Decorative sheet, decorative panel, method for manufacturing a decorative sheet, and method for manufacturing a decorative panel

Abstract

To provide decorative sheets, decorative panels, methods for manufacturing decorative sheets, and methods for manufacturing decorative panels that reproduce a texture similar to that of natural materials. [Solution] A decorative sheet comprising a sheet substrate, a pattern layer provided on one surface of the sheet substrate, a first surface protective layer provided on the surface of the pattern layer, and a second surface protective layer provided on the surface of the first surface protective layer, wherein the second surface protective layer has a thick film portion and a thin film portion, the thickness of the thin film portion is 20% to 65% of the maximum thickness of the second surface protective layer, the thick film portion has a first inclined portion provided at the boundary with the thin film portion in a cross section along the vertical direction, and a second inclined portion whose inclination with respect to the plate surface direction is greater than that of the first inclined portion, the area ratio of the thick film portion to the total area of ​​the second surface protective layer in a plan view, and the wire count ratio of the thick film portion to the thin film portion is 2:3 to 1:3.

Description

Technical Field

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

Background Art

[0002] Conventionally, as a decorative sheet used as a surface material for furniture and building materials for housing, there is a decorative sheet having a visual three-dimensional effect formed by a plurality of surface protection layers having different glosses. In addition, there is a decorative sheet having a three-dimensional effect by touch, in which irregularities are formed on the surface by embossing or the like.

[0003] For example, in a decorative sheet with a wood grain pattern, by imparting a visual three-dimensional effect and a three-dimensional effect by touch to the conduit portion of the wood grain pattern, a decorative sheet with a wood grain pattern closer to the appearance of natural wood can be provided.

[0004] A decorative sheet having a three-dimensional effect is disclosed in Patent Document 1. The decorative sheet disclosed in Patent Document 1 has a visual three-dimensional effect by partially laminating a second surface protection layer having a gloss different from that of the first surface protection layer on the upper side of the first surface protection layer laminated on the upper side of the pattern layer. Further, a three-dimensional effect by touch is obtained by partially laminating a third surface protection layer having a thickness of 4 times or more the thickness of the second surface protection layer on the upper side of the second surface protection layer.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The need for a decorative sheet that reproduces the texture of natural materials is increasing, and for a decorative sheet with a wood grain pattern, a touch similar to that of real natural wood (for example, a wooden board) is required when a person touches it by hand. From the perspective of imparting such a texture to the decorative sheet, the decorative sheet described in Reference 1 had room for improvement.

[0007] The present invention has been made in view of the above circumstances, and aims to provide a decorative sheet, a decorative panel, a method for manufacturing a decorative sheet, and a method for manufacturing a decorative panel, which can reproduce a tactile feel (texture) similar to that of natural materials and have emphasized unevenness. [Means for solving the problem]

[0008] To solve the above problems, this invention proposes the following means. [1] A decorative sheet comprising a sheet substrate, a pattern layer provided on one surface of the sheet substrate, a first surface protective layer provided on the surface of the pattern layer, and a second surface protective layer provided on the surface of the first surface protective layer, wherein the second surface protective layer has a thick film portion and a thin film portion, the thickness of the thin film portion is 20% to 65% of the maximum thickness of the second surface protective layer, the thick film portion has, in a cross section along the vertical direction, a first inclined portion provided at the boundary with the thin film portion and a second inclined portion whose inclination with respect to the plate surface direction is greater than that of the first inclined portion, in a plan view of the second surface protective layer, the area ratio of the thick film portion to the total area of ​​the second surface protective layer is 10% to 50%, and the ratio of X, which is the number of lines per inch of the thick film portion, to Y, which is the number of lines per inch of the thin film portion is 2:3 to 1:3. [2] The decorative sheet according to [1], wherein the second surface protective layer has a gloss different from that of the first surface protective layer. [3] The decorative sheet according to [1] or [2], wherein the second surface protective layer is partially provided on the surface of the first surface protective layer. [4] The decorative sheet according to any one of [1] to [3], wherein the thick film portion contains particles having an average particle size of 15 μm or more, and the particles are synthetic resin beads or inorganic compound fillers. [5] The decorative sheet according to [4], wherein the synthetic resin beads are acrylic resin beads. A decorative panel comprising a decorative sheet described in any one of [6][1] to [5], and a base material provided below the decorative sheet. [7] The process comprises the steps of forming a pattern layer on one surface of a sheet substrate, forming a first surface protective layer on the surface of the sheet substrate with the pattern layer, and forming a second surface protective layer on the surface of the first surface protective layer, wherein the second surface protective layer has a thin film portion and a thick film portion, the step of forming the second surface protective layer is carried out using a printing plate having a plurality of cells, the printing plate has grooves in which a thin film forming portion and a thick film forming portion are integrally formed, and the number of lines per inch of the thick film forming portion is X and A method for manufacturing a decorative sheet, wherein the ratio of the number of lines per inch, Y, of the thin film portion is 2:3 or more and 1:3 or less, the plate depth of the thin film forming portion is 20% or more and 65% or less of the maximum depth of the thick film forming portion, in a plan view of the printing plate, the area ratio of the thick film forming portion to the total area of ​​the groove is 10% or more and 50% or less, and the thick film forming portion has a first inclined forming portion and a second inclined forming portion on the thin film forming portion side, and the inclination of the first inclined forming portion is smaller than the inclination of the second inclined forming portion. [8] The method for manufacturing a decorative sheet according to [7], wherein the printing plate is a gravure plate, and when the plate depth of the thick film forming portion is 100%, the boundary between the portion forming the first inclined forming portion and the portion forming the second inclined forming portion in the gravure plate is located at a position where the plate depth is 70% or more. A method for manufacturing a decorative sheet, comprising the method for manufacturing a decorative sheet described in [9], [7], or [8], and a substrate bonding step of attaching a substrate to the lower side of the decorative sheet. [Effects of the Invention]

[0009] The present invention provides decorative sheets and decorative panels, as well as methods for manufacturing decorative sheets and decorative panels, which can reproduce a tactile feel (texture) similar to that of natural materials, and which have emphasized unevenness, and can provide decorative sheets, decorative panels, methods for manufacturing decorative sheets, and methods for manufacturing decorative panels. [Brief explanation of the drawing]

[0010] [Figure 1]This is a schematic cross-sectional view showing a decorative panel according to this embodiment. [Figure 2] This is a schematic cross-sectional view showing the second surface protective layer in a decorative panel. [Figure 3] This is a schematic cross-sectional view showing a gravure plate on which the second surface protective layer is printed. [Figure 4] This is a schematic diagram illustrating the manufacturing method of decorative sheets. [Modes for carrying out the invention]

[0011] One embodiment of the present invention will be described with reference to the drawings.

[0012] <Decorative sheets and decorative panels> Figure 1 is a schematic cross-sectional view showing the decorative panel 100 according to this embodiment. In this embodiment, as shown in Figure 1, the thickness direction of the decorative panel 100 is defined as the "vertical direction V", the side of the decorative panel 100 on which the base material 20 is provided is defined as the "lower side LO" in the vertical direction V, and the side opposite to the lower side LO is defined as the "upper side UP" in the vertical direction V. The surface direction of the decorative panel 100 is defined as the "width direction C". Here, the "surface direction (width direction C)" of the decorative panel 100 indicates a direction perpendicular to the vertical direction V. For example, if the vertical direction V is the vertical direction, then the surface direction (width direction C) indicates the horizontal direction.

[0013] The decorative panel 100 is provided with a base material 20 and a decorative sheet 10 on one side of the base material 20. As the base material 20, particleboard or medium-density fiberboard (MDF) can be used. Alternatively, as the base material 20, a metal plate-shaped member such as aluminum or stainless steel, or a composite board in which metal such as aluminum is attached to both sides of a core material made of resin such as polyethylene may be used.

[0014] The decorative sheet 10 comprises a sheet base material 1, a pattern layer 2, a first surface protective layer 3, and a second surface protective layer 4.

[0015] The sheet base material 1 is a layer provided on one surface of the decorative sheet 10. The sheet base material 1 is a sheet-like layer made of a known printable material.

[0016] In one aspect of the present invention, the sheet base material 1 includes a first paper base material 1a, a moisture-proof resin layer 1b, and a second paper base material 1c. The first paper base material 1a is a layer provided on the upper side UP of the moisture-proof resin layer 1b. Also, the second paper base material 1c is a layer provided on the lower side LO of the moisture-proof resin layer 1b. As the first paper base material 1a and the second paper base material 1c, a fibrous sheet such as tissue paper or titanium paper can be adopted.

[0017] The moisture-proof resin layer 1b is a layer made of a moisture-proof resin that does not allow water vapor to pass through. As the forming material of the moisture-proof resin layer 1b, a thermoplastic resin such as an olefin-based resin can be adopted. By sandwiching the moisture-proof resin layer vb that does not allow water vapor to pass through between the first paper base material 1a and the second paper base material 1c made of a fibrous sheet, the sheet base material 1 can be imparted with moisture-proof properties.

[0018] The pattern layer 2 is a layer provided on the upper side UP of the sheet base material 1. The pattern layer 2 is formed, for example, by printing a pattern such as a wood grain, a stone grain, or a sand grain on the upper side UP of the sheet base material 1. As the printing method of the pattern layer 2, a known printing method such as gravure printing, offset printing, flexographic printing, silk screen printing, or inkjet printing can be adopted. For the pattern layer 2, a known printing ink suitable for the adopted printing method can be adopted.

[0019] The first surface protection layer 3 is a layer provided on the upper side UP of the pattern layer 2. As the forming material of the first surface protection layer 3, an ionizing radiation curable resin such as a thermosetting resin having a urethane bond or an acrylic resin can be adopted. It is desirable to adopt a transparent or translucent material for the first surface protection layer 3 to such an extent that the pattern of the pattern layer 2 can be seen through.

[0020] As a method for laminating the first surface protective layer 3, known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be employed. Alternatively, the first surface protective layer 3 may be laminated using a known coating apparatus.

[0021] The second surface protection layer 4 is a layer provided above the first surface protection layer 3. As shown in Figure 1, the second surface protection layer 4 is partially provided above the first surface protection layer 3. As the material for forming the second surface protection layer 4, a thermosetting resin having a urethane bond or an ionizing radiation curable resin such as an acrylic resin can be used. It is desirable to use a material for forming the second surface protection layer 4 that is transparent or semi-transparent enough to allow the pattern of the pattern layer 2 to be seen through the first surface protection layer 3.

[0022] The first surface protective layer 3 and the second surface protective layer 4 have different gloss levels. One method for creating a difference in gloss between the first surface protective layer 3 and the second surface protective layer 4 is to add a matting agent to either the first surface protective layer 3 or the second surface protective layer 4. For example, if no matting agent is added to the second surface protective layer 4, but a matting agent is added to the first surface protective layer 3, the first surface protective layer 3 will have a lower gloss level than the second surface protective layer 4.

[0023] By changing the amount of matting agent added to the first surface protective layer 3 and the second surface protective layer 4, a difference in gloss can be created between the first surface protective layer 3 and the second surface protective layer 4. If there is a difference in gloss between the first surface protective layer 3 and the second surface protective layer 4, the eye can perceive a sense of depth through optical illusion.

[0024] The second surface protective layer 4 contains particles 5. The inclusion of particles 5 in the second surface protective layer 4 results in a decorative sheet with more pronounced irregularities. In Figure 1, particles 5 schematically represent the presence of particles, and the number of particles may be one or more. Particle 5 consists of synthetic resin beads or inorganic compound fillers. It is desirable that particle 5 be made of a material that is transparent or semi-transparent enough to allow the pattern of the pattern layer 2 to be seen through the first surface protective layer 3 and the second surface protective layer 4. From the viewpoint of increasing transparency and providing a three-dimensional feel through touch, it is desirable that particle 5 be made of acrylic resin beads with an average particle size of 15 μm or more.

[0025] The second surface protective layer 4 has a thin film portion 41 and a thick film portion 42. The thick film portion 42 and the thin film portion 41 are integrated to form a second surface protective layer 4. The thin film portion 41 is laminated on the upper side UP of the first surface protective layer 3 with a nearly constant thickness.

[0026] The thick film portion 42 is laminated on the upper side UP of the first surface protective layer 3. The thickness of the thick film portion 42 is not constant and varies depending on the formation position. The thick film portion 42 contains particles 5.

[0027] The second surface protective layer 4 has different thicknesses in the thick film portion 42 and the thin film portion 41. This allows the decorative sheet 10 to give a three-dimensional feel through touch. The thickness of the thick film portion 42 of the second surface protective layer 4 is further emphasized by the particle size of the particles 5. Therefore, the thickness H1 of the thin film portion 41 is smaller than the maximum thickness H2 of the second surface protective layer 4. Specifically, the thickness H1 of the thin film portion 41 is between 20% and 65% of the maximum thickness H2 of the second surface protective layer 4. This allows the second surface protective layer 4 to have a sufficient thickness difference, which further emphasizes the three-dimensional feel through touch.

[0028] Furthermore, the thick film portion 42 has a first inclined portion 42a and a second inclined portion 42b in a cross-section along the vertical direction V.

[0029] As shown in Figure 2, the first inclined portion 42a is provided at the boundary with the thin film portion 41 in the cross-section of the thick film portion 42 along the vertical direction V. The second inclined portion 42b is a portion of the thick film portion 42 in the cross-section along the vertical direction V that has a different inclination with respect to the width direction C (plate surface direction) than the first inclined portion 42a. The second inclined portion 42b is connected to the thin film portion 41 in the vertical direction V by the first inclined portion 42a.

[0030] As shown in Figure 2, the first inclined portion 42a is a part in a cross-section along the vertical direction V that has a smaller (gentler) inclination (slope) with respect to the width direction C than the second inclined portion 42b. For example, if the inclination of the second inclined portion 42b is a maximum of 90°, the second inclined portion 42b extends parallel to the vertical direction V. In this case, since the inclination of the first inclined portion 42a with respect to the width direction C is smaller than that of the second inclined portion 42b, the inclination of the first inclined portion 42a with respect to the width direction C will be less than 90°.

[0031] In a plan view of the second surface protective layer 4 (i.e., a plan view from the upper side UP), the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 is 10% or more and 50% or less, preferably 15% or more and 50%, more preferably 20% or more and 50%, and even more preferably 25% or more and 59% or less. The area ratio occupied by the thick film portion 42 can be measured by the following method.

[0032] A laser microscope is used to capture a plan view of the second surface protective layer 4 from the upper side (UP), and the glossy areas in the captured image are identified as the thick film portion 42. The area ratio is calculated from the total area of ​​the second surface protective layer 4 and the area occupied by the thick film portion 42. For example, a laser microscope such as the LEXT manufactured by Olympus Corporation can be used.

[0033] When the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 in a plan view satisfies the above range, the unevenness of the surface of the decorative sheet 10 is emphasized, giving it a tactile feel similar to that of a natural material, such as the surface of a wooden board.

[0034] Furthermore, by ensuring that the ratio (X / Y) of the number of lines per inch of the thick film portion 42 (X) to the number of lines per inch of the thin film portion 41 (Y) is between 2:3 and 1:3, the unevenness of the surface of the decorative sheet 10 is emphasized, giving it a tactile feel similar to that of a natural material, such as the surface of a wooden board. The ratio (X / Y) can be determined by examining the printed material under a microscope and counting the number of halftone dots.

[0035] The second surface protective layer 4 is formed by a printing plate having multiple cells. The cells in the printing plate are concave depressions into which the printing ink that forms the second surface protective layer 4 flows. In this specification, screen ruling refers to the number of cells per inch on the printed surface of a printing plate. The unit of screen ruling in this specification is "L / inch".

[0036] When the ratio satisfies the above range, the number of lines in the thick film portion 42 becomes coarser than that of the thin film portion 41, emphasizing the unevenness of the surface of the decorative sheet 10, and reproducing a tactile feel (texture) similar to that of natural materials.

[0037] Here, for example, if the pattern of the pattern layer 2 is a wood grain pattern, the second surface protection layer 4 is positioned in a location that is synchronized with the vascular tissue of the wood grain pattern. In decorative sheets having a wood grain pattern, the vascular tissue is generally formed to extend in one direction in the direction of the sheet surface. Therefore, the second surface protection layer 4, which is synchronized with the vascular tissue, is formed on the upper surface UP of the first surface protection layer 3 to extend in one direction in the direction of the sheet surface.

[0038] The cross-section shown in Figure 2 is, for example, a cross-section perpendicular to the direction in which the second surface protective layer 4 extends in synchronization with the conduit portion in the surface direction of the decorative sheet 10. The second surface protective layer 4 extends towards the back or front of the paper in Figure 2, while maintaining the shape shown in Figure 2.

[0039] The direction in which the second surface protective layer 4 extends is not limited to one direction; for example, in a plan view from above (UP), it may be curved or branched. In a cross-section perpendicular to the direction in which the second surface protective layer 4 extends and parallel to the vertical direction V, the thick film portion 42 has, as shown in Figure 2, a first inclined portion 42a provided at the boundary with the thin film portion 41, and a second inclined portion 42b whose inclination with respect to the width direction C is different from that of the first inclined portion 42a, and it is sufficient that the inclination of the first inclined portion 42a with respect to the width direction C is smaller than the inclination of the second inclined portion 42b.

[0040] At the boundary between the thin film portion 41 and the thick film portion 42, the second surface protective layer 4 has a progressively increasing inclination with respect to the width direction C, moving from the thin film portion 41 towards the upper surface or point UP of the thick film portion 42. In other words, the thickness (height) of the second surface protective layer 4 in the vertical direction V increases progressively.

[0041] Therefore, in the second surface protective layer 4, the difference in gloss between the thin film portion 41 and the thick film portion 42 is not easily noticeable. If the thick film portion does not have a first inclined portion, and the thickness of the second surface protective layer changes abruptly at the boundary between the thin film portion and the thick film portion, the difference in gloss between the thin film portion and the thick film portion may be noticeable, potentially resulting in poor design aesthetics. By having the thick film portion 42 have a first inclined portion 42a, and gradually changing the thickness of the second surface protective layer 4 at the boundary between the thin film portion 41 and the thick film portion 42, the difference in gloss between the thin film portion 41 and the thick film portion 42 becomes less noticeable.

[0042] The decorative sheet 10 and decorative panel 100 have a three-dimensional feel due to the difference in thickness between the thin film portion 41 and the thick film portion 42 of the second surface protective layer 4.

[0043] Furthermore, because the first surface protective layer 3 and the second surface protective layer 4 have different gloss levels, the decorative sheet 10 and decorative panel 100 have a visually three-dimensional appearance.

[0044] Furthermore, the thin film portion 41 and the thick film portion 42 are included in the second surface protective layer 4. In addition, the thick film portion 42 has a first inclined portion 42a and a second inclined portion 42b in a cross section along the vertical direction V, with respect to the width direction C being different from each other. Since the inclination of the first inclined portion 42a, which is provided at the boundary with the thin film portion 41, is smaller than the inclination of the second inclined portion 42b, the boundary between the thin film portion 41 and the thick film portion 42 is less noticeable, and the decorative sheet 10 and decorative panel 100 have excellent design.

[0045] <Method for manufacturing decorative sheets and decorative panels> Next, a method for manufacturing the decorative sheet 10 and the decorative panel 100 will be described.

[0046] First, the manufacturing method of the decorative panel involves a process of printing a pattern. In the process of printing the pattern, the pattern is printed on the upper side UP of the sheet substrate 1 to form the pattern layer 2.

[0047] Next, the manufacturing method of the decorative panel involves a step of forming the first surface protective layer. In the step of forming the first surface protective layer, the resin that is the material for forming the first surface protective layer 3 is printed on the upper side UP of the pattern layer 2 to form the first surface protective layer 3.

[0048] Next, the manufacturing method of the decorative panel involves a step of forming a second surface protective layer. In the step of forming the second surface protective layer, a resin, which is the material for forming the second surface protective layer 4, is printed on the upper side UP of the first surface protective layer 3 to form the second surface protective layer 4. In this way, the decorative sheet 10 is formed.

[0049] As a method for laminating the second surface protective layer 4, intaglio printing such as gravure printing can be used. For example, in the grooves into which the printing resin (the resin that forms the second surface protective layer 4) of a gravure plate used for gravure printing is poured, the printing resin and particles 5 flow into grooves that are deeper than the particle size (plate depth), while in grooves that are shallower than the particle size (particle size), only the printing resin flows in, without the particles 5.

[0050] As a result, the second surface protective layer 4 is divided into areas where particles 5 are placed and areas where they are not. The areas where particles 5 are placed form a thick film portion 42, and the areas where particles 5 are not placed form a thin film portion 41.

[0051] Here, we will describe the gravure plate that forms the second surface protective layer 4. Figure 3 is a schematic cross-sectional view showing a gravure printing plate on which the second surface protective layer 4 is printed. The gravure plate P shown in Figure 3 has grooves 4p that form a second surface protective layer 4, and the grooves 4p have a thick film forming portion 42p that forms a thick film portion 42 and a thin film forming portion 41p that forms a thin film portion 41.

[0052] The thick film forming section 42P has multiple cells LC1, and the thin film forming section 41p has multiple cells SC1. By pressing the cells LC1 and the gravure plate P into which printing resin has been poured into SC1 against the upper surface UP of the first surface protective layer 3, the printing resin is transferred as shown in Figure 4, and a second surface protective layer 4 having a thin film section 41 and a thick film section 42 is formed.

[0053] The cell width of cell LC1 is larger than that of cell SC1, and the number of lines per inch of cell LC1 and cell SC1 is set such that the ratio of X, which is the number of lines per inch of the thick film portion, to Y, which is the number of lines per inch of the thin film portion, is between 2:3 and 1:3.

[0054] Furthermore, the thick film forming portion 42P and the thin film forming portion 41p are set such that, in a plan view of the second surface protective layer 4, the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 is between 10% and 50%.

[0055] As shown in Figure 3, the gravure printing plate P on which the second surface protective layer 4 is printed has a first inclined forming section P3 and a second inclined forming section P4 formed in the thick film forming section 42p.

[0056] The plate depth D1, which is the maximum depth of the thick film formation section 42p, is greater than the particle size of the particles 5. Therefore, the particles 5 flow into the thick film formation section 42p together with the printing resin, and the thick film section 42 is formed in the second surface protective layer 4.

[0057] In the gravure plate P, the plate depth D4 of the thin film formation section 41p is 20% to 65% of the plate depth D1, which is the maximum depth of the thick film formation section 42p. When the plate depth D4 is within this range, a decorative sheet can be manufactured in which the thickness of the thin film section 41 is 20% to 65% of the maximum thickness of the second surface protective layer.

[0058] Here, "plate depth" in gravure plate P refers to the dimension (depth) in the direction perpendicular to the tangent A on the bottom surface shown in Figure 3.

[0059] The first inclined forming section P3 is located at the boundary between the thick film forming section P2 and the thin film forming section P1.

[0060] In the second inclined forming section P4, in the thick film forming section 42p with a cross-section perpendicular to the tangent A of the lower surface, the inclination of the tangent A of the lower surface of the decorative sheet 10 with respect to the surface direction is smaller than that of the first inclined forming section P3.

[0061] Here, in the gravure plate P shown in Figure 3, when the tangent A on the lower surface is defined as the portion with a plate depth of 0%, the plate depth D1 of the thick film forming portion 42p represents the range of 0 to 100% in the gravure plate P that forms the second surface protective layer 4.

[0062] Thus, when the plate depth of the portion forming the thick film 42 in the groove forming the second surface protective layer 4 is set to 100%, the inclination change portion Pb, which is the boundary between the first inclination forming portion P3 and the second inclination forming portion P4, and where the inclination of the tangent A on the lower surface with respect to the surface direction changes in a cross section along a direction perpendicular to the tangent A on the lower surface, is provided in the gravure plate P with a plate depth in the range of 70 to 100%. That is, the plate depth D3 of the inclination change portion Pb is 70% or more of the plate depth D1 of the thick film forming portion 42p.

[0063] Here, the plate depth D3 of the inclined section Pb indicates the dimension in the gravure plate P in the direction perpendicular to the tangent A of the lower surface, from the tangent A of the lower surface to the inclined section Pb.

[0064] For example, if the plate depth D3 of the gradient change section Pb is 70% of the plate depth D1 of the thick film formation section P2, then the plate depth D2 of the remaining second gradient formation section P4 will be 30% of the plate depth D1 of the thick film formation section P2.

[0065] Here, the plate depth D2 of the second inclined forming section P4 indicates the dimension in the gravure plate P in the direction perpendicular to the tangent A to the lower surface of the second inclined forming section P4.

[0066] Thus, in the gravure printing plate P on which the second surface protective layer 4 is formed, the boundary (inclination change portion Pb) between the portion that forms the first inclined portion 42a (first inclined forming portion P3) and the portion that forms the second inclined portion 42b (second inclined forming portion P4) is located at a position (depth) of 70% or more when the plate depth D1 of the portion that forms the thick film portion 42 (thick film forming portion P2) is set to 100%.

[0067] When the plate depth D1 of the thick film forming portion P2 is set to 100%, the second surface protective layer 4 is formed by a gravure plate P in which the gradient change portion Pb, which is the boundary between the first inclined forming portion P3 and the second inclined forming portion P4, is located at a position of 70% or more. This ensures that the area occupied by the first inclined portion 42a relative to the thickness of the thick film portion 42 is sufficiently secured. As a result, the difference in gloss between the thin film portion 41 and the thick film portion 42 in the second surface protective layer 4 can be made less noticeable.

[0068] If the gradient change section is positioned at 100% of the plate depth of the thick film formation section, the thick film section will be formed solely by the first gradient formation section, and will not have a second gradient section, only the first gradient section. In this case, the three-dimensional feel provided by the tactile sensation of the second surface protective layer may be weakened.

[0069] Therefore, it is desirable that the gradient change section Pb be provided in the gravure plate P in a range of 70% or more and less than 100% when the plate depth D1 of the thick film formation section P2 is set to 100%.

[0070] After forming the decorative sheet 10 by the process of forming the second surface protective layer described above, the method for manufacturing the decorative panel involves a step of bonding the base material. In the step of bonding the base material, the base material 20 is bonded to the lower side LO of the decorative sheet 10 to form the decorative panel 100.

[0071] The base material 20 may be bonded to the lower LO of the decorative sheet 10 via an adhesive. Alternatively, the decorative sheet 10 and base material 20, which are stacked vertically V, may be sandwiched between press plates such as metal plates from the upper UP and lower LO, and the decorative sheet 10 and base material 20 may be bonded by applying pressure or heating from the upper UP and lower LO. As a method for applying pressure or heating to the decorative sheet 10 and base material 20, a method of flat-pressure pressing with a metal plate in contact with the base material, or a circular pressure continuous lamination method can be employed.

[0072] According to the decorative sheet 10 and decorative panel 100 of this embodiment, and the manufacturing method for the decorative sheet 10 and decorative panel 100, the sheet comprises a sheet base material 1, a pattern layer 2 provided on the upper side UP of the sheet base material 1, a first surface protection layer 3 provided on the upper side UP of the pattern layer 2, and a second surface protection layer 4 provided on the upper side UP of the first surface protection layer 3. The second surface protection layer 4 has a thin film portion 41 and a thick film portion 42 partially provided on the upper side UP of the thin film portion 41, and the thickness H1 of the thin film portion is 20% to 65% of the thickness H2 of the portion of the second surface protection layer 4 in which the thick film portion 42 is provided.

[0073] Furthermore, the thick film portion 42 has, in a cross-section along the vertical direction V, a first inclined portion 42a provided at the boundary with the thin film portion 41, and a second inclined portion 42b whose inclination with respect to the plate surface direction is different from that of the first inclined portion 42a, and the first inclined portion 42a has a smaller inclination with respect to the plate surface direction than the second inclined portion 42b.

[0074] Therefore, the decorative sheet 10 and decorative panel 100 have a three-dimensional feel due to the difference in thickness between the thin film portion 41 and the thick film portion 42 of the second surface protective layer 4.

[0075] Furthermore, the boundary between the thin film portion 41 and the thick film portion 42 is not easily noticeable, and the decorative sheet 10 and decorative panel 100 have excellent design qualities.

[0076] As a result, the emphasis on unevenness reproduces a tactile feel similar to that of natural materials, and it is possible to provide decorative sheets 10 and decorative panels 100, as well as a method for manufacturing decorative sheets 10 and decorative panels 100, which have superior design.

[0077] Furthermore, because the first surface protective layer 3 and the second surface protective layer 4 have different gloss levels, the decorative sheet 10 and decorative panel 100 can have a visually three-dimensional appearance.

[0078] Although one embodiment of the present invention has been described in detail above with reference to the drawings, the specific configuration is not limited to this embodiment, and design changes and the like that do not depart from the spirit of the present invention are also included. Furthermore, the components shown in the above-described embodiment and the following modifications can be combined as appropriate.

[0079] (Variation 1) In the above embodiment, the sheet substrate 1 comprises a first paper substrate 1a, a moisture-proof resin layer 1b, and a second paper substrate 1c, but the form of the sheet substrate is not limited thereto. The sheet substrate may be a single-layer sheet such as a fibrous sheet or a resin sheet.

[0080] (Modification 2) In the above embodiment, the thick film portion 42 comprises a first inclined portion 42a and a second inclined portion 42b, the inclinations with respect to the width direction C in a cross-section along the vertical direction V are different from each other, but the configuration of the thick film portion is not limited thereto. The thick film portion may comprise three or more inclined portions, the inclinations with respect to the width direction in a cross-section along the vertical direction are different from each other.

[0081] For example, if the thick film portion has three inclined sections in a cross-section along the vertical direction, each having a different inclination with respect to the width direction, the thick film portion comprises a first inclined section, a second inclined section, and a third inclined section. Here, in the thick film portion, the first inclined section is provided at the boundary with the thin film portion. The second inclined section is provided connecting the first and third inclined sections.

[0082] In this case, in a cross-section along the vertical direction, the second inclined portion has a smaller inclination in the width direction than the third inclined portion. Also, the first inclined portion has a smaller inclination in the width direction than the second inclined portion. Therefore, at the boundary between the thin film portion and the thick film portion, the thickness of the second surface protective layer changes in two stages, making the difference in gloss between the thin film portion and the thick film portion less noticeable. [Examples]

[0083] The present invention will be described in detail with reference to the following examples. The present invention is not limited to the following examples.

[0084] <Method for measuring area ratio> A laser microscope was used to capture a plan view of the second surface protective layer 4 from the upper side (UP), and the glossy areas in the captured image were identified as the thick film portion 42. The area ratio was calculated from the total area of ​​the second surface protective layer 4 and the area occupied by the thick film portion 42. The laser microscope used was the LEXT model manufactured by Olympus Corporation.

[0085] <Method for measuring the number of lines> The line frequency ratio (X / Y) was determined by examining the printed material with a laser microscope and counting the number of halftone dots. The laser microscope used was the LEXT model manufactured by Olympus Corporation.

[0086] (Example 1) As the sheet substrate 1, a base paper for decorative paper (HPN29 manufactured by Tenma Special Paper Co., Ltd.) was prepared. Urethane ink (PCNT manufactured by Toyo Ink Co., Ltd.) was printed on the upper side UP of the sheet substrate 1 by gravure printing to form the pattern layer 2.

[0087] An acrylic resin (G503 manufactured by DIC Graphics Co., Ltd.) was applied to the upper part of the pattern layer 2 using a gravure printing method to form the first surface protective layer 3. A second surface protective layer 4 was formed on the upper part of the first surface protective layer 3 using the same acrylic resin as the first surface protective layer 3.

[0088] Here, acrylic beads (manufactured by Toyobo Industries Ltd.) with an average particle size of 60 μm or more were mixed as particles 5 to form the printing resin that forms the second surface protective layer 4, thereby forming the thin film portion 41 and the thick film portion 42 in the second surface protective layer 4.

[0089] Furthermore, the thickness H1 of the thin film portion 41 was set to be between 20% and 65% of the thickness H2 of the portion of the second surface protective layer 4 where the thick film portion 42 is provided.

[0090] Furthermore, the thick film portion 42 is provided with a first inclined portion 42a at the boundary with the thin film portion 41 in a cross-section along the vertical direction V, and a second inclined portion 42b whose inclination with respect to the width direction C is different from that of the first inclined portion 42a, so that the inclination of the first inclined portion 42a with respect to the width direction C is smaller than the inclination of the second inclined portion 42b.

[0091] Furthermore, in the gravure plate P on which the second surface protective layer 4 is formed, the boundary (slope change portion Pb) between the portion that forms the first inclined portion 42a (first inclined forming portion P3) and the portion that forms the second inclined portion 42b (second inclined forming portion P4) is set at a position (depth) of 70% or more when the plate depth D1 of the portion that forms the thick film portion 42 (thick film forming portion P2) is set to 100%.

[0092] In a plan view of the second surface protective layer 4, the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 was 30%, and the ratio (X / Y) of the number of lines per inch of the thick film portion 42 (X) to the number of lines per inch of the thin film portion 41 (Y) was 2:3. In this way, the decorative sheet 10 of Example 1 was formed.

[0093] (Example 2) The decorative sheet 10 of Example 2 was formed in the same manner as in Example 1, except that the ratio (X / Y) of the number of lines per inch of the thick film portion 42, X, and the number of lines per inch of the thin film portion 41, Y, was changed to 1:3.

[0094] (Example 3) In a plan view of the second surface protective layer 4, the decorative sheet 10 of Example 3 was formed in the same manner as in Example 1, except that the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 was set to 50%.

[0095] (Example 4) In a plan view of the second surface protective layer 4, the decorative sheet 10 of Example 4 was formed in the same manner as in Example 1, except that the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 was set to 10%.

[0096] (Comparative Example 1) The decorative sheet 10 of Comparative Example 1 was formed in the same manner as in Example 1, except that the ratio (X / Y) of the number of lines per inch of the thick film portion 42 (X) and the number of lines per inch of the thin film portion 41 (Y) was changed to 1:1.

[0097] (Experiment 1) Tactile evaluation tests were conducted on the decorative sheets of Examples 1-4 and Comparative Example 1. In the tactile evaluation tests, 10 testers performed sensory evaluations of the tactile feel of the decorative sheets and assessed the degree of tactile feel. The evaluation criteria consisted of four levels, with a score of 3 or higher considered a passing grade. [Evaluation Criteria] 4. Between 9 and 10 people rated the texture as being similar to the surface of a wooden board. 3. Seven to eight people rated the texture as being similar to the surface of a wooden board. 2: Between 1 and 6 people rated the texture as being similar to the surface of a wooden board. 1: Zero people rated the texture as being similar to the surface of a wooden board.

[0098] (Experiment 2) Design evaluation tests were conducted on the decorative sheets of Examples 1-4 and Comparative Example 1. In the design evaluation tests, 10 testers conducted sensory evaluations of the design of the decorative sheets and assessed the degree of the design's appearance. [Evaluation Criteria] 4. Nine to ten people rated the design as having a good appearance. 3. Seven to eight people evaluated the design as having a good appearance. 2. Between one and six people evaluated the design as having a good appearance. 1: Zero people rated the design as having a good appearance.

[0099] (Experimental results) The results of Experiment 1-2 are shown in Table 1. In a plan view of the second surface protective layer 4, the area ratio of the thick film portion 42 to the total area of ​​the second surface protective layer 4 is 10% to 50%, and the ratio (X / Y) is 2:3 to 1:3. The decorative sheets 10 of Examples 1 to 4 showed better results than Comparative Example 1, with Experiment 1 results of 4 or 3.

[0100] Furthermore, the decorative sheets 10 of Examples 1 to 4 were evaluated as having a good design appearance in Experiment 2.

[0101] [Table 1] [Explanation of Symbols]

[0102] 100 decorative panels 10 decorative sheets 1 sheet substrate 1a First paper base material 1b Moisture-proof resin layer 1c Second paper base material 2 Pattern Layers 3 First surface protective layer 4 Second surface protection layer 41 Thin film section 42 Thick film portion 42a First slope part 42b Second slope part 5 particles 20 Base material V vertical direction UP upper side LO (lower side) C Width direction (board surface direction) H1: Thickness of the thin film H2 Thickness of the portion of the second surface protective layer where a thick film is provided. P Gravure Edition Pb gradient change section 41p Thin film forming part 42p thick film forming part P3 First slope forming part P4 Second slope forming part D1 Thick film formation area depth D2 Plate depth of the second inclined formation section D3 Plate depth at the slope change section

Claims

1. Sheet base material and A pattern layer provided on one surface of the aforementioned sheet substrate, A first surface protective layer provided on the surface of the pattern layer, The first surface protective layer comprises a second surface protective layer provided on the surface of the first surface protective layer, The second surface protective layer has a thick film portion and a thin film portion, The thickness of the thin film portion is 20% to 65% of the maximum thickness of the second surface protective layer. The thick film portion has, in a cross-section along the vertical direction, a first inclined portion provided at the boundary with the thin film portion, and a second inclined portion whose inclination with respect to the plate surface direction is greater than that of the first inclined portion. In a plan view of the second surface protective layer, the area ratio of the thick film portion to the total area of ​​the second surface protective layer is 10% or more and 50% or less. A decorative sheet in which the ratio of X, the number of lines per inch in the thick film portion, to Y, the number of lines per inch in the thin film portion, is 2:3 or more and 1:3 or less.

2. The decorative sheet according to claim 1, wherein the second surface protective layer has a gloss different from that of the first surface protective layer.

3. The decorative sheet according to claim 1, wherein the second surface protective layer is partially provided on the surface of the first surface protective layer.

4. The thick film portion contains particles with an average particle size of 15 μm or more. The decorative sheet according to claim 1, wherein the particles are synthetic resin beads or inorganic compound fillers.

5. The decorative sheet according to claim 4, wherein the synthetic resin beads are acrylic resin beads.

6. A decorative sheet according to any one of claims 1 to 5, and a base material provided below the decorative sheet, A decorative panel equipped with these features.

7. A process of forming a patterned layer on one surface of a sheet substrate, The process of forming a first surface protective layer on the surface of the sheet substrate with the pattern layer, The process includes forming a second surface protective layer on the surface of the first surface protective layer, The second surface protective layer has a thin film portion and a thick film portion, and the process of forming the second surface protective layer is carried out using a printing plate having a plurality of cells. The aforementioned printing plate has a groove in which a thin film forming portion and a thick film forming portion are integrally formed. The ratio of X, which is the number of lines per inch in the thick film-forming portion, to Y, which is the number of lines per inch in the thin film portion, is 2:3 or more and 1:3 or less. The plate depth of the thin film formation portion is 20% to 65% of the maximum depth of the thick film formation portion. In a plan view of the aforementioned printing plate, the area ratio of the thick film forming portion to the total area of ​​the groove is 10% or more and 50% or less. The thick film forming portion has a first inclined forming portion and a second inclined forming portion on the thin film forming portion side, A method for manufacturing a decorative sheet, wherein the inclination of the first inclined forming portion is smaller than the inclination of the second inclined forming portion.

8. The aforementioned printing plate is a gravure plate, and when the plate depth of the thick film forming portion is set to 100%, The method for manufacturing a decorative sheet according to claim 7, wherein the boundary between the portion forming the first inclined portion and the portion forming the second inclined portion in the gravure plate is located at a plate depth of 70% or more.

9. A method for manufacturing a decorative sheet according to claim 7 or claim 8, A substrate bonding step in which a base material is attached to the lower side of the decorative sheet, A method for manufacturing decorative panels, comprising the features described above.

Images