Decorative sheets, decorative molded products, and methods for manufacturing the same

Abstract

The present invention provides a decorative sheet that can improve the visibility of objects viewed through the decorative sheet while suppressing deterioration of the decorative sheet's appearance. [Solution] The decorative sheet 2 comprises a transparent film 10 having a main surface 10a, a design layer 11 disposed on the main surface 10a, and a shielding layer 12 disposed on the design layer 11. Multiple holes 14 are provided in the design layer 11 and the shielding layer 12. Each of the multiple holes 14 includes a main hole 15m and sub-holes 15a, 15b, and 15c arranged around the main hole 15m. In a plan view of the main surface 10a, the first area of ​​the sub-holes 15a, 15b, and 15c is smaller than the second area of ​​the main hole 15m.

Description

Technical Field

[0001] The present disclosure relates to a decorative sheet, a decorated molded product, and a method for manufacturing them.

Background Art

[0002] International Publication No. 2020 / 196906 discloses a display device with a decorative sheet including a display device and a decorative sheet disposed opposite to the display device. The decorative sheet includes a base film, a design layer, and a light-shielding layer. Holes are formed as light-transmitting portions in the design layer and the light-shielding layer. When the display device is in an off state, a viewer observing the display device with the decorative sheet visually recognizes the design layer. When the display device is in an on state, a viewer observing the display device with the decorative sheet visually recognizes image light from the display device through the holes.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In order to improve the visibility of an object (for example, image light from a display device) visually recognized through a decorative sheet, it is necessary to increase the size of holes formed in the design layer and the light-shielding layer. However, when the size of the holes is increased, the appearance of the decorative sheet deteriorates. The present disclosure has been made in view of the above problems, and an object thereof is to provide a decorative sheet, a decorated molded product, and a method for manufacturing them that can improve the visibility of an object visually recognized through the decorative sheet while suppressing deterioration of the appearance of the decorative sheet.

Means for Solving the Problems

[0005] The decorative sheet of this disclosure comprises a transparent film having a main surface, a design layer disposed on the main surface, and a shielding layer disposed on the design layer. The design layer and the shielding layer are provided with a plurality of holes. Each of the plurality of holes includes a main hole and sub-holes disposed around the main hole. In a plan view of the main surface of the transparent film, the first area of ​​the sub-holes is smaller than the second area of ​​the main holes.

[0006] The decorative molded article of this disclosure comprises a decorative sheet of this disclosure and a molded body disposed on a shielding layer of the decorative sheet.

[0007] The method for manufacturing a decorative sheet according to this disclosure includes forming a design layer on the main surface of a transparent film, forming a shielding layer on the design layer, and forming a plurality of holes in the design layer and the shielding layer by irradiating them with laser light from the side of the shielding layer opposite to the side of the transparent film. Each of the plurality of holes includes a main hole and sub-holes arranged around the main hole. In a plan view of the main surface of the transparent film, the first area of ​​the sub-holes is smaller than the second area of ​​the main holes.

[0008] The method for manufacturing a decorative molded article according to the present disclosure includes manufacturing a decorative sheet by the method for manufacturing a decorative sheet according to the present disclosure, and forming a molded article on a shielding layer of the decorative sheet. [Effects of the Invention]

[0009] The decorative sheets, decorative molded articles, and methods for manufacturing them described herein can improve the visibility of objects viewed through the decorative sheet while suppressing deterioration of the appearance of the decorative sheet. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic perspective view of the decorated molded product and display device according to the embodiment. [Figure 2] This is a schematic plan view of a decorative molded product and a display device in an embodiment where the object is not visible. [Figure 3]It is a schematic plan view of the decorative molded product and the display device according to the embodiment when the object is visible. [Figure 4] It is a schematic partially enlarged plan view of the decorative molded product and the display device according to the embodiment. [Figure 5] It is a schematic partially enlarged cross-sectional view of the decorative molded product and the display device according to the embodiment taken along the cross-section line V-V shown in FIG. 4. [Figure 6] It is a diagram showing a flowchart of a method for manufacturing the decorative molded product according to the embodiment. [Figure 7] It is a schematic partially enlarged cross-sectional view showing a step of forming a plurality of holes. [Figure 8] It is a schematic partially enlarged cross-sectional view showing one step of the step of forming a molded body. [Figure 9] It is a schematic partially enlarged cross-sectional view showing the next step of the step shown in FIG. 8 in the step of forming a molded body. [Figure 10] It is a schematic partially enlarged cross-sectional view of the decorative molded product and the display device according to the first modification of the embodiment. [Figure 11] It is a schematic partially enlarged cross-sectional view of the decorative molded product and the display device according to the second modification of the embodiment. [Figure 12] It is a schematic partially enlarged cross-sectional view of the decorative molded product and the display device according to the third modification of the embodiment.

Embodiments for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present disclosure will be described. In addition, the same configuration is assigned the same reference numeral, and the description thereof will not be repeated.

[0012] Referring to FIGS. 1 to 5, the decorative molded product 1 according to the embodiment will be described. The decorative molded product 1 is, for example, a cover panel such as an interior panel or an exterior panel of a vehicle. The decorative molded product 1 is applied to, for example, a display device 6 including a light emitter 23. The decorative molded product 1 includes a decorative sheet 2 and a molded body 22. The decorative molded product 1 may further include an adhesive layer 20.

[0013] Referring to FIG. 2, when the light emitter 23 (see FIG. 5) does not output light, a person viewing the decorative molded article 1 visually recognizes the design layer 11 (see FIG. 5) of the decorative sheet 2. Referring to FIG. 3, when the light emitter 23 outputs light, a person viewing the decorative molded article 1 visually recognizes, in addition to the design layer 11, the light passing through the plurality of holes 14 (see FIGS. 4 and 5) of the decorative sheet 2 as an object 7.

[0014] Referring to FIGS. 4 and 5, the decorative sheet 2 has a front surface 3 and a back surface 4 opposite to the front surface 3. A person viewing the decorative molded article 1 views the decorative sheet 2 from the front surface 3 of the decorative sheet 2. The decorative sheet 2 includes a transparent film 10, a design layer 11, and a shielding layer 12.

[0015] The transparent film 10 is transparent to visible light such as light from the light emitter 23. The transparent film 10 is formed of, for example, at least one of a resin or an elastomer. As the resin constituting the transparent film 10, for example, a polyester resin, a polyethylene terephthalate (PET) resin, an acrylic resin, a polycarbonate resin, a polybutylene terephthalate (PBT) resin, a triacetyl cellulose resin, a styrene resin, an acrylonitrile - butadiene - styrene (ABS) resin, or the like can be used. As the elastomer constituting the transparent film 10, for example, a thermoplastic elastomer (TPE) can be used. The thermoplastic elastomer is, for example, an amide - based TPE (TPA), an ester - based TPE (TPC), an olefin - based TPE (TPO), a styrene - based TPE (TPS), a urethane - based TPE (TPU), or the like. The transparent film 10 may be a single - layer film or a multi - layer film.

[0016] The transparent film 10 may contain a weather resistance improver. The weather resistance improver is, for example, an ultraviolet absorber, a light stabilizer, or an ultraviolet blocker. Therefore, the weather resistance of the decorative sheet 2 is improved.

[0017] The transparent film 10 is a base film that supports the design layer 11 and the shielding layer 12. The transparent film 10 is positioned near the front surface 3 of the decorative sheet 2 relative to the design layer 11. The transparent film 10 has a main surface 10a that faces the design layer 11. The main surface 10a is the main surface of the transparent film that is distal to the front surface 3 of the decorative sheet 2.

[0018] Referring to Figure 5, the design layer 11 is arranged on the main surface 10a of the transparent film 10. The design layer 11 includes, for example, a binder and a pigment dispersed in the binder. The pigment is, for example, an interference pigment, an absorption pigment, or a metallic pigment, or a combination of two or more of these pigments. An interference pigment is a pigment that generates colored light through the interference of light reflected by the interference pigment. An absorption pigment is a pigment that generates colored light by absorbing light of a certain wavelength from the light incident on the absorption pigment. A metallic pigment is a pigment that exhibits metallic luster, such as metal flakes such as aluminum flakes. A pattern such as wood grain may be formed on the design layer 11. The design layer 11 may be a single layer or multiple layers.

[0019] Referring to Figure 5, the shielding layer 12 is positioned on the design layer 11. The shielding layer 12 is positioned near the back surface 4 of the decorative sheet 2 relative to the design layer 11. The shielding layer 12 is positioned on the side opposite to the transparent film 10 relative to the design layer 11. The shielding layer 12 blocks visible light, such as light from the light-emitting element 23, and also conceals objects on the back surface 4 side of the decorative sheet 2 (e.g., the light-emitting element 23) from those viewing the decorated molded product 1. The shielding layer 12 includes, for example, a binder and a black pigment dispersed in the binder.

[0020] Referring to Figures 4 and 5, a plurality of holes 14 are provided in the design layer 11 and the shielding layer 12. Each of the plurality of holes 14 includes a main hole 15m and sub-holes 15a, 15b, and 15c arranged around the main hole 15m. Each of the plurality of holes 14 may consist of a single main hole 15m and sub-holes 15a, 15b, and 15c. The number of sub-holes 15a, 15b, and 15c arranged around the main hole 15m may be one or more.

[0021] In a plan view of the main surface 10a of the transparent film 10, the shapes of the main hole 15m and the sub-holes 15a, 15b, and 15c are not particularly limited, but may be circular, elliptical, triangular, square, or hexagonal. The shapes of the sub-holes 15a, 15b, and 15c may be the same as the shape of the main hole 15m, or they may be different from the shape of the main hole 15m.

[0022] In a plan view of the main surface 10a of the transparent film 10, the first area of ​​the sub-holes 15a, 15b, and 15c is smaller than the second area of ​​the main hole 15m. When multiple sub-holes 15a, 15b, and 15c are arranged around the main hole 15m, the first area refers to the area of ​​each of the multiple sub-holes 15a, 15b, and 15c. The first area is, for example, 0.04% or more of the second area. The first area may be 4% or more of the second area. The first area is, for example, 50% or less of the second area. The first area may be 25% or less of the second area. The first area is, for example, 0.04% or more and 50% or less of the second area. The first area may be 4% or more and 25% or less of the second area. When multiple sub-holes 15a, 15b, and 15c are arranged around a main hole 15m, the total area of ​​the multiple sub-holes 15a, 15b, and 15c is smaller than the second area of ​​the main hole 15m in a plan view of the main surface 10a.

[0023] The main hole 15m and the sub-holes 15a, 15b, and 15c are sized to be difficult for an observer to see the decorated molded product 1. The second area of ​​the main hole 15m is, for example, 1.8 mm². 2 The following applies: The second area is 1.0 mm². 2The following is also acceptable: The second area is, for example, 3840 μm². 2 That concludes the explanation. The second area is 0.018 mm². 2 The above is also acceptable. The second area is, for example, 3840 μm². 2 1.8mm 2 The following is true: The second area is 0.018 mm². 2 1.0mm or more 2 The following is also acceptable.

[0024] The aperture ratio of the multiple holes 14 is, for example, 10% or more. The aperture ratio is, for example, 20% or less. The aperture ratio is, for example, 10% or more and 20% or less. In this specification, the aperture ratio of the multiple holes 14 is the ratio of the area of ​​the multiple holes 14 to the area of ​​the shielding layer 12 in a plan view of the main surface 10a of the transparent film 10. Because the aperture ratio is 20% or less, it is possible to prevent objects on the back side 4 of the decorative sheet 2 (for example, light-emitting body 23, etc.) from being visible to a person viewing the decorative sheet 2. Because the aperture ratio is 10% or more, the visibility of the object 7 visible through the multiple holes 14 is improved.

[0025] In a plan view of the main surface 10a, the multiple holes 14 and multiple main holes 15m are arranged, for example, in a staggered arrangement (see Figure 4), a triangular grid arrangement, a square grid arrangement, or a hexagonal grid arrangement. Referring to Figure 4, the multiple holes 14 and multiple main holes 15m are arranged along a first direction DR1 and a second direction DR2 intersecting the first direction DR1. The second direction DR2 may be perpendicular to the first direction DR1. The first direction DR1 may be the longitudinal direction of the transparent film 10, and the second direction DR2 may be the short direction of the transparent film 10. The main surface 10a of the transparent film 10 extends in the first direction DR1 and the second direction DR2. The multiple holes 14 and multiple main holes 15m may be arranged along a third direction DR3 oblique to the first direction DR1 and the second direction DR2. The third direction DR3 may be at an angle of 45° with respect to the first direction DR1 and the second direction DR2.

[0026] Referring to Figure 4, the multiple holes 14 and multiple main holes 15m are arranged in the first direction DR1 with a first pitch P1. The first pitch P1 is the distance between the centers of two adjacent main holes 15m in the first direction DR1. The multiple holes 14 and multiple main holes 15m are arranged in the second direction DR2 with a second pitch P2. The second pitch P2 is the distance between the centers of two adjacent main holes 15m in the second direction DR2. The multiple holes 14 and multiple main holes 15m are arranged in the third direction DR3 with a third pitch P3. The third pitch P3 is the distance between the centers of two adjacent main holes 15m in the third direction DR3.

[0027] The sub-holes 15a, 15b, and 15c are arranged in the direction of the arrangement of the multiple holes 14 and the multiple main holes 15m relative to the main hole 15m. For example, sub-hole 15a is arranged in the first direction DR1 relative to the main hole 15m. Sub-hole 15b is arranged in the second direction DR2 relative to the main hole 15m. Sub-hole 15c is arranged in the third direction DR3 relative to the main hole 15m.

[0028] The first distance D1 between the sub-hole 15a and the main hole 15m is, for example, 25% or less of the first pitch P1. The first distance D1 may also be 20% or less of the first pitch P1, or 15% or less of the first pitch P1. The first distance D1 is the distance between the center of the sub-hole 15a and the center of the main hole 15m. The second distance D2 between the sub-hole 15b and the main hole 15m is, for example, 25% or less of the second pitch P2. The second distance D2 may also be 20% or less of the second pitch P2, or 15% or less of the second pitch P2. The second distance D2 is the distance between the center of the sub-hole 15b and the center of the main hole 15m. The third distance D3 between the sub-hole 15c and the main hole 15m is, for example, 25% or less of the third pitch P3. The third distance D3 may also be 20% or less of the third pitch P3, or 15% or less of the third pitch P3. The third distance D3 is the distance between the center of sub-hole 15c and the center of main hole 15m.

[0029] A laser processing mark 18 may be formed on the bottom surface 16 of the main hole 15m. The bottom surface 16 of the main hole 15m is the first surface that is closest to the transparent film 10 among the surfaces that define the main hole 15m. A laser processing mark 19 may be formed on the bottom surface 17 of the sub-holes 15a, 15b, and 15c. The bottom surface 17 of the sub-holes 15a, 15b, and 15c is the second surface that is closest to the transparent film 10 among the surfaces that define the sub-holes 15a, 15b, and 15c. Laser processing marks 18 and 19 are formed on the bottom surface 16 of the main hole 15m and the bottom surfaces 17 of the sub-holes 15a, 15b, and 15c by irradiating the design layer 11 and the shielding layer 12 with laser light 27 (see Figure 7) from the side opposite to the transparent film 10, in order to form the main hole 15m and the sub-holes 15a, 15b, and 15c.

[0030] The main hole 15m may penetrate the design layer 11 and the shielding layer 12, and the bottom surface 16 of the main hole 15m may be the first part of the main surface 10a of the transparent film 10. The sub-holes 15a, 15b, and 15c may penetrate the design layer 11 and the shielding layer 12, and the bottom surface 17 of the sub-holes 15a, 15b, and 15c may be the second part of the main surface 10a of the transparent film 10. The first and second parts of the main surface 10a are rougher than the other parts of the main surface 10a.

[0031] The overall light transmittance of the decorative sheet 2 is, for example, 5% or more. The overall light transmittance of the decorative sheet 2 may be 10% or more. The overall light transmittance of the decorative sheet 2 is, for example, 50% or less. The overall light transmittance of the decorative sheet 2 may be 30% or less. The overall light transmittance of the decorative sheet 2 is, for example, 5% or more and 50% or less. The overall light transmittance of the decorative sheet 2 may be 10% or more and 30% or less.

[0032] The molded body 22 is placed on the shielding layer 12 of the decorative sheet 2. The molded body 22 is placed on the back surface 4 of the decorative sheet 2. The molded body 22 supports the decorative sheet 2. The molded body 22 is placed between the decorative sheet 2 and the light-emitting body 23. The molded body 22 is transparent to visible light, such as light from the light-emitting body 23. The molded body 22 is formed from a resin such as a thermoplastic resin or a thermosetting resin, or from glass, for example. The molded body 22 is shaped into a three-dimensional form, such as a flat plate or a curved plate.

[0033] As shown in Figure 5, the multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c) may be filled with the molded body 22. The laser processing marks 18, 19 are filled with the molded body 22. The portion of the molded body 22 that fills the main hole 15m and the sub-holes 15a, 15b, 15c is in contact with the transparent film 10. The difference between the refractive index of the molded body 22 and the refractive index of the transparent film 10 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. Therefore, the portion of the molded body 22 that fills the main hole 15m and the sub-holes 15a, 15b, 15c reduces the scattering of visible light caused by the laser processing marks 18, 19. The visibility of the object 7 seen through the main hole 15m and sub-holes 15a, 15b, 15c is improved. The molded body 22 may be formed from the same resin material as the transparent film 10.

[0034] The molded body 22 may be bonded to the shielding layer 12 using an adhesive layer 20. The adhesive layer 20 is transparent to visible light, such as light from the light emitter 23. The adhesive layer 20 is formed of, for example, an optically transparent adhesive (OCA) or an optically transparent resin (OCR).

[0035] Referring to Figures 1 and 5, the display device 6 includes a decorated molded product 1 and a light-emitting element 23. The display device 6 may further include an adhesive layer 24.

[0036] The light-emitting element 23 is positioned on the back surface 4 of the decorative sheet 2. The light-emitting element 23 is positioned on the side opposite to the decorative sheet 2 relative to the molded body 22.

[0037] The light-emitting element 23 may be an illumination light source such as a light-emitting diode (LED) light source. The illumination light source itself does not have the function of displaying characters, numbers, icons, symbols, or figures. When the light-emitting element 23 is an illumination light source, the multiple holes 14 are arranged in the shape of characters, numbers, icons, symbols, or figures. The multiple holes 14 can function as multiple pixels of characters, numbers, icons, symbols, or figures. When the illumination light source illuminates the decorative sheet 2, a person viewing the decorative molded product 1 can see characters, numbers, icons, symbols, or figures as objects 7 through the multiple holes 14 (main holes 15m and sub-holes 15a, 15b, 15c) along with the design layer 11.

[0038] The light-emitting element 23 may be a display device such as an LED display, an organic electroluminescent (EL) display, or a liquid crystal display (LCD). The display device outputs image light such as characters, numbers, icons, symbols, or figures toward the molded body 22 and the decorative sheet 2. When the light-emitting element 23 is a display device, the multiple holes 14 are arranged two-dimensionally and periodically and can function as multiple pixels. A person viewing the decorative molded product 1 will see the characters, numbers, icons, symbols, or figures displayed by the display device, along with the design layer 11, as objects 7 through the multiple holes 14 (main holes 15m and sub-holes 15a, 15b, 15c).

[0039] The light-emitting element 23 may be bonded to the molded body 22 using an adhesive layer 24. The adhesive layer 24 is transparent to visible light, such as light from the light-emitting element 23. The adhesive layer 24 is formed of, for example, an optically transparent adhesive (OCA) or an optically transparent resin (OCR). The difference between the refractive index of the molded body 22 and the refractive index of the adhesive layer 24 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. The difference between the refractive index of the front surface of the light-emitting element 23 facing the molded body 22 and the refractive index of the adhesive layer 24 is smaller than the difference between the refractive index of the front surface of the light-emitting element 23 and the refractive index of air. Therefore, the adhesive layer 24 reduces the reflection of light from the light-emitting element 23 on the back surface of the molded body 22 and the front surface of the light-emitting element 23. The visibility of the object 7, which is visible through the multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c), is improved.

[0040] An example of a manufacturing method for the decorated molded product 1 of this embodiment will be described, mainly with reference to Figures 6 to 9.

[0041] Referring to Figures 6 and 7, a design layer 11 is formed on the main surface 10a of the transparent film 10 (step S1). For example, an ink containing a binder and a pigment is printed on the main surface 10a of the transparent film 10. The ink is dried. In this way, the design layer 11 is formed.

[0042] Referring to Figures 6 and 7, a shielding layer 12 is formed on the design layer 11 (step S2). For example, a black ink containing a binder and black pigment dispersed in the binder is printed on the design layer 11. The black ink is dried. In this way, the shielding layer 12 is formed.

[0043] Referring to Figures 6 and 7, a plurality of holes 14 are formed in the design layer 11 and the shielding layer 12 (step S3). Each of the plurality of holes 14 includes a main hole 15m and sub-holes 15a, 15b, and 15c arranged around the main hole 15m. In a plan view of the main surface 10a of the transparent film 10, the first area of ​​the sub-holes 15a, 15b, and 15c is smaller than the second area of ​​the main hole 15m.

[0044] For example, laser light 27 is irradiated onto the design layer 11 and the shielding layer 12 from the side opposite to the transparent film 10. Parts of the design layer 11 and the shielding layer 12 are absorbed by the laser light 27 and removed. In this way, multiple holes 14 (main holes 15m and sub-holes 15a, 15b, 15c) are formed in a shorter time. The productivity of the decorative sheet 2 is improved. The laser light 27 has a wavelength of, for example, 0.2 μm to 11 μm. The light source of the laser light 27 is, for example, a carbon dioxide laser, a fiber laser, or a solid-state laser (for example, a yttrium vanadate (YVO4) laser or a yttrium aluminum garnet (YAG) laser).

[0045] By irradiating the design layer 11 and the shielding layer 12 with laser light 27, a laser processing mark 18 is formed on the bottom surface 16 of the main hole 15m, and a laser processing mark 19 is formed on the bottom surface 17 of the sub-holes 15a, 15b, and 15c. The main hole 15m may penetrate the design layer 11 and the shielding layer 12, and the bottom surface 16 of the main hole 15m may be the first part of the main surface 10a of the transparent film 10. The sub-holes 15a, 15b, and 15c may penetrate the design layer 11 and the shielding layer 12, and the bottom surface 17 of the sub-holes 15a, 15b, and 15c may be the second part of the main surface 10a of the transparent film 10. The first and second parts of the main surface 10a are rougher than the other parts of the main surface 10a.

[0046] When forming multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c) in the design layer 11 and the shielding layer 12, laser light 27 is incident on the design layer 11 and the shielding layer 12 from the back surface 4 of the decorative sheet 2, thus preventing the weather-resistant improving agent contained in the transparent film 10 from absorbing the laser light 27. Multiple holes 14 with a clean shape can be formed. The visibility of the object 7 seen through the multiple holes 14 is improved.

[0047] Steps S1-S3 yield the decorative sheet 2 of this embodiment. In other words, the method for manufacturing the decorative sheet 2 of this embodiment includes steps S1-S3.

[0048] Referring to Figures 5, 6, 8, and 9, a molded body 22 is formed on the shielding layer 12 of the decorative sheet 2 (step S4).

[0049] Referring to Figures 8 and 9, in the first example of step S4, the decorative sheet 2 is bonded to the molded body 22 during injection molding of the molded body 22. Specifically, an adhesive layer 20 is formed on the shielding layer 12 of the decorative sheet 2. Referring to Figure 8, the decorative sheet 2 is placed on the first mold 31. The first mold 31 and the second mold 32 are clamped together. The adhesive layer 20 of the decorative sheet 2 faces the second mold 32. The second mold 32 is provided with a sprue 34, which is a passage for molten resin. The first mold 31 may be a movable mold with a recess formed therein, and the second mold 32 may be a fixed mold with a convex portion formed therein. A cavity 33 is formed between the decorative sheet 2 and the second mold 32. The sprue 34 is in communication with the cavity 33. Referring to Figure 9, molten resin is injected into the cavity 33 through the sprue 34. Multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c) are filled with molten resin. The molten resin is cooled and solidified. In this way, the molded body 22 is formed. Multiple holes 14 are filled in the molded body 22. The decorative sheet 2 is bonded to the molded body 22 with an adhesive layer 20.

[0050] In the second example of step S4, without the adhesive layer 20, the decorative sheet 2 is transferred to the molded body 22 during injection molding of the molded body 22.

[0051] (modified version) Referring to Figure 10, in the first modified example of this embodiment, the multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c) may terminate within the design layer 11. The bottom surface 16 of the main hole 15m and the bottom surfaces 17 of the sub-holes 15a, 15b, 15c, where laser processing marks 18, 19 are formed, may be part of the surface of the design layer 11. The difference between the refractive index of the molded body 22 and the refractive index of the design layer 11 is smaller than the difference between the refractive index of the molded body 22 and the refractive index of air. Therefore, the portion of the molded body 22 that is filled with the main hole 15m and sub-holes 15a, 15b, 15c reduces the scattering of visible light caused by the laser processing marks 18, 19. The visibility of the object 7 seen through the multiple holes 14 is improved.

[0052] Referring to Figure 11, in a second modified example of this embodiment, the multiple holes 14 (main hole 15m and sub-holes 15a, 15b, 15c) do not need to be filled with the molded body 22. In step S4 shown in Figure 7, the molded body 22 is formed, and then the decorative sheet 2 is bonded to the molded body 22 with an adhesive layer 20. The molded body 22 may be formed by injection molding, extrusion molding, blow molding, vacuum forming, pressure forming or compression molding, or it may be formed by machining. Thus, the decorative molded product 1 shown in Figure 11 is obtained.

[0053] Referring to Figure 12, in a third modification of this embodiment, the light-emitting element 23 may be positioned on the side opposite to the decorative sheet 2 relative to the molded body 22 without using the adhesive layer 24. The light-emitting element 23 may be positioned at a distance from the molded body 22 as shown in Figure 12, or it may be in contact with the molded body 22.

[0054] The effects of the decorative sheet 2, the decorative molded product 1, and the manufacturing methods thereof in this embodiment will be explained. The decorative sheet 2 of this embodiment comprises a transparent film 10 having a main surface 10a, a design layer 11 disposed on the main surface 10a, and a shielding layer 12 disposed on the design layer 11. A plurality of holes 14 are provided in the design layer 11 and the shielding layer 12. Each of the plurality of holes 14 includes a main hole 15m and sub-holes (e.g., sub-holes 15a) disposed around the main hole 15m. In a plan view of the main surface 10a, the first area of ​​the sub-holes is smaller than the second area of ​​the main hole 15m.

[0055] The sub-holes (e.g., sub-hole 15a) increase the aperture ratio of the decorative sheet 2 without increasing the area of ​​the main hole 15m. The brightness of the object 7 visible through the multiple holes 14 is improved. The visibility of the object 7 visible through the decorative sheet 2 may be improved. Furthermore, since the area of ​​the main hole 15m is not increased, and the first area of ​​the sub-hole is smaller than the second area of ​​the main hole 15m, a person viewing the decorative sheet 2 cannot see the main hole 15m, the sub-holes, or objects on the back side 4 of the decorative sheet 2 (e.g., light-emitting body 23). The deterioration of the appearance of the decorative sheet 2 can be suppressed. In addition, the brightness and saturation of the design layer 11 and the object 7 can be fine-tuned by the sub-holes. The applications of the decorative sheet 2 can be expanded.

[0056] In the decorative sheet 2 of this embodiment, in a plan view of the main surface 10a of the transparent film 10, the sub-holes (for example, sub-holes 15a) are arranged in the direction of the arrangement of the multiple holes 14 relative to the main hole 15m.

[0057] Therefore, it is possible to improve the visibility of the object 7 seen through the decorative sheet 2 while suppressing the deterioration of the appearance of the decorative sheet 2.

[0058] The decorated molded product 1 of this embodiment comprises the decorative sheet 2 of this embodiment and a molded body 22 disposed on the shielding layer 12.

[0059] The decorated molded product 1 includes a decorative sheet 2. Therefore, it is possible to improve the visibility of the object 7 visible through the decorative sheet 2 while suppressing deterioration of the appearance of the decorative sheet 2.

[0060] In the decorated molded product 1 of this embodiment, the main hole 15m and the sub-hole (for example, sub-hole 15a) are filled with the molded body 22.

[0061] Therefore, the molded body 22 reduces the scattering of visible light on the surface of the main hole 15m and the surface of the sub-holes (e.g., sub-hole 15a). The visibility of the object 7 viewed through the decorative sheet 2 may be improved.

[0062] The manufacturing method of the decorative sheet 2 of this embodiment includes forming a design layer 11 on the main surface 10a of a transparent film 10 (step S1), forming a shielding layer 12 on the design layer 11 (step S2), and forming a plurality of holes 14 in the design layer 11 and the shielding layer 12 by irradiating the design layer 11 and the shielding layer 12 with laser light 27 from the side of the shielding layer 12 opposite to the side of the transparent film 10 (step S3). Each of the plurality of holes 14 includes a main hole 15m and a sub-hole (for example, a sub-hole 15a) arranged around the main hole 15m. In a plan view of the main surface 10a, the first area of ​​the sub-hole is smaller than the second area of ​​the main hole 15m.

[0063] The sub-holes (e.g., sub-hole 15a) increase the aperture ratio of the decorative sheet 2 without increasing the area of ​​the main hole 15m. The brightness of the object 7 visible through the multiple holes 14 is improved. The visibility of the object 7 visible through the decorative sheet 2 may be improved. Also, since the area of ​​the main hole 15m is not increased, and the first area of ​​the sub-hole is smaller than the second area of ​​the main hole 15m, a person viewing the decorative sheet 2 cannot see the main hole 15m, the sub-holes, or objects on the back side 4 of the decorative sheet 2 (e.g., light-emitting body 23). The deterioration of the appearance of the decorative sheet 2 may be suppressed. Since the main hole 15m and sub-holes are formed by laser processing, the main hole 15m and sub-holes are formed in a shorter time. The productivity of the decorative sheet 2 may be improved. Furthermore, the sub-holes allow for fine-tuning of the brightness and saturation of the design layer 11 and the brightness and saturation of the object 7. The applications of the decorative sheet 2 can be expanded.

[0064] The method for manufacturing the decorative molded product 1 of this embodiment includes manufacturing the decorative sheet 2 by the method for manufacturing the decorative sheet 2 of this embodiment (steps S1-S3) and forming a molded body 22 on the shielding layer 12 of the decorative sheet 2 (step S4). Forming the molded body 22 includes filling the main hole 15m and the sub-hole (for example, sub-hole 15a) with the molded body 22.

[0065] The decorated molded product 1 includes a decorative sheet 2. Therefore, the visibility of the object 7 seen through the decorative sheet 2 can be improved while suppressing deterioration of the appearance of the decorative sheet 2. In addition, the laser processing marks 18 and 19 formed in the main hole 15m and sub-holes (e.g., sub-hole 15a) are filled with the molded body 22. The molded body 22 reduces the scattering of visible light caused by the laser processing marks 18 and 19. The visibility of the object 7 seen through the decorative sheet 2 can be improved.

[0066] The various aspects of this disclosure are summarized below as an appendix. (Note 1) A transparent film having a main surface, The design layer arranged on the main surface, The design layer comprises a shielding layer disposed on the aforementioned design layer, Multiple holes are provided in the design layer and the shielding layer. Each of the aforementioned plurality of holes includes a main hole and a sub-hole arranged around the main hole. A decorative sheet in which, in a plan view of the main surface, the first area of ​​the sub-hole is smaller than the second area of ​​the main hole. (Note 2) The transparent film is a decorative sheet as described in Appendix 1, containing a weather-resistant improving agent. (Note 3) The decorative sheet according to Appendix 1 or Appendix 2, wherein, in the plan view of the main surface, the sub-holes are arranged in the direction of the arrangement of the plurality of holes with respect to the main hole. (Note 4) The decorative sheet according to any one of the appendices 1 to 3, wherein laser processing marks are formed on the first surface closest to the transparent film among the surfaces defining the main holes and the second surface closest to the transparent film among the surfaces defining the sub-holes. (Note 5) The decorative sheet described in any of Appendix 1 to Appendix 4, A decorative molded product comprising a molded body disposed on the aforementioned shielding layer. (Note 6) The main hole and the sub-hole are filled with the molded body, as described in Appendix 5, for the decorated molded product. (Note 7) Forming a design layer on the main surface of a transparent film, Forming a shielding layer on the aforementioned design layer, The process includes irradiating the design layer and the shielding layer with laser light from the side of the shielding layer opposite to the side of the transparent film, thereby forming a plurality of holes in the design layer and the shielding layer, each of which includes a main hole and sub-holes arranged around the main hole. A method for manufacturing a decorative sheet, wherein, in a plan view of the main surface, the first area of ​​the sub-hole is smaller than the second area of ​​the main hole. (Note 8) A method for manufacturing a decorative sheet according to Appendix 7, wherein laser processing marks are formed on the first surface closest to the transparent film among the surfaces defining the main holes and the second surface closest to the transparent film among the surfaces defining the sub-holes, by irradiating the design layer and the shielding layer with the laser light. (Note 9) The decorative sheet is manufactured by the method for manufacturing the decorative sheet described in Appendix 7 or Appendix 8, A method for manufacturing a decorated molded product, comprising forming a molded body on the shielding layer of the decorative sheet. (Note 10) The method for manufacturing a decorative molded article according to Appendix 9, wherein forming the molded body includes filling the main hole and the sub-hole with the molded body.

[0067] The embodiments and variations thereof disclosed herein should be considered illustrative and not restrictive. The scope of this disclosure is indicated by the claims rather than the foregoing description and is intended to include all modifications within the meaning and scope equivalent to the claims. [Explanation of symbols]

[0068] 1 Decorative molded product, 2 Decorative sheet, 3 Front, 4 Back, 6 Display device, 7 Object, 10 Transparent film, 10a Main surface, 11 Design layer, 12 Shielding layer, 14 Hole, 15a, 15b, 15c Sub-hole, 15m Main hole, 16, 17 Bottom surface, 18, 19 Laser processing marks, 20, 24 Adhesive layer, 22 Molded body, 23 Light-emitting body, 27 Laser beam, 31 First mold, 32 Second mold, 33 Cavity, 34 Sprue.

Claims

1. A transparent film having a main surface, The design layer arranged on the main surface, The design layer comprises a shielding layer disposed on the aforementioned design layer, Multiple holes are provided in the design layer and the shielding layer. Each of the aforementioned plurality of holes includes a main hole and a sub-hole arranged around the main hole. A decorative sheet in which, in a plan view of the main surface, the first area of ​​the sub-hole is smaller than the second area of ​​the main hole.

2. The decorative sheet according to claim 1, wherein, in the plan view of the main surface, the sub-holes are arranged in the direction of the arrangement of the plurality of holes with respect to the main holes.

3. The decorative sheet according to claim 1 or claim 2, A decorative molded product comprising a molded body disposed on the aforementioned shielding layer.

4. The decorated molded article according to claim 3, wherein the main hole and the sub-hole are filled with the molded body.

5. Forming a design layer on the main surface of a transparent film, Forming a shielding layer on the aforementioned design layer, The process includes irradiating the design layer and the shielding layer with laser light from the side of the shielding layer opposite to the side of the transparent film, thereby forming a plurality of holes in the design layer and the shielding layer, each of which includes a main hole and sub-holes arranged around the main hole. A method for manufacturing a decorative sheet, wherein, in a plan view of the main surface, the first area of ​​the sub-hole is smaller than the second area of ​​the main hole.

6. A decorative sheet is manufactured by the method for manufacturing the decorative sheet described in claim 5, This includes forming a molded body on the shielding layer of the decorative sheet, A method for manufacturing a decorative molded article, comprising filling the main hole and the sub-hole with the molded article to form the molded article.

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