Decorative sheet, decorative plate, and method for producing decorative sheet

Abstract

To provide a decorative sheet having a base material comprising a vinyl chloride resin and a transparent resin layer and capable of enhancing the adhesion strength between the base material and the transparent resin layer while having a pattern layer and a bright layer, a decorative panel and a method for manufacturing the decorative sheet.SOLUTION: The decorated sheet 10 is constituted by laminating a vinyl chloride resin-made base material 11, an ink layer 12 having a pattern layer 12a comprising an evaporation drying type ink and a bright layer 12b comprising a bright ink and a vinyl chloride resin-made transparent layer 13 having light permeability in this order and has adhesion strength of 8N / inch or more between the base material 11 and the transparent layer 13.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a decorative sheet, a decorative board, and a method for producing a decorative sheet. [Background technology]

[0002] Decorative sheets used for the interior and exterior decoration of buildings, furniture coverings, etc., have a pattern layer provided on a resin substrate, with a transparent resin layer provided on the pattern layer. In order to improve the design of such decorative sheets, the pattern layer is formed by inkjet printing with ultraviolet-curable ink (UV ink), resulting in a high-definition pattern, and a glitter layer is further formed on the pattern layer using glitter ink containing glitter pigments, thereby enhancing the gloss and creating a luxurious feel. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-195917 Summary of the Invention [Problem to be solved by the invention]

[0004] In the decorative sheets described above, for example, vinyl chloride resin may be applied to the substrate or transparent resin layer in order to improve weather resistance. Such decorative sheets can be produced by forming a pattern layer on a vinyl chloride resin substrate by inkjet printing with UV ink, forming a glossy layer on the pattern layer with glossy ink, and then overlaying a transparent resin layer made of vinyl chloride resin on the glossy layer and performing a doubling (thermal lamination) process.

[0005] However, when a decorative sheet comprising a vinyl chloride resin substrate and a transparent resin layer as described above is produced by doubling, it has been difficult to obtain sufficient adhesive strength between the substrate and the transparent resin layer. The reasons for this are thought to be as follows.

[0006] UV ink solidifies immediately upon exposure to ultraviolet (UV) light when applied to the substrate, making it difficult to spread and prone to thickening, leading to the formation of minute irregularities on the surface. Air trapped in these minute recesses prevents the layer above the UV ink design layer from making contact with the recessed areas, resulting in point contact rather than surface contact. This is thought to reduce the adhesive strength with the layer above the design layer, making it difficult to achieve sufficient adhesion strength between the substrate and the transparent resin layer.

[0007] For these reasons, the present invention aims to provide a decorative sheet and decorative board that has a substrate and a transparent resin layer made of vinyl chloride resin, and that can increase the adhesion strength between the substrate and the transparent resin layer while also having a picture layer and a glossy layer, as well as a method for manufacturing a decorative sheet. [Means for solving the problem]

[0008] In order to solve the above-mentioned problems, the decorative sheet of the present invention is characterized by comprising a substrate made of vinyl chloride resin, an ink layer having a pattern layer made of evaporation-drying ink and a glossy layer made of glossy ink, and a transparent resin layer made of vinyl chloride resin with optical transparency laminated in this order, and the adhesive strength between the substrate and the transparent resin layer is 8 N / inch or more.

[0009] Furthermore, the decorative sheet according to the present invention is preferably the decorative sheet described above, wherein the ink layer is provided with the glitter layer on at least one side of the picture layer, the substrate side and the transparent resin layer side.

[0010] Furthermore, the decorative sheet according to the present invention is preferably the decorative sheet described above, wherein a primer layer is disposed between the substrate and the ink layer.

[0011] Furthermore, the decorative sheet according to the present invention is preferably the decorative sheet described above, wherein a surface protective layer having optical transparency is disposed on the transparent resin layer.

[0012] Furthermore, in the decorative sheet according to the present invention, it is preferable that the evaporation drying ink is a water-based ink.

[0013] Furthermore, in order to solve the above-mentioned problems, the decorative board according to the present invention is characterized by comprising the above-mentioned decorative sheet and a substrate laminated on the base material side of the decorative sheet.

[0014] The method for manufacturing a decorative sheet according to the present invention, which solves the above-mentioned problems, is a method for manufacturing a decorative sheet as described above, characterized in that the evaporative drying ink is inkjet printed onto the substrate to form the pattern layer, and the glossy ink is gravure printed to form the glossy layer, thereby providing the ink layer, and then the substrate and the transparent resin layer are heated and pressed together so that the ink layer is sandwiched between them to bond the transparent resin layer. [Effects of the Invention]

[0015] According to the present invention, a decorative sheet and decorative board can be provided which have a substrate and a transparent resin layer made of vinyl chloride resin, and which have a picture layer and a glossy layer, while still being able to increase the adhesion strength between the substrate and the transparent resin layer, as well as a method for manufacturing a decorative sheet. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a cross-sectional view showing a schematic configuration of a main embodiment of a decorative sheet according to the present invention. [Figure 2] 1 is a cross-sectional view showing a schematic configuration of a main embodiment of a decorative board according to the present invention. [Figure 3] FIG. 2 is a cross-sectional view showing a schematic configuration of another embodiment of the decorative sheet according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] The decorative sheet and decorative board according to the present invention, as well as the method for manufacturing the decorative sheet, will be described with reference to the drawings. Note that the present invention is not limited to the following embodiments described with reference to the drawings, and various technical matters described in each embodiment can be appropriately combined or substituted as necessary.

[0018] [Main embodiment] The main embodiments of the decorative sheet, decorative board, and method for manufacturing a decorative sheet according to the present invention will be described with reference to FIGS.

[0019] <Overall structure of decorative sheet> As shown in Figure 1, a design layer 12a made of evaporation-drying ink is disposed on a vinyl chloride resin substrate 11. A glossy layer 12b made of glossy ink is disposed on the design layer 12a. A light-transmitting transparent resin layer 13 made of vinyl chloride resin is disposed on the glossy layer 12b. The adhesive strength between the substrate 11 and the transparent resin layer 13 is 8 N / inch or more.

[0020] That is, the decorative sheet 10 according to this embodiment comprises a substrate 11, an ink layer 12 including a pattern layer 12a and a glitter layer 12b, and a transparent resin layer 13 laminated in this order, with the adhesive strength between the substrate 11 and the transparent resin layer 13 being 8 N / inch or more. Each layer of the decorative sheet 10 according to this embodiment will be described in detail below.

[0021] <Base material 11> The substrate 11 is made of vinyl chloride resin and may contain various additives as required. The substrate 11 preferably has a thickness of 30 μm or more and 200 μm or less.

[0022] <Picture layer 12a> The pattern layer 12a is formed from an evaporation-drying type ink. The evaporation-drying type ink is obtained by mixing a coloring agent and a binder in a liquid medium and dispersing or dissolving them, and contains various other additives as required. Examples of the evaporation-drying type ink include aqueous inks and latex inks in which the liquid medium is aqueous, and oil-based inks in which the liquid medium is oil-based. Examples of the aqueous liquid medium include water and the like. The pattern layer 12a preferably has a thickness of 0.1 μm or more and 10 μm or less.

[0023] 〈Glossy layer 12b〉 The glossy layer 12b is formed from a glossy ink. The glossy ink is an evaporation-drying type obtained by mixing a pearl pigment and a binder in a liquid medium and dispersing or dissolving them, and contains various other additives as required. Examples of the pearl pigment include titanium dioxide-coated mica, gold, silver, aluminum, and the like. The pearl pigment preferably has an average diameter of 1 μm or more and 100 μm or less, and more preferably 5 μm or more and 60 μm or less. The glossy layer 12b preferably has a thickness of 0.1 μm or more and 10 μm or less.

[0024] 〈Transparent resin layer 13〉 The transparent resin layer 13 is made of a vinyl chloride resin and can also contain various additives as required. The transparent resin layer 13 preferably has a thickness of 30 μm or more and 200 μm or less.

[0025] 〈Overall structure of the decorative panel〉 And, as shown in FIG. 2, the decorative panel according to the present embodiment is such that the above-described decorative sheet 10 is disposed on the substrate 101. The substrate 101 and the decorative sheet 10 are joined via an adhesive layer (not shown). That is, in the present embodiment, the decorative panel 100 is configured to include the decorative sheet 10 and the substrate 101 laminated on the base material 11 side of the decorative sheet 10.

[0026] 〈Substrate 101〉 Substrate 101 is made of a hard material such as a wood substrate such as wood plywood, a composite substrate made of a mixture of wood flour and plastic, or a resin substrate made of polyolefins such as polyethylene (PE) and polypropylene (PP), or polyvinyl chloride (PVC). Examples of wood substrates include tropical plywood, particle board, medium-density fiberboard (MDF), and ordinary plywood as specified by the Japanese Agricultural Standards. Substrates made of olefin-based resins containing wood flour can also be used. Substrate 101 preferably has a thickness of 30 μm or more and 200 μm or less. When substrate 101 is made of a wood-based material, the adhesive layer is preferably made of a vinyl acetate emulsion, a two-component curing urethane, or the like.

[0027] <Method for manufacturing decorative sheet 10> The manufacturing method of the decorative sheet 10 according to this embodiment as described above will be described below. First, a film-shaped substrate 11 made of vinyl chloride resin is prepared, and a pattern is printed on the surface of the substrate 11 using evaporation-drying ink by inkjet printing. After that, the substrate is heated with heat rays such as infrared rays or hot air to evaporate the liquid medium and dry the ink, forming the pattern layer 12a.

[0028] Next, glitter ink is printed on the surface of the design layer 12a by gravure printing, and then the liquid medium is evaporated by heating with infrared or other heat rays or hot air, etc., to dry the ink and form the glitter layer 12b. This forms the ink layer 12 on the substrate 11. Next, a film-shaped transparent resin layer 13 made of vinyl chloride resin is prepared, and the substrate 11 and the transparent resin layer 13 are overlapped with the ink layer 12 sandwiched between them, and then thermally doubled and heat-pressed to obtain the decorative sheet 10.

[0029] <Effects of Decorative Sheet 10> In the decorative sheet 10 manufactured in this manner, the pattern layer 12a is formed from an evaporation-drying ink, and since the evaporation-drying ink adheres to the substrate 11, wets and spreads, and then dries, the thickness of the pattern layer 12a tends to be uniform, and the generation of fine irregularities on the surface of the pattern layer 12a can be greatly suppressed.

[0030] This significantly increases the surface contact area between the pattern layer 12a and the glossy layer 12b, thereby increasing the adhesive strength between the pattern layer 12a and the glossy layer 12b, thereby increasing the adhesive strength between the substrate 11 and the transparent resin layer 13 to 8 N / inch or more.

[0031] Therefore, the decorative sheet 10 of this embodiment and the decorative panel 100 using it have a base material 11 and a transparent resin layer 13 made of vinyl chloride resin, and while also having a pattern layer 12a and a glossy layer 12b, the adhesion strength between the base material 11 and the transparent resin layer 13 can be increased.

[0032] Furthermore, because the glossy layer 12b is also formed using an evaporation-drying ink, the thickness of the glossy layer 12b is easily made uniform and the generation of minute irregularities on the surface of the glossy layer 12b can be suppressed. This significantly increases the surface contact area with the transparent resin layer 13 disposed on the glossy layer 12b, increasing the adhesive strength between the glossy layer 12b and the transparent resin layer 13 and further increasing the adhesion strength between the substrate 11 and the transparent resin layer 13.

[0033] Furthermore, according to the manufacturing method of the decorative sheet 10 of this embodiment, it is possible to easily manufacture a decorative sheet 10 that has a substrate 11 and a transparent resin layer 13 made of vinyl chloride resin, as well as a pattern layer 12a and a glossy layer 12b, while still having increased adhesion strength between the substrate 11 and the transparent resin layer 13.

[0034] Furthermore, since the picture layer 12a is formed by inkjet printing, it is easy to make the picture layer 12a highly precise. Furthermore, since the glitter layer 12b is formed by gravure printing, the diameter size of the pearl pigment in the glitter ink can be increased, and the glitter of the glitter layer 12b can be enhanced.

[0035] [Other embodiments] In the above-described embodiment, the decorative sheet 10 is described as having the substrate 11, the ink layer 12 having the picture layer 12a and the glossy layer 12b, and the transparent resin layer 13 laminated in this order, but the present invention is not limited to this. As other embodiments, for example, as shown in Fig. 3, it is possible to have an ink layer 22 in which the picture layer 12a is sandwiched between a pair of glossy layers 12b, 22b, a base layer 24 disposed between the substrate 11 and the ink layer 22 to improve adhesion between the substrate 11 and the ink layer 22, and a surface protection layer 25 disposed on the transparent resin layer 13 to protect the surface.

[0036] Here, it is also possible to omit the glossy layer 12b on the transparent resin layer 13 side and create a decorative sheet in which an ink layer consisting of the glossy layer 22b and the design layer 12a on the substrate 11 side is applied. In other words, the ink layer is provided with a glossy layer on at least one side of the design layer 12a, either the substrate 11 side or the transparent resin layer 13 side. [Example]

[0037] Examples carried out to confirm the effects of the present invention will be specifically described below, but the present invention is not limited to the specific examples described below.

[0038] [Preparation of test specimens and comparison specimens] <Test specimen 1> First, a white base paper made of vinyl chloride resin film manufactured by Bando Chemical Industries, Ltd. was prepared as a substrate (thickness: 50 μm). A design was inkjet-printed on the surface of this substrate using an evaporation-drying water-based inkjet ink manufactured by Toyo Ink Co., Ltd., and then the ink was dried by heating to evaporate the ink medium, forming a design layer (resolution: 1200 dpi × 1200 dpi).

[0039] Next, the surface of the design layer is gravure-printed with an evaporation-drying type glossy ink, and then heated to evaporate the ink medium, thereby drying the ink and forming a glossy layer, thereby forming an ink layer on the substrate.

[0040] Next, a vinyl chloride resin clear film was prepared as a transparent resin layer (thickness 80 μm). The substrate and the transparent resin layer were then overlapped with the ink layer sandwiched between them, and thermally doubled and heat-pressed to produce decorative sheet specimen 1.

[0041] <Comparative body 1> Comparative decorative sheet 1 was produced under the same conditions as test sample 1, except that the glossy layer was omitted and an ink layer was formed, that is, the ink layer was formed only with a picture layer.

[0042] <Comparative body 2> Comparative decorative sheet 2 was produced under the same conditions as test piece 1, except that a UV-curable inkjet ink was used instead of the water-based inkjet ink, and the image layer was formed by irradiating the ink with UV light to solidify it.

[0043] [Evaluation method] <Design> The design of Test Sample 1 and Comparative Samples 1 and 2 was evaluated visually. The results are shown in Table 1. In Table 1, "○" indicates an excellent design that is both highly detailed and has a luxurious feel, while "×" indicates a design that is highly detailed but lacks a luxurious feel.

[0044] <Adhesion strength> For specimen 1 and comparative specimens 1 and 2, a 180-degree peel test was performed between the substrate and the transparent resin layer in accordance with Japanese Industrial Standard "JIS K 6854-2" to measure the adhesive strength and evaluate the adhesion strength. The results are shown in Table 1. In Table 1, "○" indicates that the adhesive strength was 8 N / inch or more, and "×" indicates that the adhesive strength was less than 8 N / inch.

[0045] [Evaluation results] The evaluation results are shown in Table 1 below.

[0046] [Table 1]

[0047] As can be seen from Table 1, Comparative Example 1, which did not include a glossy layer, achieved a grade of "Good" for adhesion strength, but an "Poor" for design. Comparative Example 2, which used a UV-curable inkjet ink, achieved a grade of "Good" for design, but an "Poor" for adhesion strength. Therefore, Comparative Examples 1 and 2 received an overall grade of "Poor."

[0048] In contrast, for specimen 1, both the design and adhesive strength were rated as "good," resulting in an overall rating of "good." This confirmed the effects of the present invention. [Industrial Applicability]

[0049] The present invention provides decorative sheets and decorative boards that have a substrate and a transparent resin layer made of vinyl chloride resin, and that have a pattern layer and a glossy layer, while still being able to increase the adhesion strength between the substrate and the transparent resin layer, and a method for manufacturing decorative sheets, and therefore can be used to great advantage in various industries, including the construction industry. [Explanation of symbols]

[0050] 10 Decorative Sheet 11 Base material 12 Ink layer 12a Picture layer 12b Bright layer 13 Transparent resin layer 20 Decorative Sheet 22 Ink layer 22b Bright layer 24 Base layer 25 Surface protective layer 100 decorative panels 101 Substrate

Claims

1. a base material made of vinyl chloride resin; an ink layer including a pattern layer made of an evaporation drying type ink and a glitter layer made of a glitter ink; A transparent resin layer made of vinyl chloride resin and having optical transparency. These are stacked in this order, The adhesive strength between the substrate and the transparent resin layer is 8 N / inch or more. A decorative sheet characterized by:

2. The ink layer has the glitter layer on at least one side of the picture layer, the side of the substrate, and the side of the transparent resin layer.

2. The decorative sheet according to claim 1.

3. A primer layer is disposed between the substrate and the ink layer.

2. The decorative sheet according to claim 1.

4. A surface protection layer having optical transparency is disposed on the transparent resin layer.

2. The decorative sheet according to claim 1.

5. The evaporation-drying ink is a water-based ink.

2. The decorative sheet according to claim 1.

6. The decorative sheet according to any one of claims 1 to 5, a substrate laminated on the base material side of the decorative sheet; A decorative panel characterized by comprising:

7. A method for producing the decorative sheet according to claim 1, The ink layer is formed by ink-jet printing the evaporation drying ink onto the substrate to form the pattern layer and gravure printing the glitter ink to form the glitter layer, and then: The substrate and the transparent resin layer are heated and pressed together with the ink layer sandwiched therebetween to bond the transparent resin layer. A method for producing a decorative sheet, comprising:

Images