Decorative sheets and decorative components

Abstract

To provide decorative sheets and decorative components that have an uneven surface and excellent stain resistance. [Solution] The decorative sheet 10 comprises a base layer 1, a thermoplastic resin layer 3 provided on the upper side UP of the base layer 1 and having an uneven surface 3a of the upper side UP, a first surface protection layer 4 provided in the recesses 31 of the uneven surface and having a thickness H2 in the vertical direction V that is smaller than the depth H1 of the recesses 31, and a second surface protection layer 5 provided on the upper side UP of the thermoplastic resin layer 3 and the first surface protection layer 4.

Description

Technical Field

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

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 three-dimensional feeling by touch by forming a concavo-convex shape (emboss) on the surface by embossing or the like.

[0003] For example, in a decorative sheet with a wood grain pattern, by imparting a three-dimensional feeling 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 realized.

[0004] For a decorative sheet having a three-dimensional feeling due to the concavo-convex shape on the surface, a concavo-convex shape with a deeper depth is required to reproduce a more realistic texture.

[0005] In addition, a decorative sheet used as a surface material for furniture and building materials for housing is required to have stain resistance. For example, the stain resistance can be improved by coating a surface protective layer on the surface of the decorative sheet.

[0006] As a decorative sheet subjected to embossing, there is a decorative sheet described in Patent Document 1. The decorative sheet described in Patent Document 1 is a decorative sheet having a pattern layer, a first adhesive layer, a polyester resin layer, and a surface protective layer in this order on a thermoplastic resin base sheet.

[0007] The decorative sheet described in Patent Document 1 is embossed from above the surface protective layer, thereby forming a concavo-convex pattern.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

[0009] However, in the case of decorative sheets with an embossed surface, such as the decorative sheet described in Patent Document 1, if the depth of the uneven shape formed by the embossing becomes too deep, the surface protective layer may not be sufficiently applied to the recesses in the uneven shape, which could result in poor stain resistance.

[0010] Furthermore, in order to adequately coat the recessed areas with the surface protective layer, it is necessary to increase the amount of the surface protective layer applied, which may increase manufacturing costs and production time.

[0011] Based on the above circumstances, the present invention aims to provide decorative sheets and decorative components having an uneven surface and excellent stain resistance. [Means for solving the problem]

[0012] To solve the above problems, this invention proposes the following means. The decorative sheet of the present invention comprises a base layer, a thermoplastic resin layer provided on the upper side of the base layer and having an uneven surface, a first surface protection layer provided in the recesses of the uneven surface and having a thickness in the vertical direction less than the depth of the recess, and a second surface protection layer provided on the upper side of the thermoplastic resin layer and the first surface protection layer.

[0013] In the decorative sheet described above, the thickness of the first surface protective layer may be 10% or more of the depth of the recess.

[0014] In the decorative sheet described above, the second surface protective layer may contain silicone.

[0015] In the decorative sheet described above, the first surface protective layer may contain silicone.

[0016] In the above-described cosmetic sheet, the depth of the concave portion may be 30 μm or more.

[0017] In the above-described cosmetic sheet, the second surface protective layer may contain a thermosetting resin or a radiation-curable resin.

[0018] The cosmetic member of the present invention includes any of the above-described cosmetic sheets and a base material provided on the lower side of the cosmetic sheet.

Effect of the Invention

[0019] According to the present invention, it is possible to provide a cosmetic sheet and a cosmetic member having an uneven shape on the surface and excellent stain resistance.

Brief Description of the Drawings

[0020] [Figure 1] It is a cross-sectional view schematically showing a cosmetic member according to the present embodiment.

Mode for Carrying Out the Invention

[0021] An embodiment of the present invention will be described with reference to the drawings.

[0022] FIG. 1 is a cross-sectional view schematically showing a cosmetic member 100 according to the present embodiment.

[0023] In the present embodiment, as shown in FIG. 1, the thickness direction of the cosmetic member 100 is defined as the "vertical direction V", the side of the cosmetic member 100 where 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.

[0024] The cosmetic member 100 includes a cosmetic sheet 10 and a base material 20.

[0025] The base material 20 is a layer provided on the lower side LO of the cosmetic member 100. As the base material 20, a particle board or a medium density fiberboard (MDF) or the like can be adopted.

[0026] 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.

[0027] The decorative sheet 10 comprises a base layer 1, a pattern layer 2, a thermoplastic resin layer 3, a first surface protection layer 4, a second surface protection layer 5, and a primer layer 6.

[0028] The base layer 1 is a layer located above the primer layer 6. Details of the primer layer 6 will be described later. The base layer 1 is a sheet-like layer made of a known material that can be printed on.

[0029] For example, a resin material such as a thermoplastic resin can be used as the material for the base layer 1. Examples of thermoplastic resins used for the base layer 1 include vinyl chloride resin, acrylic resin, polyolefin-based polypropylene resin, or polyethylene resin.

[0030] From the viewpoint of environmental compatibility, processability, and cost, it is preferable to use polyolefin resin as the material for the raw material layer 1.

[0031] The pattern layer 2 is a layer provided on the upper side UP of the base material layer 1. The pattern layer 2 is formed by printing patterns such as wood grain, cork, stone, tile, ceramics, or abstract patterns.

[0032] As a method for printing the pattern layer 2, known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be used.

[0033] A known printing ink suitable for the printing method used can be used for the pattern layer 2. Preferably, a suitable printing ink is used for the pattern layer 2, taking into consideration adhesion to the base layer 1, printability, weather resistance, etc.

[0034] The thermoplastic resin layer 3 is a layer provided above the pattern layer 2. It is preferable that the thermoplastic resin layer 3 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 it.

[0035] For example, a resin material such as a thermoplastic resin can be used as the material for the thermoplastic resin layer 3. Examples of thermoplastic resins used for the thermoplastic resin layer 3 include vinyl chloride resin, acrylic resin, polyolefin-based polypropylene resin, or polyethylene resin.

[0036] From the viewpoint of environmental compatibility, processability, and cost, it is preferable to use a polyolefin resin as the material for the thermoplastic resin layer 3.

[0037] The thermoplastic resin layer 3 is formed by laminating a sheet made of, for example, a polyolefin resin onto the upper surface UP of the pattern layer 2 using a known lamination method such as dry lamination, wet lamination, non-solvent lamination, wax lamination, or thermal lamination.

[0038] The thermoplastic resin layer 3 may be formed by melt extrusion molding, or by known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing, or by known coating apparatus.

[0039] As shown in Figure 1, the surface 3a of the thermoplastic resin layer 3 is provided with an uneven shape. The surface 3a of the thermoplastic resin layer 3 represents the upper side UP of the thermoplastic resin layer 3.

[0040] The uneven surface 3a of the thermoplastic resin layer 3 is formed, for example, by embossing, such as by pressing an embossing plate onto the surface 3a of the thermoplastic resin layer 3.

[0041] As shown in Figure 1, the uneven shape provided on the surface 3a of the thermoplastic resin layer 3 includes recesses 31 and protrusions 32.

[0042] The recessed portion 31 is a recessed portion on the lower side LO in the uneven shape provided on the surface 3a of the thermoplastic resin layer 3.

[0043] The protrusion 32 is a portion of the uneven shape provided on the surface 3a of the thermoplastic resin layer 3 that is convex upward UP.

[0044] The surface 3a of the thermoplastic resin layer 3 is provided with an uneven shape due to the difference in height in the vertical direction V between the recessed portion 31 and the convex portion 32.

[0045] The depth H1 of the recess 31 is preferably 30 μm or more. The depth H1 of the recess 31 refers to the dimension in the vertical direction V between the bottom of the recess 31 and the apex of the convex portion 32, as shown in Figure 1.

[0046] The bottom of the recess 31 refers to the lowest part LO of the recess 31. The apex of the convex part 32 refers to the highest part UP of the convex part 32.

[0047] By making the depth H1 of the recess 31 30 μm or more, a sufficiently deep uneven shape can be formed on the surface 10a of the decorative sheet 10, enabling excellent texture expression through tactile and visual three-dimensionality.

[0048] The surface 10a of the decorative sheet 10 shows the upper side UP of the decorative sheet 10, as shown in Figure 1.

[0049] The recessed portion 31 and the raised portion 32 may be positioned in a manner that aligns with the pattern on the pattern layer 2. By aligning the recessed portion 31 and the raised portion 32 with the pattern on the pattern layer 2, for example, a more realistic appearance can be given to patterns such as wood grain or stone patterns.

[0050] The first surface protective layer 4 is a layer provided in the recess 31 on the upper side UP of the thermoplastic resin layer 3. The first surface protective layer 4 covers at least the bottom of the recess 31. Also, as shown in Figure 1, the first surface protective layer 4 does not cover the protrusion 32.

[0051] For the first surface protective layer 4, it is preferable to use a material that is transparent or semi-transparent enough to allow the pattern of the pattern layer 2 to be seen through the thermoplastic resin layer 3.

[0052] The material of the first surface protective layer 4 can be a thermosetting resin, an ionizing radiation-curable resin, or a mixture of a thermosetting resin and an ionizing radiation-curable resin.

[0053] The first surface protective layer 4 may contain silicone for the purpose of improving the stain resistance of the surface 10a of the decorative sheet 10.

[0054] The thickness H2 of the first surface protective layer 4 in the vertical direction V is smaller than the depth H1 of the recess 31. Preferably, the thickness H2 of the first surface protective layer 4 is 10% or more of the depth H1 of the recess 31, more preferably 20% or more, and even more preferably 30% or more.

[0055] Furthermore, the ratio of the thickness H2 of the first surface protective layer 4 to the depth H1 of the recess 31 is preferably such that it provides a sufficient tactile feel to the surface 10a of the decorative sheet 10.

[0056] The second surface protection layer 5 is a layer provided above the thermoplastic resin layer 3 and the first surface protection layer 4. As shown in Figure 1, the second surface protection layer 5 covers the recesses 31 and protrusions 32 of the thermoplastic resin layer 3.

[0057] For the second surface protective layer 5, it is preferable to use a material that is transparent or semi-transparent enough to allow the pattern of the pattern layer 2 to be seen through the thermoplastic resin layer 3 and the first surface protective layer 4.

[0058] The material for the second surface protective layer 5 can be a thermosetting resin, an ionizing radiation-curable resin, or a mixture of a thermosetting resin and an ionizing radiation-curable resin.

[0059] The second surface protective layer 5 contains silicone. As shown in Figure 1, the second surface protective layer 5 is a layer that covers the surface 10a of the decorative sheet 10.

[0060] By including silicone in the second surface protective layer 5 that covers the surface 10a of the decorative sheet 10, the stain resistance of the surface 10a of the decorative sheet 10 can be improved.

[0061] For example, when applying the second surface protective layer 5 to the surface 3a of the thermoplastic resin layer 3, the deeper the depth H1 of the recess 31, the thinner the film thickness of the second surface protective layer 5 applied to the recess 31 becomes, which may reduce the stain resistance performance of the surface 10a of the decorative sheet 10.

[0062] In this embodiment, a first surface protection layer 4 is provided in the recess 31 of the thermoplastic resin layer 3. Therefore, the second surface protection layer 5 is applied to the upper side UP of the recess 31, above the first surface protection layer 4.

[0063] In the recess 31, by applying the second surface protective layer 5 to the upper side UP of the first surface protective layer 4, it is possible to suppress the thinning of the film thickness of the second surface protective layer 5 compared to the case where the second surface protective layer 5 is directly applied to the surface 3a of the thermoplastic resin layer 3, thereby providing the decorative sheet 10 with sufficient stain resistance.

[0064] By using a material that is transparent or semi-transparent enough for the first surface protective layer 4 to allow the pattern of the pattern layer 2 to be seen through the thermoplastic resin layer 3, the depth H1 of the recess 31 can be made visible even when the first surface protective layer 4 is applied to the recess 31, thereby giving the surface 10a of the decorative sheet 10 a visually three-dimensional appearance.

[0065] Furthermore, by making the thickness H2 of the first surface protective layer 4 smaller than the depth H1 of the recess 31, even when the first surface protective layer 4 is provided in the recess 31, the decorative sheet 10 can be given a tactile sensation due to the difference in height of the uneven shape on the surface 10a of the decorative sheet 10. In other words, the decorative sheet 10 can be given a three-dimensional feel through touch.

[0066] The primer layer 6 is a layer provided on the lower LO of the base material layer 1. The primer layer 6 is provided for the purpose of improving the adhesion between the decorative sheet 10 and the base material 20.

[0067] As the primer layer 6, polyester resin, urethane resin, or acrylic resin can be used.

[0068] As a method for laminating the primer layer 6, known printing methods such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing, or formation methods using known coating equipment can be employed.

[0069] The decorative sheet 10 of this embodiment comprises a base layer 1, a thermoplastic resin layer 3 provided on the upper side UP of the base layer 1 and having an uneven surface 3a on the upper side UP, a first surface protection layer 4 provided in the recesses 31 of the uneven surface and having a thickness H2 in the vertical direction V that is smaller than the depth H1 of the recesses 31, and a second surface protection layer 5 provided on the upper side UP of the thermoplastic resin layer 3 and the first surface protection layer 4.

[0070] The decorative member 100 of this embodiment comprises a decorative sheet 10 and a base material 20 provided on the lower side LO of the decorative sheet 10.

[0071] According to the decorative sheet 10 and decorative member 100 of this embodiment, it is possible to provide a decorative sheet 10 and decorative member 100 that have an uneven surface 10a and excellent stain resistance.

[0072] 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.

[0073] (Variation 1) In the above embodiment, the decorative sheet 10 includes a primer layer 6, but the form of the decorative sheet is not limited thereto. The decorative sheet does not need to include a primer layer 6.

[0074] The primer layer 6 is a layer provided to improve the adhesion between the raw material layer 1 of the decorative sheet 10 and the substrate 20.

[0075] If sufficient adhesion can be achieved at the bonding surface between the decorative sheet and the substrate 20 without improving adhesion with the primer layer 6, the decorative sheet does not need to have the primer layer 6.

[0076] (Modification 2) In the above embodiment, the second surface protection layer 5 provided in the recess 31 is provided above the first surface protection layer 4, but the form of the second surface protection layer is not limited thereto.

[0077] For example, after applying a second surface protective layer to the surface 3a of the thermoplastic resin layer 3, the first surface protective layer may be applied to the upper side UP of the second surface protective layer in the recess 31.

[0078] In this case, on the surface 3a of the thermoplastic resin layer 3, a second surface protective layer is provided on the upper side UP of the protrusion 32, and a first surface protective layer is provided on the upper side UP of the recess 31 via the second surface protective layer. That is, in the recess 31, the first surface protective layer is exposed on the upper side UP.

[0079] In this case, the first surface protective layer is made of a material containing silicone. By including silicone in the first surface protective layer exposed on the surface of the decorative sheet, the stain resistance of the decorative sheet can be improved in the recess 31 by the first surface protective layer.

[0080] The present invention will be described in detail with reference to the following examples. The present invention is not limited to the following examples.

[0081] (Example 1) A urethane-based printing ink was applied to the upper side UP of the 55 μm thick base material layer 1 to form a pattern layer 2. A urethane-based primer was also applied to the lower side LO of the base material layer 1 to form a primer layer 6.

[0082] A 70 μm polypropylene (PP) film was placed on the upper side UP of the pattern layer 2 to form a thermoplastic resin layer 3. An embossed design was applied to the surface 3a of the thermoplastic resin layer 3 such that the depth H1 of the recesses 31 was 30 μm.

[0083] A first surface protective layer 4 containing silicone components was applied to the recesses 31 using a wiping gravure coating (embossed recess resin filling coating). The thickness H2 of the first surface protective layer 4 was set to 5 μm.

[0084] The surface 10a of the decorative sheet 10 was coated with a second surface protective layer 5, which was formed by adding a silicone component and applying a gravure coating, to obtain the decorative sheet 10 of Example 1. The thickness of the second surface protective layer 5 was 6 μm.

[0085] (Comparative Example 1) A decorative sheet of Comparative Example 1 was obtained by the same method as in Example 1, except that it did not have a first surface protective layer. In the recesses of the thermoplastic resin layer, the thickness of the second surface protective layer was about 2 μm.

[0086] (Comparative Example 2) A decorative sheet of Comparative Example 2 was obtained by the same method as in Example 1, except that it did not have a first surface protective layer and the depth of the recesses in the embossed design applied to the surface of the thermoplastic resin layer was set to 15 μm. In the recesses of the thermoplastic resin layer, the thickness of the second surface protective layer was approximately 5 μm.

[0087] (Test 1) A stain resistance test was conducted on the decorative sheets of Example 1 and Comparative Examples 1-2. In the stain resistance test, oil-based black marker ink was applied to the surface of the decorative sheet, and after the ink dried, the surface of the decorative sheet was wiped dry with a cloth, and the removal rate of the marker ink was evaluated.

[0088] Furthermore, the surface of the decorative sheet was designed so that recessed areas were included in the areas where the magic ink was applied and where it was wiped dry.

[0089] The evaluation criteria consisted of three levels, with ○ being considered a pass. ○ (Good): The removal rate of the magic marker ink is 95% or more of the area where the magic marker ink was applied. △(Fair): The removal rate of the magic marker ink is 70% or more but less than 95% of the area where the magic marker ink was applied. × (Poor): The removal rate of the magic marker ink is less than 70% of the area where the magic marker ink was applied.

[0090] (Exam 2) A design evaluation test was conducted on the decorative sheets of Example 1 and Comparative Examples 1-2. In the design evaluation test, ten testers performed visual and tactile sensory tests, focusing on the quality of the design on the surface of the decorative sheet.

[0091] The evaluation criteria consisted of two levels, with a circle (〇) indicating a passing grade. ○ (Good): More than 9 people rated the surface design of the decorative sheet as good. △(Fair): Fewer than 9 people rated the surface design of the decorative sheet as good.

[0092] (Test results) The results of Test 1-2 are shown in Table 1. Table 1 also shows the overall evaluation results, which are a comprehensive assessment of the results of Test 1-2. The overall evaluation criteria were based on two levels: ○ (Good) and × (Poor), with ○ being a passing grade.

[0093] The decorative sheet 10 of Example 1, which has a first surface protective layer 4 in the recess 31, showed good results in Test 1-2 and passed the overall evaluation.

[0094] The decorative sheet of Comparative Example 1, which lacked a first surface protective layer, failed Test 1. Furthermore, the decorative sheet of Comparative Example 1, with a recess depth equivalent to that of Example 1, showed good results in Test 2. The decorative sheet of Comparative Example 1 failed the overall evaluation.

[0095] The decorative sheet of Comparative Example 2, which lacked a first surface protective layer and had shallower recess depths compared to Example 1, passed Test 1 but failed Test 2. The decorative sheet of Comparative Example 2 failed the overall evaluation.

[0096] Thus, the decorative sheets of Example 1 and Comparative Example 1, which had recess depths of 30 μm, showed good results in the design evaluation. However, the decorative sheet of Comparative Example 1, which did not have a first surface protective layer in the recesses, had inferior stain resistance compared to Example 1. In addition, the decorative sheet of Comparative Example 2, which had recess depths of 15 μm, had inferior design.

[0097] A decorative sheet 10 having an uneven surface 10a can achieve both aesthetic appeal and stain resistance by providing a first surface protective layer 4 on the upper side UP of the recess 31.

[0098] [Table 1] [Explanation of Symbols]

[0099] 100 Decorative components 10 Decorative sheets 10a Surface of decorative sheet 1. Anti-nuclear layer 3 Thermoplastic resin layer 3a Surface of the thermoplastic resin layer 31 Recess 4 First surface protective layer 5 Second surface protection layer 20 Base material H1 Depth of recess H2: Thickness of the first surface protective layer V vertical direction UP upper side LO (lower side)

Claims

1. The nuclear franc and, A thermoplastic resin layer provided on the upper side of the raw material layer, having an uneven surface on the upper surface, A first surface protective layer is provided in the recess of the aforementioned uneven shape, and its thickness in the vertical direction is less than the depth of the recess, The thermoplastic resin layer and the second surface protective layer provided above the first surface protective layer, Equipped with, Decorative sheet.

2. The thickness of the first surface protective layer is 10% or more of the depth of the recess. The decorative sheet according to claim 1.

3. The second surface protective layer contains silicone, The decorative sheet according to claim 2.

4. The first surface protective layer contains silicone, The decorative sheet according to claim 3.

5. The depth of the recess is 30 μm or more. The decorative sheet according to claim 3.

6. The second surface protective layer comprises a thermosetting resin or an ionizing radiation curing resin. The decorative sheet according to claim 3.

7. A decorative sheet according to any one of claims 1 to 6, A base material provided below the decorative sheet, Equipped with, Decorative material.

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