a that matched the design of the design layer 3, as shown in FIG. 1 . The light irradiated by the infrared heater was short-wavelength-rich infrared light, i.e., infrared light with a high content of wavelengths in the range of 800 nm to 2500 nm, and whose power was stronger than that of other wavelengths.

[0080] Example 2 The decorative sheet of Example 2 was obtained using the same procedure as in Example 1, except that the light irradiated by the infrared heater was infrared light consisting of the entire wavelength range of infrared light, i.e., light in the range of 800 nm to 1 mm. Example 3 The decorative sheet of Example 3 was obtained in the same manner as Example 1 above, except that in the decorative sheet of Example 1, the gloss matte-exhibiting pattern portion 6 was formed using a urethane-based printing ink that used tin-doped indium oxide as the infrared-absorbing material instead of the urethane-based printing ink containing black ink with carbon black as the infrared-absorbing material.

[0081] Example 4 The decorative sheet of Example 4 was obtained in the same manner as in Example 1 above, except that in the decorative sheet of Example 1, the gloss matte-exhibiting pattern portion 6 was formed using a urethane-based printing ink containing antimony-doped tin oxide as the infrared-absorbing material instead of the urethane-based printing ink containing black ink with carbon black as the infrared-absorbing material. Example 5 The decorative sheet of Example 5 was obtained in the same manner as Example 1 above, except that in the decorative sheet of Example 1, the gloss matte-exhibiting pattern portion 6 was formed using a urethane-based printing ink using lanthanum hexaboride as an infrared-absorbing material instead of the urethane-based printing ink containing black ink with carbon black as an infrared-absorbing material.

[0082] Example 6 The decorative sheet of Example 6 was obtained in the same manner as in Example 1 above, except that in the decorative sheet of Example 1, the gloss matte-exhibiting pattern portion 6 was formed using a urethane-based printing ink that used cesium-doped tungsten oxide as the infrared-absorbing material instead of the urethane-based printing ink containing black ink with carbon black as the infrared-absorbing material.

[0083] (Comparative Example 1) The decorative sheet of Comparative Example 1 was obtained using the same procedure as in Example 1, except that the pattern portion for expressing gloss matte was printed using a mixed color ink of yellow, red, and blue ink, which has a higher infrared transmittance than black ink made from a urethane-based ink. (Comparative Example 2) The decorative sheet of Comparative Example 2 was obtained using the same procedure, except that the pattern portion for expressing gloss matte on the decorative sheet of Example 2 was printed using a mixed color ink of yellow, red, and blue ink, which has a higher infrared transmittance than black ink made from a urethane-based ink.

[0084] 〔evaluation〕 The decorative sheets of Examples 1 to 6 and Comparative Examples 1 and 2 were evaluated by measuring infrared transmittance, measuring glossiness, and evaluating gloss / matt design. The evaluation methods were as follows.

[0085] (Measurement of infrared transmittance) After printing a pattern portion for developing a glossy matte finish on one side of the colored thermoplastic resin layer and a picture layer on the other side, infrared transmittance was measured. The infrared transmittance was measured using an ultraviolet-visible-near-infrared spectrophotometer (UV-3600, manufactured by Shimadzu Corporation). For each of the decorative sheets of Examples 1 and 2 and Comparative Examples 1 and 2, the infrared transmittance of light having wavelengths of 800 nm, 2000 nm, and 2500 nm was measured.

[0086] (Gloss measurement) After the embossing was completed, the glossiness of the surface protective layer was measured at an 85° angle using a specular glossmeter (micro-TRI-gloss manufactured by BYK) in the areas that overlapped the matte gloss pattern in a plan view and in the areas that did not overlap the matte gloss pattern in a plan view.

[0087] (GM (Gloss Matte) design) The evaluation was based on whether the difference in gloss between the area of ​​the surface protection layer that overlaps with the pattern portion for expressing gloss matte in a planar view and the area that does not overlap with the pattern portion for expressing gloss matte in a planar view was greater than "3," which is the level at which gloss matte can be expressed.

[0088] ◎: 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 matte is visible. △: The gloss difference is smaller than "3", but the gloss matte expression is visible. ×: The gloss matte expression is not visible. The measurement and evaluation results are shown in Table 1.

[0089] [Table 1]

[0090] As shown in Table 1, when black ink having the property of absorbing light with wavelengths in the range of 800 nm to 2500 nm more than light with other wavelengths was used as the infrared-absorbing material (Examples 1 and 2), the infrared transmittance for light with a wavelength of 2500 nm was 23.6%, the infrared transmittance for light with a wavelength of 2000 nm was 16.5%, and the infrared transmittance for light with an wavelength of 800 nm was 1.4%, confirming that a good gloss / matt design could be obtained. It also shows that the difference in gloss is greater when the irradiation wavelength is the narrower 800 nm to 2500 nm than when the irradiation wavelength covers the entire infrared light range of 800 nm to 1 mm. Similarly, when tin-doped indium oxide, antimony-doped tin oxide, lanthanum hexaboride, and cesium-doped tungsten oxide were used as infrared absorbing materials having the property of absorbing light in the wavelength range of 800 nm or more and 2500 nm or less more than light of other wavelengths (Examples 3 to 6), results equivalent to those of Example 1 were obtained, and it was confirmed that good gloss matte design properties could be obtained.

[0091] On the other hand, when ink with a higher infrared transmittance than black ink was used (Comparative Examples 1 and 2), the infrared transmittance for light with a wavelength of 2500 nm was 71.8%, the infrared transmittance for light of 2000 nm was 64.5%, and the infrared transmittance for light of 800 nm was 22.1%.Even when the infrared transmittance was higher than in Examples 1 and 2 and the irradiation wavelength was 800 nm to 2500 nm, a sufficient gloss difference could not be obtained, and it was confirmed that a gloss-matt appearance could not be obtained in either Comparative Example 1 or 2. [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 step of laminating a colored resin layer, a pattern layer, a transparent resin layer, and a surface protective layer in this order; a step of forming a pattern portion for developing gloss matte on the other surface of the colored resin layer at a position synchronized with the pattern of the pattern layer; a step of irradiating light having a wavelength of 800 nm or more and 2500 nm or less, the power of which is greater than the power of light of other wavelengths, after the laminating step and the step of forming the pattern portion for developing gloss matte; and a step of pressing an embossing plate into the surface protective layer to form an embossed portion, after the step of irradiating light, an ink for forming a pattern portion for developing gloss matte, An ink for forming a pattern portion that exhibits gloss and matte finish, characterized by having the property of absorbing light having a wavelength in the range of 800 nm to 2500 nm more than light of other wavelengths.

2. 2. The ink for forming a pattern portion for producing a matte gloss finish according to claim 1, comprising a black ink containing carbon black.

3. 2. The ink for forming a pattern portion for expressing gloss and matte finish according to claim 1, characterized in that it contains at least one inorganic material selected from the group consisting of tin-doped indium oxide, antimony-doped tin oxide, lanthanum hexaboride, and cesium-doped tungsten oxide.

4. a step of laminating a colored resin layer, a pattern layer, a transparent resin layer, and a surface protective layer in this order; A process of forming a pattern portion for expressing gloss matte on the other surface of the colored resin layer at a position synchronized with the pattern of the pattern layer using a material having the property of absorbing light of a wavelength in the range of 800 nm to 2500 nm more than light of other wavelengths; After the laminating step and the step of forming the gloss matte pattern portion, a step of irradiating light having a wavelength in the range of 800 nm to 2500 nm inclusive, the power of light having a wavelength greater than the power of light having other wavelengths; A method for producing a decorative sheet, comprising the step of forming an embossed portion by pressing an embossing plate into the surface protective layer after the step of irradiating with light.

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