Decorative sheet

Abstract

To provide a decorative sheet improved in texture expression by light reflection.SOLUTION: A decorated sheet 10 includes a colored sheet base material 1, a picture pattern layer 2 provided on an upper side UP of the colored sheet base material 1, a first concave 4a recessed to a lower side LO, and a second concave 4a adjacent to the first concave 4a and recessed to the lower side LO more than the first concave 4b. A first surface protection layer 5 provided on the upper side UP of the thermoplastic-resin layer 4 and covering the 4a of the first recess and the 4b of the second recess, the first surface protection layer 5 being provided on the upper side UP of the thermoplastic-resin layer 4 and covering the 4a of the first recess; And a second surface protection layer 6 that does not cover the second recess side 4b, wherein the first recess side 4a has a height H1 of 20 μm or more and 160 μm or less, and the second recess side 4b has a height H2 of 10 μm or more and a widthwise W1 of 150 μm or more and 600 μm or less.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Conventionally, decorative sheets used as surface materials for furniture and residential building materials include decorative sheets whose gloss is adjusted by laminating multiple layers with different glosses. For example, the gloss of a decorative sheet can be adjusted by laminating a picture pattern layer containing a glitter pigment and a low-gloss protective layer. Decorative sheets with adjusted gloss have excellent texture expression through light reflection and have a visual three-dimensional effect.

[0003] There are also decorative sheets that have a three-dimensional feel to the touch by forming a concave-convex pattern (embossment) on the surface by embossing or the like.

[0004] By imparting a visual three-dimensional effect and a three-dimensional effect by touch, it is possible to realize a decorative sheet having a design that imitates materials such as wood grain, stone, etc. Furthermore, by harmonizing the gloss pattern resulting from differences in gloss and the uneven pattern resulting from embossing with the pattern of the picture pattern layer, it is possible to realize a decorative sheet with even better design expression.

[0005] A decorative sheet with adjusted gloss is disclosed in Patent Document 1. The decorative material described in Patent Document 1 is a decorative material comprising a substrate having a pattern layer and a protective layer made primarily of a transparent resin composition provided on the surface thereof. The protective layer is composed of, in order from the substrate side, a first protective layer containing a matting agent and a second protective layer containing hard spherical particles but no matting agent. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 4578756 Summary of the Invention [Problem to be solved by the invention]

[0007] However, decorative sheets in which a low-gloss protective layer is provided over the entire surface of the pattern layer, such as the decorative material described in Patent Document 1, make it difficult to express gloss through partial bright spots, and there is a risk that the texture expression due to light reflection will become unclear.

[0008] In view of the above circumstances, an object of the present invention is to provide a decorative sheet that improves the expression of texture through light reflection. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention proposes the following means. The decorative sheet of the present invention has a colored sheet substrate, a picture pattern layer provided on the upper side of the colored sheet substrate, a first recess that is concave downward, and a second recess that is adjacent to the first recess and is concave downward more than the first recess on its surface, and is also provided with a thermoplastic resin layer provided on the upper side of the picture pattern layer, a first surface protective layer provided on the upper side of the thermoplastic resin layer and covering the first recess and the second recess, and a second surface protective layer provided on the upper side of the first surface protective layer and covering the first recess but not the second recess, wherein the first recess has a height of 20 μm or more and 160 μm or less, and the second recess has a height of 10 μm or more and a width of 150 μm or more and 600 μm or less.

[0010] In the decorative sheet, the 60-degree specular gloss of the small area on the upper surface where the second recess is provided may be 20 or more and 80 or less, and the 60-degree specular gloss of the area other than the small area may be 2 or more and 15 or less.

[0011] In the decorative sheet, the arithmetic mean roughness Ra of the small regions on the upper surface where the second recesses are provided may be 0.20 μm or more and 0.85 μm or less.

[0012] In the decorative sheet, the first surface protective layer may have a thickness of 3 μm or more and 30 μm or less. [Effects of the Invention]

[0013] According to the present invention, a decorative sheet can be provided that improves the texture expression due to light reflection. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a cross-sectional view schematically showing a decorative sheet according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] An embodiment of the present invention will be described with reference to the drawings.

[0016] Fig. 1 is a cross-sectional view schematically showing a decorative sheet 10 according to this embodiment. Note that Fig. 1 is a diagram schematically showing each component of the decorative sheet 10, and the scale and ratio of each component of the decorative sheet 10 are not limited to those shown in Fig. 1.

[0017] In this embodiment, as shown in Figure 1, the thickness direction of the decorative sheet 10 is defined as the "vertical direction V", the side of the decorative sheet 10 on which the second surface protective layer 6 is provided is defined as the "upper side UP" in the vertical direction V, and the side opposite the upper side UP is defined as the "lower side LO" in the vertical direction V.

[0018] The sheet surface direction of the decorative sheet 10 is defined as the "width direction C." Here, the "sheet surface direction (width direction C)" of the decorative sheet 10 refers to a direction perpendicular to the up-down direction V. For example, when the up-down direction V refers to the vertical direction, the sheet surface direction (width direction C) refers to the horizontal direction.

[0019] The decorative sheet 10 comprises a colored sheet substrate 1, a picture pattern layer 2, an adhesive layer 3, a thermoplastic resin layer 4, a first surface protective layer 5, a second surface protective layer 6, and a back surface coating layer 7.

[0020] The colored sheet substrate 1 is a sheet-like layer made of a known material on which printing can be performed. As the material of the colored sheet substrate 1, for example, a resin material such as a thermoplastic resin can be used.

[0021] Examples of the thermoplastic resin used for the colored sheet substrate 1 include vinyl chloride resin, acrylic resin, polyolefin-based polypropylene resin, polyethylene resin, and the like.

[0022] As the thermoplastic resin used for the colored sheet substrate 1, it is preferable to use a polyolefin resin from the viewpoints of environmental compatibility, processability, cost, and the like.

[0023] An appropriate material can be selected for the colored sheet substrate 1, taking into consideration ease of sheeting, printability, and suitability for bending. Here, sheeting of the colored sheet substrate 1 refers to a processing method for forming the material used for the colored sheet substrate 1 into a sheet.

[0024] The colored sheet substrate 1 may contain a colorant such as a pigment. By coloring the colored sheet substrate 1 with a colorant, when a substrate such as MDF is attached to the lower side LO of the decorative sheet 10, it is possible to impart concealing properties that prevent the color and texture of the substrate from being transmitted through to the surface 10s of the decorative sheet 10. The surface 10s of the decorative sheet 10 refers to the surface of the upper side UP of the decorative sheet 10, as shown in FIG. 1.

[0025] Furthermore, by coloring the colored sheet substrate 1, any hue can be imparted as the base color of the picture pattern layer 2.

[0026] For example, when the colored sheet substrate 1 is formed by sheeting a thermoplastic resin, the colored sheet substrate 1 can be colored by mixing and kneading a coloring agent such as a pigment into the thermoplastic resin.

[0027] Alternatively, the colored sheet substrate 1 may be colored by providing a colored layer on the upper surface UP of the colored sheet substrate 1 as a solid ink layer using a coating method, printing method, or the like.

[0028] The picture pattern layer 2 is a layer provided on the upper side UP of the colored sheet substrate 1. The picture pattern layer 2 is formed by printing a pattern such as wood grain, cork, stone grain, tile, pottery, or an abstract pattern.

[0029] As a printing method for the picture pattern layer 2, for example, a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be used.

[0030] Known printing inks suitable for the printing method to be adopted can be used for the picture pattern layer 2. It is preferable to use an appropriate printing ink for the picture pattern layer 2 in consideration of adhesion to the colored sheet substrate 1, printability, or weather resistance.

[0031] In this embodiment, the picture pattern layer 2 is partially provided on the upper side UP of the colored sheet substrate 1 as shown in FIG. 1, but may cover the entire surface of the colored sheet substrate 1 (the surface of the upper side UP).

[0032] The adhesive layer 3 is a layer provided on the upper side UP of the picture and pattern layer 2. When the picture and pattern layer 2 is partially provided on the surface of the colored sheet substrate 1, the adhesive layer 3 is provided on the upper side UP of the colored sheet substrate 1 and the picture and pattern layer 2.

[0033] The adhesive layer 3 is a layer provided to improve the adhesion between the colored sheet substrate 1 and the picture pattern layer 2 and the thermoplastic resin layer 4.

[0034] The adhesive layer 3 strengthens the adhesion between the colored sheet substrate 1 and the picture pattern layer 2 and the thermoplastic resin layer 4, thereby imparting to the decorative sheet 10 the ability to be bent to conform to curved or right-angled surfaces.

[0035] The adhesive layer 3 is preferably made of a transparent or semi-transparent material that allows the design of the design pattern layer 2 to be seen through.

[0036] The adhesive layer 3 may be made of a material such as a urethane-based material, an acrylic-based material, an ethylene-vinyl acetate copolymer, a vinyl chloride-vinyl acetate copolymer, a polyester-based material, or a polyolefin-based material.

[0037] Known printing methods such as gravure printing, offset printing, flexographic printing, inkjet printing, etc. can be used to laminate the adhesive layer 3. The adhesive layer 3 may be laminated using a known coating device.

[0038] The thermoplastic resin layer 4 is a layer provided on the upper side UP of the adhesive layer 3. For the thermoplastic resin layer 4, it is preferable to use a transparent or semi-transparent material that allows the pattern of the picture pattern layer 2 to be seen through the adhesive layer 3.

[0039] The thermoplastic resin layer 4 may be made of, for example, vinyl chloride resin, acrylic resin, or polyolefin-based polypropylene resin or polyethylene resin.

[0040] As the material used for the thermoplastic resin layer 4, it is preferable to use a polyolefin resin from the viewpoints of environmental compatibility, processability, cost, and the like.

[0041] An appropriate material can be selected for the thermoplastic resin layer 4, taking into consideration ease of sheeting, printability, and suitability for bending. Here, sheeting of the thermoplastic resin layer 4 refers to a processing method in which the material used for the thermoplastic resin layer 4 is formed into a sheet.

[0042] For the thermoplastic resin layer 4, it is preferable to use a material that has bending workability and can prevent whitening and cracks from occurring at bent portions.

[0043] By providing the thermoplastic resin layer 4, thickness and depth can be imparted to the decorative sheet 10 from a design perspective. In addition, by providing the thermoplastic resin layer 4, the weather resistance and abrasion resistance of the decorative sheet 10 can be improved.

[0044] The thermoplastic resin layer 4 can be formed, for example, by melt extrusion molding.

[0045] Alternatively, the thermoplastic resin layer 4 may be formed by laminating sheets made of polyolefin resin or the like by a known lamination method such as dry lamination, wet lamination, non-solvent lamination, wax lamination, or thermal lamination.

[0046] The surface (upper side UP) of the thermoplastic resin layer 4 is provided with a first recess 4a recessed toward the lower side LO and a second recess 4b recessed further toward the lower side LO than the first recess 4a.

[0047] The first recesses 4a and the second recesses 4b are provided by, for example, embossing, which forms a concave-convex shape by pressing an embossing plate against the surface of the thermoplastic resin layer 4.

[0048] The first recess 4a and the second recess 4b are provided adjacent to each other in the width direction C. The first recess 4a may be provided to surround the second recess 4b in the width direction C.

[0049] The height H1 of the first recess 4a in the vertical direction V is 20 μm or more and 160 μm or less. The height H1 of the first recess 4a indicates the dimension in the vertical direction V between the apex located on the uppermost side UP and the bottom point located on the lowermost side LO of the first recess 4a.

[0050] By setting the height H1 of the first recess 4a to 20 μm or more, the first recess 4a can have a shape that can be macroscopically recognized as a three-dimensional object.

[0051] Furthermore, by making the height H1 of the first recesses 4a 20 μm or more, it is possible to achieve a feel that is closer to the real thing when touched with the fingers on the surface 10s of the decorative sheet 10. Here, the real thing refers to the material that the decorative sheet 10 imitates by the pattern of the picture pattern layer 2.

[0052] For example, if the picture pattern layer 2 has a stone pattern, the decorative sheet 10 is a decorative material that imitates stone. By making the height H1 of the first recesses 4a 20 μm or more, the decorative sheet 10 can be given a texture that is closer to that of actual stone.

[0053] By setting the height H1 of the first recess 4a to 160 μm or less, it is possible to prevent the first surface protective layer 5 or the second surface protective layer 6 from being missing when the first surface protective layer 5 or the second surface protective layer 6 described below is applied to the upper side UP of the thermoplastic resin layer 4.

[0054] Here, coating voids refer to an area that is actually coated insufficiently compared to a predetermined area that should be coated.

[0055] The height H2 of the second recess 4b in the vertical direction V is 10 μm or more. The height H2 of the second recess 4b indicates the dimension in the vertical direction V between the bottom point of the lowest side LO of the first recess 4a adjacent to the second recess 4b and the bottom point of the lowest side LO of the second recess 4b.

[0056] The width W1 of the second recess 4b is 150 μm or more and 600 μm or less. The width W1 of the second recess 4b is the dimension in the width direction C, and indicates the diameter of the second recess 4b in the width direction C when the second recess 4b has a circular shape in a plan view from the upper side UP.

[0057] The thermoplastic resin layer 4 may have a first recess 4a that is not adjacent to a second recess 4b, as shown in Fig. 1. The first recess 4a and the second recess 4b are provided, for example, at positions that are in harmony with the pattern of the picture pattern layer 2.

[0058] The first recess 4a and the second recess 4b may have a continuous multi-step shape within the maximum height difference of the uneven shape formed by the first recess 4a and the second recess 4b.

[0059] For the embossing plate (shaping plate) that forms the first recesses 4a and the second recesses 4b, it is preferable to use a roll-shaped embossing roll in order to enable continuous processing.

[0060] The first surface protective layer 5 is a layer provided on the upper side UP of the thermoplastic resin layer 4. The first surface protective layer 5 covers the entire surface of the thermoplastic resin layer 4.

[0061] For the first surface protective layer 5, it is preferable to use a transparent or semi-transparent material that allows the design of the design pattern layer 2 to be seen through the adhesive layer 3 and the thermoplastic resin layer 4.

[0062] As the material for the first surface protective layer 5, it is preferable to use a thermosetting resin from the viewpoints of adhesion to the thermoplastic resin layer 4, conformability to deformation of the decorative sheet 10, and scratch resistance.

[0063] Furthermore, from the viewpoint of cost and versatility, it is more preferable to use a thermosetting resin (binder) having urethane bonds, such as a two-component curing urethane resin, as the material for the first surface protective layer 5.

[0064] The two-component curing urethane resin used for the first surface protective layer 5 may be, for example, a urethane resin containing a polyol as a main component and an isocyanate as a crosslinking agent (curing agent).

[0065] The polyol may be one having two or more hydroxyl groups in the molecule, such as polyethylene glycol, polypropylene glycol, acrylic polyol, polyester polyol, polyether polyol, polycarbonate polyol, or polyurethane polyol.

[0066] Furthermore, as the isocyanate, a polyvalent isocyanate having two or more isocyanate groups in the molecule can be used. For example, aromatic isocyanates such as 2,4-tolylene diisocyanate, xylene diisocyanate, and 4,4'-diphenylmethane diisocyanate, or aliphatic (or alicyclic) isocyanates such as 1,6-hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, and hydrogenated diphenylmethane diisocyanate can be used.

[0067] As the isocyanate, an adduct or polymer of the above-mentioned various isocyanates can be used, for example, an adduct of tolylene diisocyanate, a tolylene diisocyanate trimer, etc. can be used.

[0068] Of the above isocyanates, aliphatic (or alicyclic) isocyanates are preferred because they can also provide good weather resistance and heat yellowing resistance. For example, the weather resistance and heat yellowing resistance of the decorative sheet 10 can be improved by using 1,6-hexamethylene diisocyanate.

[0069] Furthermore, from the viewpoint of hardness, it is preferable to use an ionizing radiation curable resin as the material for the first surface protective layer 5. By using an ionizing radiation curable resin for the first surface protective layer 5, the scratch resistance of the decorative sheet 10 can be improved.

[0070] Examples of the ionizing radiation curable resin used in the first surface protective layer 5 include ultraviolet curable resins such as (meth)acrylic resins, silicone resins, polyester resins, urethane resins, amide resins, and epoxy resins.

[0071] By using the above-mentioned ultraviolet-curable resin for the first surface protective layer 5, the hardness of the surface 10s of the decorative sheet 10 can be improved, and the surface properties of the decorative sheet 10 such as abrasion resistance, scratch resistance, and solvent resistance can be improved.

[0072] The binder used in the first surface protective layer 5 may be a mixture of a thermosetting resin and an ionizing radiation curing resin.

[0073] In order to maintain high light reflectance, it is preferable not to add resin fillers or inorganic fillers to the first surface protective layer 5 in order to impart scratch resistance. However, if a filler is added to the first surface protective layer 5, it is preferable to suppress light scattering by making the optical refractive indexes of the binder resin and the filler approximately equal, and to select a material that does not impair the smoothness of the surface by using a filler with a particle size sufficiently smaller than the thickness of the first surface protective layer 5.

[0074] The thickness of the first surface protective layer 5 is smaller than the height H1 of the first recess 4a and the height H2 of the second recess 4b. The thickness of the first surface protective layer 5 is preferably 3 μm or more and 30 μm or less.

[0075] By making the thickness of the first surface protective layer 5 30 μm or less, the first surface protective layer 5 can be prevented from being applied so as to completely fill the first recesses 4a and second recesses 4b of the thermoplastic resin layer 4, thereby preventing the design of the decorative sheet 10 from being impaired.

[0076] Furthermore, by making the thickness of the first surface protective layer 5 3 μm or more, the first surface protective layer 5 can acquire a strength sufficient to protect the surface of the thermoplastic resin layer 4 .

[0077] Known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, and inkjet printing can be used to laminate the first surface protective layer 5. The first surface protective layer 5 may be laminated using a known coating device.

[0078] The second surface protective layer 6 is a layer provided on the upper side UP of the first surface protective layer 5. As shown in Fig. 1, the second surface protective layer 6 covers the first recesses 4a but does not cover the second recesses 4b. That is, the second surface protective layer 6 is provided on the surface (upper side UP) of the first surface protective layer 5 in an area excluding the second recesses 4b.

[0079] In the following description, as shown in Figure 1, the area on the surface 10s of the decorative sheet 10 where the first recess 4a and the second recess 4b are provided will be referred to as the "recessed area R," the area of ​​the recessed area R where the second recess 4b is provided will be referred to as the "small area (bright spot area) R1," and the area where the first recess 4a is provided will be referred to as the "coated area R2."

[0080] The recessed region R is a region formed by the small region R1 and the covered region R2, or by only the covered region R2.

[0081] The second surface protective layer 6 is provided on the surface 10s of the decorative sheet 10 except for the small region R1.

[0082] The second surface protective layer 6 is preferably made of a transparent or semi-transparent material that allows the design of the design layer 2 to be seen through the adhesive layer 3, thermoplastic resin layer 4 and first surface protective layer 5.

[0083] The second surface protective layer 6 may be made of the same material as the first surface protective layer 5. The second surface protective layer 6 has a lower gloss than the first surface protective layer 5.

[0084] The second surface protective layer 6 contains a resin filler or an inorganic filler. By adding a filler to the second surface protective layer 6, it is possible to impart to the second surface protective layer 6 mechanical properties such as gloss, touch, texture, surface strength, and abrasion resistance that are lower than those of the first surface protective layer 5.

[0085] The filler to be added to the second surface protective layer 6 may be, for example, silica, alumina, metal oxide, or beads or irregular particles of acrylic, polyolefin, silicone, or the like.

[0086] The thickness of the second surface protective layer 6, together with the thickness of the first surface protective layer 5, is preferably 3 μm or more and 30 μm or less. The total thickness of the first surface protective layer 5 and the second surface protective layer 6 is smaller than the height H1 of the first recess 4a.

[0087] Known printing methods such as gravure printing, offset printing, flexographic printing, silk screen printing, and inkjet printing can be used to laminate the second surface protective layer 6. The second surface protective layer 6 may be laminated using a known coating device.

[0088] By providing a covered area R2 covered by the second surface protective layer 6 and a small area R1 not covered by the second surface protective layer 6 on the surface 10s of the decorative sheet 10, it is possible to achieve a glossy appearance using partial bright spots, thereby realizing a decorative sheet 10 with improved texture expression due to light reflection.

[0089] The small region R1 is formed at the bottom of the recessed region R. The small region R1 preferably has a 60-degree specular gloss measured in accordance with JIS Z 8741 of 20 or more and 80 or less, and more preferably 50 or more and 80 or less.

[0090] On the surface 10s of the decorative sheet 10, the measured value of the 60-degree specular gloss of the area other than the small area R1 is preferably 2 or more and 15 or less.

[0091] Here, the region other than the small region R1 refers to the covered region R2 of the recessed region R and the region other than the recessed region R on the front surface 10s of the decorative sheet 10.

[0092] By setting the 60-degree specular gloss of the areas other than the small area R1 to 2 or more and 15 or less, the reflected light from the small area R1 is more visible on the surface 10s of the decorative sheet 10, further improving the texture expression by light reflection.

[0093] If the 60-degree specular gloss of the area other than the small area R1 is 15 or more, the reflected light from the corners of the covered area R2 will be intensified, and the light reflection from the small area R1 may become inconspicuous.

[0094] On the surface 10s of the decorative sheet 10, the arithmetic mean roughness Ra of the small regions R1 is preferably 0.20 μm or more and 0.85 μm or less.

[0095] The arithmetic mean roughness Ra of the small region R1 is a surface texture parameter obtained under the measurement conditions of a measuring needle R=2 μm and a cutoff λc=0.8 mm in the line roughness specified in JIS B 0601, and is a surface texture parameter that indicates the surface roughness in the thickness direction of the uneven surface shape of the first surface protective layer 5 in the small region R1.

[0096] The arithmetic mean roughness Ra is an index that indicates that the lower the value, the smoother the surface is. The smoother the surface, the less diffused reflection of light there is, and therefore the higher the light reflectance.

[0097] The uneven pattern formed by the first recesses 4a and the second recesses 4b and the arithmetic mean roughness Ra of the small regions R1 can be adjusted by an existing plate-making technique for an embossing plate that forms the first recesses 4a and the second recesses 4b.

[0098] Specifically, by combining embossed etching, multi-stage mask chemical etching, mechanical engraving, laser engraving, full or partial sandblasting, partial polishing, etc. to produce an embossed plate of the desired shape, a decorative sheet 10 with any desired relief pattern and surface quality parameters can be formed.

[0099] As described above, the small region R1 is a region where the second recess 4b is provided, and the width W1 of the second recess 4b is 150 μm or more and 600 μm or less.

[0100] If the width W1 of the second recesses 4b is smaller than 150 μm, the small regions R1 will be difficult to see as bright spots on the surface 10s of the decorative sheet 10, and the texture representation by light reflection may be poor.

[0101] That is, by making the width W1 of the second recesses 4b 150 μm or more, small regions R1 that are sufficiently visible as bright spots can be formed on the surface 10s of the decorative sheet 10, improving the texture expression by light reflection.

[0102] If the width W1 of the second recesses 4b is greater than 600 μm, the reflective surface of the small regions R1 on the surface 10s of the decorative sheet 10 will likely be visually perceived as a flat surface, and the three-dimensional effect of the decorative sheet 10 may be impaired.

[0103] Furthermore, if the width W1 of the second recess 4b is greater than 600 μm, there is a risk that the second surface protective layer 6 will flow into the small region R1 when the second surface protective layer 6 is applied, and the flowed-in second surface protective layer 6 may reduce the light reflectance of the small region R1.

[0104] In other words, by making the width W1 of the second recess 4b 600 μm or less, a sufficient three-dimensional effect can be imparted to the decorative sheet 10, and further, the flow of the second surface protective layer 6 into the small region R1 can be suppressed, thereby improving the coating stability of the second surface protective layer 6.

[0105] When small regions R1 are arranged over a wide area on the surface 10s of the decorative sheet 10, small regions R1 with sufficient light reflectivity can be arranged over a wide area by arranging multiple second recesses 4b, each having a width W1 of 150 μm or more and 600 μm or less, on the surface of the thermoplastic resin layer 4.

[0106] The back coating layer 7 is a layer provided on the lower side LO of the colored sheet substrate 1. The back coating layer 7 is provided for the purpose of improving the adhesion between the colored sheet substrate 1 and the adhesive when a substrate such as MDF is adhered to the lower side LO of the decorative sheet 10 with an adhesive to form a decorative board.

[0107] Therefore, it is preferable to use a material for the back surface coating layer 7 that corresponds to the type of adhesive to be applied to the surface of the lower side LO of the colored sheet substrate 1.

[0108] The back surface coating layer 7 may be made of a resin material such as a urethane-based, acrylic-based, ethylene-vinyl acetate copolymer-based, vinyl chloride-vinyl acetate copolymer-based, or polyester-based material.

[0109] In particular, it is preferable to use a two-component curing urethane resin material made by blending polyester polyol and polyisocyanate as the material for the back surface coating layer 7. Furthermore, by adding inorganic fillers such as silica, barium sulfate, calcium carbonate, etc. to these materials, the adhesive strength can be improved by the anchoring effect.

[0110] The back coating layer 7 can be laminated by a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing. The back coating layer 7 may be laminated using a known coating device.

[0111] The decorative sheet 10 of this embodiment has a colored sheet substrate 1, a picture pattern layer 2 provided on the upper side UP of the colored sheet substrate 1, a first recess 4a that is recessed on the lower side LO, and a second recess 4b that is adjacent to the first recess 4a and is recessed on the lower side LO below the first recess 4a, on its surface, and is equipped with a thermoplastic resin layer 4 provided on the upper side UP of the picture pattern layer 2, a first surface protective layer 5 provided on the upper side UP of the thermoplastic resin layer 4 and covering the first recess 4a and the second recess 4b, and a second surface protective layer 6 provided on the upper side UP of the first surface protective layer 5 and covering the first recess 4a but not the second recess 4b.

[0112] The first recess 4a has a height H1 of 20 μm or more and 160 μm or less. The second recess 4b has a height H2 of 10 μm or more and a width W1 of 150 μm or more and 600 μm or less.

[0113] According to the decorative sheet 10 of this embodiment, it is possible to provide a decorative sheet 10 that has improved texture expression due to light reflection.

[0114] Although one embodiment of the present invention has been described above in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design modifications and the like are also included within the scope of the present invention. Furthermore, the components shown in the above-described embodiment and the following modified examples can be appropriately combined to form a configuration.

[0115] (Variation 1) In the above embodiment, the decorative sheet 10 comprises an adhesive layer 3 and a backside coating layer 7, but the embodiment of the decorative sheet 10 is not limited to this. The decorative sheet does not have to comprise the adhesive layer 3 or the backside coating layer 7.

[0116] The adhesive layer 3 is a layer provided to improve the adhesion between the colored sheet substrate 1 and the picture pattern layer 2 and the thermoplastic resin layer 4.

[0117] The back surface coating layer 7 is a layer provided to improve the adhesion between the colored sheet substrate 1 and an adhesive applied to the lower surface of the colored sheet substrate 1.

[0118] If each layer of the decorative sheet and the adhesive applied to the underside of the decorative sheet can have sufficient adhesion without improving adhesion with adhesive layer 3 or back coating layer 7, the decorative sheet does not need to have adhesive layer 3 or back coating layer 7.

[0119] The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[0120] Example 1 A colored polyethylene sheet having a thickness of 60 μm was prepared as the colored sheet substrate 1, and a picture pattern layer 2 was printed on the upper side UP of the colored sheet substrate 1.

[0121] As the printing ink for the picture pattern layer 2, a urethane-vinyl chloride resin (manufactured by Toyo Ink Co., Ltd.) was used.

[0122] A 70 μm thick layer of transparent polypropylene (manufactured by Sun Allomer Co., Ltd.) was laminated on the upper side UP of the colored sheet substrate 1 and the picture pattern layer 2 via a urethane adhesive layer (manufactured by Toyo Morton Co., Ltd.) as the adhesive layer 3, forming a thermoplastic resin layer 4.

[0123] A two-component curing urethane resin was applied to the surface of the lower side LO of the colored sheet substrate 1 to form a backside coating layer 7 .

[0124] The surface of the thermoplastic resin layer 4 was embossed using an embossing plate to form first recesses 4a with a height H1 of 40 μm and second recesses 4b with a height H2 of 10 μm and a width W1 of 150 μm.

[0125] Two-component curing urethane resin was applied to the upper side UP of the embossed thermoplastic resin layer 4 at 3 g / m 2 The first surface protective layer 5 was formed by coating.

[0126] On the upper side UP of the first surface protective layer 5, 3 g / m of two-component hardening urethane resin mixed with 15 parts by weight of silica filler having an average particle size of 2 to 3 μm is applied. 2The second surface protective layer 6 was applied so as not to cover the second recessed portion 4b.

[0127] In this way, a decorative sheet 10 of Example 1 was obtained, having a recessed area R formed by embossing, and within the recessed area R, a covered area R2 formed by the first recess 4a to which the first surface protective layer 5 and the second surface protective layer 6 were applied, and a small area R1 formed by the second recess 4b to which only the first surface protective layer 5 was applied.

[0128] The 60-degree specular gloss of the small region R1 was set to 71.

[0129] Example 2 A decorative sheet 10 of Example 2 was obtained in the same manner as in Example 1, except that the height H1 of the first recesses 4a was 20 μm and the 60-degree specular gloss of the small regions R1 was 73.

[0130] Example 3 The decorative sheet 10 of Example 3 was obtained in the same manner as Example 1, except that the height H1 of the first recess 4a was 160 μm, the thickness of the thermoplastic resin layer 4 was 200 μm, and the 60-degree specular gloss of the small region R1 was 70.

[0131] Example 4 The decorative sheet 10 of Example 4 was obtained in the same manner as Example 1, except that the content of silica filler contained in the second surface protective layer 6 was 3 parts by weight and the width W1 of the second recess 4b was 600 μm.

[0132] (Test 1) A coating stability test was carried out on the decorative sheets 10 of Examples 1 to 4. In the coating stability test, whether or not the second surface protective layer 6 was coated in a predetermined area was visually confirmed and evaluated.

[0133] The evaluation criteria were two-level. ◯ (Very Good): The second surface protective layer is coated in a predetermined area. Δ (Good): The area where the second surface protective layer is coated exceeds or falls short of a predetermined range, within an acceptable range.

[0134] (Test 2) A tactile evaluation test was conducted on the decorative sheets 10 of Examples 1-4. The tactile feel of the surface 10s of the decorative sheet 10 varies depending on the height of the unevenness formed on the surface 10s of the decorative sheet 10. Therefore, in the tactile evaluation test, evaluation was made based on the height H1 of the first recesses 4a formed in the thermoplastic resin layer 4.

[0135] The evaluation criteria were set to three levels. Excellent: The height of the first recess is very large within the allowable range. ◯ (Very Good): The height of the first recess is sufficiently large within an acceptable range. Δ (Good): The height of the first recess is small within an allowable range.

[0136] (Test 3) A texture expression evaluation test was conducted on the decorative sheets 10 of Examples 1-4. In the texture expression evaluation test, a sensory test was conducted on the texture expression of the surface 10s of the decorative sheet 10, and the degree of texture expression was evaluated. The sensory test for the texture expression evaluation test was conducted visually.

[0137] The evaluation criteria were two-level. 〇 (Very Good): The texture expression of the surface of the decorative sheet is excellent. △(Good): The texture expression of the surface of the decorative sheet is excellent.

[0138] (Test result 1) The results of Tests 1-3 are shown in Table 1. Table 1 also shows the height H1 of the first recess 4a, the thickness of the thermoplastic resin layer 4, the width W1 of the second recess 4b, and the 60-degree specular gloss (gloss value) of the small region R1.

[0139] The decorative sheet 10 of Example 1 showed good results in Tests 1-3.

[0140] In the decorative sheet 10 of Example 2, in which the height H1 of the first recesses 4a was smaller than that of Example 1, the second surface protective layer 6 flowed into part of the second recesses 4b in Test 1. Furthermore, in Test 2, the decorative sheet 10 of Example 2 felt flat to the touch.

[0141] The decorative sheet 10 of Example 2 was inferior to Example 1 in Test 1-2, but was evaluated to be within the acceptable range.

[0142] In the decorative sheet 10 of Example 3, in which the height H1 of the first recesses 4a was greater than in Example 1, some areas were unintentionally not covered by the second surface protective layer 6 in Test 1. Furthermore, the decorative sheet 10 of Example 3 achieved better results than Example 1 in Test 2.

[0143] The decorative sheet 10 of Example 3 was inferior to Example 1 in Test 1, but was evaluated to be within the acceptable range.

[0144] In the decorative sheet 10 of Example 4, in which the width W1 of the second recesses 4b was larger than in Example 1, the second surface protective layer 6 flowed into part of the second recesses 4b in Test 1. Furthermore, in Test 3, the decorative sheet 10 of Example 4 had a reflective flat surface of the small region R1 that was partially visible to the naked eye, and was inferior to Example 1 in the delicacy of texture expression.

[0145] The decorative sheet 10 of Example 4 was inferior to Example 1 in Tests 1 and 3, but was evaluated to be within the acceptable range.

[0146] [Table 1]

[0147] Next, evaluation of the contrast of the small region R1 will be described.

[0148] Example 5 The decorative sheet 10 of Example 5 was obtained in the same manner as Example 1, except that the 60-degree specular gloss of the small area R1 was set to 50 and the 60-degree specular gloss of the areas other than the small area R1 was set to 3.

[0149] Example 6 The decorative sheet 10 of Example 6 was obtained in the same manner as Example 1, except that the 60-degree specular gloss of the small area R1 was set to 20 and the 60-degree specular gloss of the areas other than the small area R1 was set to 3.

[0150] Example 7 The decorative sheet 10 of Example 7 was obtained in the same manner as Example 1, except that the 60-degree specular gloss of the small area R1 was set to 20 and the 60-degree specular gloss of the areas other than the small area R1 was set to 15.

[0151] Example 8 The decorative sheet 10 of Example 8 was obtained in the same manner as Example 1, except that the 60-degree specular gloss of the small area R1 was set to 80 and the 60-degree specular gloss of the areas other than the small area R1 was set to 15.

[0152] (Comparative Example 1) The decorative sheet of Comparative Example 1 was obtained in the same manner as in Example 1, except that the 60-degree specular gloss of the small area was set to 80 and the 60-degree specular gloss of the area other than the small area was set to 20.

[0153] (Test 4) A roughness measurement test was carried out on the decorative sheets 10 of Examples 5-8 and the decorative sheet of Comparative Example 1. In the roughness measurement test, the arithmetic mean roughness Ra of a small area was measured. In the roughness measurement test, the average value of 5 arithmetic mean roughnesses Ra was measured under the measurement conditions of line roughness specified in JIS B 0601, measuring needle R=2 μm, and cutoff λc=0.8 mm.

[0154] (Test 5) A contrast evaluation test was conducted on the decorative sheets 10 of Examples 5-8 and the decorative sheet of Comparative Example 1. In the contrast evaluation test, attention was focused on the contrast of small areas on the surface of the decorative sheet, and the degree of design expression relative to the contrast of the small areas was evaluated visually.

[0155] The evaluation criteria were on a 5-point scale, with 1 (Poor) being considered a failure. 5 (Excellent): The contrast of small areas on the surface of the decorative sheet is very good. 4 (Very Good): The contrast of small areas on the surface of the decorative sheet is excellent. 3 (Good): The contrast in small areas on the surface of the decorative sheet is sufficient. 2 (Average): The contrast in small areas on the surface of the decorative sheet is slightly poor, but within the acceptable range. 1 (Poor): The contrast in small areas on the surface of the decorative sheet is poor.

[0156] (Test result 2) The results of Tests 4 and 5 are shown in Table 2. Table 2 also lists the 60-degree specular gloss (gloss value) of the small area and the 60-degree specular gloss (gloss value) of areas other than the small area. Additionally, the "line roughness Ra of the small area" shown in Table 2 indicates the arithmetic mean roughness Ra of the small area.

[0157] In Test 4, the arithmetic mean roughness Ra of Example 5, in which the gloss value of the small area was 50, was 0.66 μm. The arithmetic mean roughness Ra of Examples 6 and 7, in which the gloss value of the small area was 20, was approximately 0.85 μm. The arithmetic mean roughness Ra of Example 8 and Comparative Example 1, in which the gloss value of the small area was 80, was approximately 0.20 μm.

[0158] In Test 5, Examples 5-6 and 8, in which the contrast due to the difference in gloss value between the small region and the non-small region was large and the gloss value in the non-small region was 15 or less, showed good results.

[0159] In Example 6, in Test 5, the brightness of small areas appeared slightly dull, but the contrast was good.

[0160] In Example 7, in Test 5, the contrast in the small areas was slightly low, but the light reflection in the small areas was sufficiently visible.

[0161] In Example 7, which had little difference in gloss value between the inside and outside of the small area, in Test 5 the light reflection in the small area was difficult to see due to the overall glitter on the surface of the decorative sheet, resulting in a design expression that lacked sharpness, but was within the acceptable range.

[0162] In Comparative Example 1, in which the gloss value outside the small area was greater than 15, the light reflection in the small area was difficult to see due to the overall glitter on the surface of the decorative sheet in Test 5, resulting in a design expression that lacked sharpness and was therefore rejected.

[0163] From these results, it is preferable that the 60-degree specular gloss of the small region R1 is 20 or more and 80 or less, and that the 60-degree specular gloss of the region other than the small region R1 is 2 or more and 15 or less.

[0164] [Table 2] [Explanation of symbols]

[0165] 10 Decorative Sheet 10s Decorative sheet surface 1. Colored sheet base material 2. Pattern layer 4 Thermoplastic resin layer 4a First recess 4b Second recess 5 First surface protective layer 6 Second surface protection layer R1 small area W1 Width of second recess H1 Height of first recess H2 Height of the second recess

Claims

1. A colored sheet substrate; A picture pattern layer provided on the upper side of the colored sheet substrate; a thermoplastic resin layer provided on the upper side of the picture pattern layer, the thermoplastic resin layer having a first recessed portion that is recessed downward and a second recessed portion that is adjacent to the first recessed portion and is recessed downward more than the first recessed portion on its surface; a first surface protective layer provided on the upper side of the thermoplastic resin layer and covering the first recess and the second recess; a second surface protective layer provided on the upper side of the first surface protective layer, covering the first recess but not the second recess; Equipped with The first recess has a height of 20 μm or more and 160 μm or less, The second recess has a height of 10 μm or more and a width of 150 μm or more and 600 μm or less. Decorative sheet.

2. On the upper surface, the 60-degree specular gloss of the small region where the second recess is provided is 20 or more and 80 or less, and the 60-degree specular gloss of the region other than the small region is 2 or more and 15 or less. The decorative sheet according to claim 1 .

3. On the upper surface, the arithmetic mean roughness Ra of the small region in which the second recess is provided is 0.20 μm or more and 0.85 μm or less. The decorative sheet according to claim 1 or 2.

4. The thickness of the first surface protective layer is 3 μm or more and 30 μm or less. The decorative sheet according to claim 3.

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