Decorative sheet and decorative sheet roll

Abstract

A decorative sheet (10) of the present invention is provided with, in the following order, a concealing layer (12), a printing layer (14), a transparent film (16), and a resin coating layer (20) containing a matte filler (18). The surface of the resin coating layer (20) is provided with protruding parts (20a) that conform to the shape of the matte filler (18).

Description

[Technical field]

[0001] The present invention relates to a decorative sheet and a wound body in which the decorative sheet is wound around a core. [Background technology]

[0002] In the construction of interior and exterior walls of houses and buildings, decorative sheets are sometimes applied to enhance the design of the walls. By forming an embossed surface on the decorative sheet, the gloss of the surface is reduced, design is imparted, and contamination by fingerprints and the like is suppressed. Patent Document 1 discloses a decorative sheet on whose surface an uneven pattern of a mold is transferred.

[0003] Furthermore, decorative sheets have traditionally been produced by molding using a press machine. Due to the characteristics of the press machine, the length of the decorative sheet is limited to a maximum of 10 shaku (3 m), and the application surface is limited to flat surfaces, making it impossible to apply the sheet to curved surfaces (curved surface application). In recent years, decorative sheets that can be applied to curved surfaces have been developed, but the applicable curvature radius is large, and the application surface is limited. Patent Document 2 discloses a decorative sheet having a coating layer containing a melamine resin. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-128217 A [Patent Document 2] JP 2018-24238 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the conventional technology described in Patent Document 1, the embossed shape is created by pressing the unevenness of a molding die against the surface layer, so if the pressing force is insufficient or if the decorative sheet to be embossed is not placed horizontally, there may be places where the embossed shape is not formed or where the embossed shape is shallow. Therefore, conventional decorative sheets have room for improvement in terms of suppressing the surface gloss and suppressing contamination such as fingerprints.

[0006] If the decorative sheet could be provided as a roll wound around a core, it would be easy to apply and would be easy to transport and bring in. Patent Document 2 does not mention the decorative sheet being rolled, so there is room for improvement in application to curved surfaces. [Means for solving the problem]

[0007] As a result of extensive research, the inventors have discovered that by giving the surface of a resin coating layer a specific shape, it is possible to solve the problems of suppressing the surface gloss of a decorative sheet and suppressing contamination by fingerprints and the like, and have completed the invention provided below.

[0008] According to the present invention, A concealment layer; A printing layer; A transparent film and A resin coating layer containing a matte filler, in this order; The matte filler comprises a melamine-based resin or silica; The resin coating layer has a surface provided with protrusions conforming to the shape of the matte filler, thereby providing a decorative sheet.

[0009] Furthermore, the inventors discovered that the problem of improving installation workability, transportation, delivery, etc. can be solved by wrapping a strip-shaped melamine decorative sheet having a predetermined length in the longitudinal direction around a core to form a rolled body, and completed the invention provided below.

[0010] According to the present invention, A release layer; A concealment layer; A printing layer; A transparent film and Melamine Resin and matte filler Including and a surface of the matte filler having a convex portion conforming to the shape of the matte filler. A resin coat layer; A decorative sheet roll in which a strip-shaped decorative sheet having the above components is wound around a core, The matte filler comprises a melamine-based resin or silica; A roll of the decorative sheet is provided, the length of which in the longitudinal direction is 4 m or more.

[0011] The inventors have discovered that the above-mentioned problems of improving installation workability, transportation, delivery, etc. can be solved by making the coating layer of a decorative sheet having a specific layer structure a predetermined thickness and rolling up this decorative sheet, and have completed the invention provided below.

[0012] According to the present invention, A release layer; A concealment layer; A printing layer; A transparent film and Contains matte filler A resin coat layer; A decorative sheet roll in which a strip-shaped decorative sheet having the above components is wound around a core, The matte filler comprises a melamine-based resin or silica particles; The resin coating layer contains a melamine resin or a thermoplastic resin, and has a layer thickness of 12 μm or less. and has a surface having a convex portion conforming to the shape of the matte filler. , a decorative sheet roll is provided. Effect of the Invention

[0013] According to the present invention, a decorative sheet having excellent surface gloss suppression effect, antifouling effect, and fingerprint resistance can be provided. Furthermore, the decorative sheet of the present invention has a configuration with excellent manufacturing stability, and can obtain a decorative sheet having the above effects by incorporating a matte filler in the resin coating layer. Furthermore, according to the present invention, it is possible to provide a decorative sheet roll that is easy to apply to curved surfaces, can be applied to a wide area at once, has excellent application workability, and can reduce the number of rolls required for the application area, making it easy to transport and carry in. [Brief description of the drawings]

[0014] [Figure 1] 1 is a schematic cross-sectional view showing a decorative sheet according to an embodiment of the present invention. [Diagram 2] 1 is a schematic perspective view illustrating a structure of a decorative sheet roll according to an embodiment. FIG. [Diagram 3] FIG. 2 is a schematic cross-sectional view of a decorative material sheet constituting a decorative sheet roll according to an embodiment. [Figure 4] FIG. 2 is a schematic process flow diagram showing a method for producing a decorative sheet roll according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In all drawings, similar components are given similar reference symbols and their description will be omitted as appropriate. In addition, "~" indicates "above" to "below" unless otherwise specified.

[0016] <Decorative sheet> FIG. 1 is a cross-sectional view showing the structure of the decorative sheet of this embodiment. 1, the decorative sheet 10 of this embodiment comprises, in this order, a concealing layer 12, a printed layer 14, a transparent film 16, and a resin coating layer 20 containing a matte filler 18. The resin coating layer 20 has protrusions 20a on its surface that correspond to the shape of the matte filler 18. The overall layer thickness of the decorative sheet 10 is about 0.1 mm to 2 mm.

[0017] [Hidden Layer 12] The concealing layer 12 can conceal the application surface located on the back side of the surface opposite to 14, and the application surface cannot be seen from the resin coat layer 20 side. Furthermore, when viewed from the resin coat layer 20 side, the concealing layer 12 can improve the visibility of the pattern of the printed layer 14 or change the color by combining it with the printed layer 14 described later. The concealing layer 12 can be composed of a resin film 12a and a metal deposition layer 12b.

[0018] The resin film 12a may contain a thermoplastic resin, a curable resin material, or the like. Specifically, the resin film 12a may contain a polyolefin such as polyethylene, polypropylene, an ethylene-propylene copolymer, or an ethylene-vinyl acetate copolymer (EVA), a cyclic polyolefin (COP), a modified polyolefin, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamide (e.g., nylon 6, nylon 46, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, nylon 6-66), polyimide, polyamideimide, polycarbonate, etc. Polyesters, polyethers, polyethylenes, etc., such as poly(4-methylpentene-1), ionomers, acrylic resins, polymethyl methacrylate, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylonitrile-styrene copolymers (AS resins), butadiene-styrene copolymers, polyoxymethylene, polyvinyl alcohol (PVA), ethylene-vinyl alcohol copolymers (EVOH), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polycyclohexane terephthalate (PCT). Polyether ketone (PEK), polyether ether ketone (PEEK), polyetherimide, polyacetal (POM), polyphenylene oxide, modified polyphenylene oxide, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, aromatic polyester (liquid crystal polymer), polytetrafluoroethylene, polyvinylidene fluoride, other fluorine resins, styrene, polyolefin, polyvinyl chloride, polyurethane, polyester, polyamide, polybutadiene, trans polyisoprene, fluorocarbon resin Various thermoplastic elastomers such as rubber-based and chlorinated polyethylene-based, epoxy resins, phenolic resins, urea resins, melamine-based resins, unsaturated polyesters, silicone-based resins, urethane-based resins, poly-para-xylylene, poly-monochloro-para-xylylene, poly-dichloro-para-xylylene, poly-monofluoro-para-xylylene,Examples of the material include polyparaxylylene resins such as polymonoethyl-para-xylylene, or copolymers, blends, and polymer alloys mainly made of these resins, and the material may include at least one selected from these resins. In this embodiment, the material is preferably a polyvinyl chloride film.

[0019] The metal vapor deposition layer 12b is formed on one surface of the resin film 12a, and may contain at least one of aluminum oxide, silicon oxide, silicon nitride, and silicon oxynitride. The thickness of the concealing layer 12 is about 10 μm to 300 μm as a whole. The concealing layer 12 may be provided with an adhesive layer (not shown) on the surface opposite to the surface facing the printed layer 14, so that it can be configured to be attached to an application surface (such as a wall surface).

[0020] [Print layer 14] The printed layer 14 has various patterns such as a wood grain pattern, a stone pattern, a geometric pattern, etc., and the patterns are visible when viewed by a user from the resin coat layer 20 side.

[0021] The printed layer 14 may contain a resin and a colorant such as a pigment or dye, and various patterns are formed by the colorant. Examples of the resin contained in the printed layer 14 include the resins exemplified for the resin film 12a. The thickness of the printed layer 14 is 0.1 to 15 μm, and preferably 1 to 5 μm.

[0022] [Transparent Film 16] The decorative sheet of the present embodiment has excellent flexibility due to the inclusion of the transparent film 16. Furthermore, it transmits light reflected by the printed layer 14, allowing the user to visually recognize the pattern of the printed layer 14.

[0023] Examples of the resin contained in the transparent film 16 include the resins exemplified for the resin film 12a, and it is preferable that the resin contains polyethylene terephthalate. The transparent film 16 has a thickness of about 10 μm to 300 μm.

[0024] [Resin coat layer 20] The resin coating layer 20 has a surface including protrusions 20a that correspond to the shape of the matte filler 18. By providing the resin coating layer 20 with the protrusions 20a, the decorative sheet 10 of the present embodiment has a suppressed gloss and excellent aesthetics, and is also resistant to the adhesion of contaminating materials, resulting in excellent anti-fouling effect and fingerprint resistance.

[0025] From the viewpoint of the effects of the present invention, it is preferable that the average particle size of the matte filler 18 is larger than the average film thickness of the resin coating layer 20 . The average particle size of the matte filler 18 is 3 μm to 100 μm, preferably 5 to 70 μm, and more preferably 5 to 50 μm. The average film thickness of the resin coating layer 20 is 2 μm to 80 μm, preferably 4 to 50 μm, and more preferably 5 to 30 μm.

[0026] The surface roughness (arithmetic mean height (μm) Sa) of the resin coat layer 20 surface is 0.1 to 10 μm, preferably 0.2 to 7 μm, and more preferably 0.5 to 5 μm. If the surface roughness of the resin coat layer 20 surface is within the above range, a decorative sheet having excellent surface gloss suppression effect, antifouling effect, and fingerprint resistance can be provided.

[0027] Furthermore, in the decorative sheet 10 of this embodiment, the ratio of the area of ​​the matte filler 18 to the area (100%) of the surface of the resin coat layer 20 (area occupancy rate of the matte filler 18) is 5 to 60%, preferably 10 to 50%, and more preferably 15 to 40%, when viewed from above on the surface having the convex portions of the resin coat layer 20. If the area ratio of the matte filler 18 is within the above range, a decorative sheet having excellent surface gloss suppression effect, anti-soiling effect, and fingerprint resistance can be provided. The area ratio of the matte filler 18 can be obtained by binarizing an image of the surface of the resin coat layer 20 taken by a laser microscope and calculating the area ratio of the matte filler 18 in the resin coat layer 20 (100%).

[0028] From the viewpoint of the effects of the present invention, it is more preferable that the surface roughness of the surface of the resin coating layer 20 and the area ratio of the matte filler 18 are both within the above ranges.

[0029] Examples of the resin contained in the resin coating layer 20 include the resins exemplified in the resin film 12a. The resin is preferably a thermoplastic resin or a melamine-based resin. The thermoplastic resin is preferably an acrylic resin.

[0030] The matte filler 18 contains at least one selected from an acrylic resin, a melamine-based resin, a polystyrene resin, and silica. Examples of the matte filler 18 include acrylic resin particles, melamine-based resin particles, polystyrene resin particles, silica particles, composite particles of these resins and silica, and the like. In this embodiment, from the viewpoint of visibility of the printing layer 14, it is preferable that the matte filler contains an acrylic resin or a melamine-based resin.

[0031] Examples of matte fillers 18 include Metablen (acrylic resin particles, manufactured by Mitsubishi Chemical Corporation), Tuftic (acrylic resin particles, manufactured by Toyobo Co., Ltd.), Techpolymer (acrylic resin particles, manufactured by Sekisui Chemical Co., Ltd.), Techpolymer (polystyrene resin particles, manufactured by Sekisui Chemical Co., Ltd.), silica particles (manufactured by Denka Co., Ltd.), Eposter (melamine resin particles, manufactured by Nippon Shokubai Co., Ltd.), and Optobeads (melamine resin / silica composite particles, manufactured by Nissan Chemical Co., Ltd.).

[0032] If the refractive index of the matte filler 18 is significantly different from that of the resin layer constituting the resin coat layer 20 (portions of the resin coat layer 20 other than the matte filler 18), the transparency of the resin coat layer 20 decreases, and the matte effect of the resin coat layer 20 is not fully exhibited, resulting in a decrease in the aesthetic appeal of the appearance. Therefore, from the viewpoint of improving the aesthetic appeal of the appearance, it is preferable to use, for the matte filler 18, a transparent material whose refractive index difference with the resin constituting the resin coat layer 20 is 0.2 or less.

[0033] The refractive index of the resin constituting the resin coat layer 20 is about 1.4 to 1.7, and the refractive index of the preferably used melamine resin is about 1.6, so that the refractive index of the matte filler 18 is in the range of about 1.3 to 1.8.

[0034] The difference between the linear expansion coefficient of the resin constituting the resin coating layer 20 and the linear expansion coefficient of the matte filler 18 is 10×10 -5 / ℃ or less, preferably 8×10 -5 / ℃ or less, more preferably 5×10 -5 / °C or less. Within this range, the difference in the degree of expansion and contraction between the matte filler 18 and the resin constituting the resin coating layer 20 in response to temperature changes is small, and the multiple convex portions 20a of the resin coating layer 20 can be maintained, and thus the gloss suppression effect, antifouling effect, and fingerprint resistance can be stably obtained.

[0035] In this embodiment, the resin coating layer 20 is preferably a combination in which the base resin is a melamine-based resin and the resin contained in the matte filler 18 is an acrylic resin, or a combination in which the base resin is a thermoplastic resin and the resin contained in the matte filler 18 is a melamine-based resin.

[0036] [Manufacturing method of decorative sheet] The decorative sheet 10 of this embodiment can be produced by laminating a concealing layer 12, a printed layer 14, a transparent film 16, and a resin coating layer 20 containing a matte filler 18 in this order.

[0037] Specifically, this embodiment includes a printing step a of forming a printed layer 14 on one surface of the transparent film 16, a step b of forming a resin coating layer 20 on the other surface of the transparent film 16, and a step c of laminating the printed layer 14 on one surface of the concealing layer 12. Furthermore, a step d of forming a release layer on the other surface of the concealing layer 12 may also be included.

[0038] In the printing step a, the printed layer 14 can be formed on one side of the transparent film 16 by various printing methods. Examples of the printing methods include the inkjet method, the screen printing method, the gravure printing method, and the octopus printing method. The ink usually contains a colorant as a solid content. For example, various pigments and various dyes can be used as the colorant. The ink may contain a solvent.

[0039] In step b, a resin coat layer 20 is formed on the surface of the transparent film 16 opposite to the surface on which the print layer 14 is formed. The resin coating layer 20 is formed by forming a layer made of a composition for forming a resin coating layer on the surface of the transparent film 16 by various methods, such as a dipping method, a spray method, a coating method using various coaters such as a kiss coater, a comma coater, a roll coater, a knife coater, or a blade coater, and various printing methods. Then, the resin coating layer 20 can be formed by carrying out a curing reaction.

[0040] The composition for forming the resin coat layer used to form the resin coat layer 20 contains the above-mentioned resin and / or its precursor that constitutes the resin coat layer 20, and the matte filler .

[0041] The volume of the matte filler 18 can be 0.1 to 10 times, preferably 0.5 to 8 times, and more preferably 1 to 5 times the volume of the above-mentioned resin and / or its precursor. This allows the resin coating layer 20 to efficiently form convex portions 20a on its surface that conform to the shape of the matte filler 18, thereby providing a decorative sheet that has excellent surface gloss suppressing effect, antifouling effect, and fingerprint resistance.

[0042] The resin coat layer forming composition can be obtained by mixing the resin and / or its precursor, the matte filler 18, and, if necessary, a solvent, etc., by a known method. By using a solvent, the composition can easily follow the shape of the matte filler 18, and the convex portion 20a can be efficiently formed. Furthermore, since the resin or its precursor is dissolved or dispersed, the resin coat layer forming composition can be easily handled. In addition, the adhesion between the transparent film 16 and the resin coat layer 20 can be improved. As the solvent contained in the composition for forming the resin coat layer, a polar solvent can be suitably used.

[0043] Specific examples of the solvent include water; alcoholic solvents such as methanol, ethanol, and isopropanol; ketone-based solvents such as methyl ethyl ketone and acetone; amide-based solvents such as dimethylformamide (DMF); ether-based solvents such as tetrahydrofuran (THF) and tetrahydropyran; and sulfoxide-based solvents such as dimethyl sulfoxide (DMSO).

[0044] The composition for forming the resin coating layer may contain, as necessary, a catalyst, a release agent, a polymerization initiator, a slip agent (leveling agent), a dispersant, a polymerization accelerator, a polymerization inhibitor, a penetration accelerator, a wetting agent (moisturizing agent), a colorant, a fixing agent, an antifungal agent, a preservative, an antioxidant, a chelating agent, a thickener, an antifoaming agent, a sensitizer (sensitizing dye), and the like.

[0045] In step c, the printed layer 14 is laminated on the metal vapor deposition layer 12b of the concealing layer 12. The printed layer 14 and the metal vapor deposition layer 12b can be laminated via an adhesive layer. Furthermore, an adhesive layer and a release layer can be laminated on the resin film 12a of the concealing layer 12. When the decorative sheet 10 is applied to a wall surface or the like, the release layer can be peeled off and the sheet can be attached to the application surface via the adhesive layer.

[0046] Although the embodiments of the present invention have been described above, these are merely examples of the present invention, and various configurations other than those described above can be adopted as long as they do not impair the effects of the present invention. In this embodiment, the concealing layer 12 is shown as being composed of a resin film 12a and a metal vapor deposition layer 12b, but it can also be composed of a laminate of the resin film 12a and a separately prepared metal layer, or it can be composed of only the colored resin film 12a, or it can be composed of the resin film 12a that has been whitened by internal voids.

[0047] <Decorative sheet roll> The decorative sheet roll of the present invention will be described with reference to a first embodiment or a second embodiment.

[0048] [First embodiment] As shown in FIG. 2, the decorative sheet roll (melamine decorative sheet roll) 30 of this embodiment has a structure in which a strip-shaped melamine decorative sheet 10 is wound around a winding core 20. The length in the longitudinal direction of the melamine decorative sheet 10 can be 4 m or more, preferably 8 m or more, and more preferably 12 m or more. The decorative sheet roll 30 of this embodiment can provide a decorative sheet 10 that is long in the longitudinal direction, and can reduce the number of seams between the decorative sheets 10 that occur on the application surface, thereby improving the design of the application surface. Furthermore, it can provide a decorative sheet roll that is easy to apply to curved surfaces, has excellent application workability, and is easy to transport and carry in. The upper limit of the longitudinal length of the melamine decorative sheet 10 is about 50 m or less, from the viewpoint of workability and construction area. Furthermore, the decorative sheet roll 30 of this embodiment has an outer diameter of the core 20 of 190 mm or less. This makes it possible to provide a decorative sheet roll that is excellent in workability, and because the outer diameter of the roll is smaller, it is easier to transport and bring in. Furthermore, storage space can be secured.

[0049] The melamine decorative sheet 10 can be configured in a roll shape wound around a core 20 so that a melamine resin coating layer 22 described below is on the inside (core 20 side) and the release layer 11 is on the outside.

[0050] A schematic cross-sectional view of the decorative material sheet constituting the rolled decorative sheet is shown in Fig. 3. As shown in Fig. 3, the melamine decorative sheet 10 of this embodiment includes a release layer 11, a concealing layer 12, a printed layer 14, a transparent film 16, and a melamine resin coating layer 22, in this order. By using a melamine decorative sheet having a specific layer structure, the decorative sheet roll 30 of this embodiment can be suitably provided.

[0051] The thickness of the melamine resin coating layer 22 is preferably 12 μm or less. In this way, by making the melamine resin coating layer 22 have a predetermined thickness in a decorative sheet having a specific layer structure, the decorative sheet is thin and has excellent flexibility, so that application to curved surfaces is easy and workability is excellent, and a rolled body can be manufactured by rolling up a long decorative sheet in the longitudinal direction. Therefore, the rolled body of the present invention can be applied to a wide area at once with the rolled decorative sheet, and has excellent workability in application, and the number of rolls required for the application area can be reduced, making it easy to transport and carry in.

[0052] Furthermore, by using the decorative sheet 10 of this embodiment, the length in the longitudinal direction of the strip-shaped decorative sheet 10 in the decorative sheet roll 30 can be set to 4 m or more, and the outer diameter of the roll core 20 can be set to 190 mm or less. This makes it possible to provide a decorative sheet roll that is excellent in workability, and furthermore, because the outer diameter of the roll is smaller, it is easier to transport and bring in. Each layer constituting the melamine decorative sheet 10 will now be described.

[0053] (Release layer 11) The melamine decorative sheet 10 has a peelable release layer 11 on the side opposite to the design side (the side of the melamine resin coating layer 22). Examples of the release layer 11 include paper such as kraft paper, polyolefins such as polyethylene and polypropylene, and resin films made of polymer materials including polyesters such as ethylene vinyl acetate, polyurethane, and polyethylene terephthalate. The thickness of the release layer 11 is about 5 μm or more and 300 μm or less. The release surface of the release layer 11 may be coated with a release agent such as a silicone-containing material or a fluorocarbon-containing material, if necessary.

[0054] (Concealment Layer 12) The concealing layer 12 can conceal the applied surface located on the back side of the surface facing the printed layer 14, and the applied surface cannot be seen from the melamine resin coating layer 22 side.

[0055] Furthermore, when viewed from the melamine resin coating layer 22 side, the concealing layer 12 can improve the visibility of the pattern of the printed layer 14 or change the color by combining it with the printed layer 14 described below. Examples of the material constituting the concealing layer 12 include resin materials, metal materials, and metal compounds such as metal oxides.

[0056] The resin material may include thermoplastic resins, curable resin materials, etc., and specifically, polyolefins such as polyethylene, polypropylene, ethylene-propylene copolymer, and ethylene-vinyl acetate copolymer (EVA), cyclic polyolefins (COP), modified polyolefins, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamides (e.g., nylon 6, nylon 46, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, nylon 6-66), polyimides, polyamide-imides, and polycarbonates. Polyesters, polyethers, and polyamides, such as (PC), poly-(4-methylpentene-1), ionomers, acrylic resins, polymethyl methacrylate, acrylonitrile-butadiene-styrene copolymers (ABS resins), acrylonitrile-styrene copolymers (AS resins), butadiene-styrene copolymers, polyoxymethylene, polyvinyl alcohol (PVA), ethylene-vinyl alcohol copolymers (EVOH), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polycyclohexane terephthalate (PCT). Polyether ketone (PEK), polyether ether ketone (PEEK), polyetherimide, polyacetal (POM), polyphenylene oxide, modified polyphenylene oxide, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, aromatic polyester (liquid crystal polymer), polytetrafluoroethylene, polyvinylidene fluoride, other fluorine resins, styrene, polyolefin, polyvinyl chloride, polyurethane, polyester, polyamide, polybutadiene, trans polyisoprene, fluorocarbon Thermoplastic elastomers such as rubber-based and chlorinated polyethylene-based, epoxy resins, phenolic resins, urea resins, melamine resins, unsaturated polyesters, silicone-based resins, urethane-based resins, poly-para-xylylene, poly-monochloro-para-xylylene, poly-dichloro-para-xylylene, poly-monofluoro-para-xylylene,Examples of the film include polyparaxylylene resins such as polymonoethyl-para-xylylene, or copolymers, blends, and polymer alloys mainly made of these resins, and at least one selected from these resins may be included. In this embodiment, the film is preferably a polyvinyl chloride film or a polyethylene terephthalate film.

[0057] Furthermore, the concealing layer 12 can contain, for example, white pigments such as titanium oxide and zinc oxide; black pigments such as carbon black; other pigments; various dyes; various metal materials; and the like.

[0058] By including such components, it is possible to more effectively prevent a decrease in the properties of the concealing layer 12 other than its concealing ability (e.g., adhesion to the printing layer 14, toughness, flexibility, etc.), while further improving the concealing ability of the concealing layer 12.

[0059] It is preferable that the concealing layer 12 is made of a material containing at least one of titanium oxide and zinc oxide in addition to a resin material, which can improve the durability of the decorative sheet 10 and can provide the concealing layer 12 with a bright white color or metallic luster. The thickness of the concealing layer 12 is about 10 μm to 300 μm.

[0060] When the hiding layer 12 does not contain the above-mentioned pigments, dyes, etc., the hiding layer 12 may have a metal vapor deposition layer between the printing layer 14. The metal vapor deposition layer may contain at least one of aluminum oxide, silicon oxide, silicon nitride, and silicon oxynitride.

[0061] The surface of the concealing layer 12 facing the peel-off layer 11 is provided with an adhesive layer (not shown), and the concealing layer 12 can be configured so that the peel-off layer 11 can be peeled off and the concealing layer 12 can be attached to an application surface (such as a wall surface) via the adhesive layer.

[0062] (Print layer 14) The printed layer 14 has various patterns such as a wood grain pattern, a stone pattern, a geometric pattern, etc., and the patterns are visible when the user views the printed layer 14 from the melamine resin coat layer 22 side.

[0063] The printed layer 14 may contain a resin and a colorant such as a pigment or dye, and various patterns are formed by the colorant. Examples of the resin contained in the printed layer 14 include the resins exemplified for the concealing layer 12. The overall thickness of the printed layer 14 is about 1 μm to 10 μm.

[0064] (Transparent Film 16) The decorative sheet of the present embodiment is provided with a transparent film (printed substrate layer) 16, which allows the pattern of the printed layer 14 to be fixed and also provides flexibility. Furthermore, the transparent film transmits light reflected by the printed layer 14, allowing the user to visually recognize the pattern of the printed layer 14. Examples of the resin contained in the transparent film 16 include the resins exemplified for the concealing layer 12, and it is preferable that the resin contains polyethylene terephthalate. The transparent film 16 has a thickness of about 10 μm to 300 μm.

[0065] (Melamine resin coating layer 22) The thickness of the melamine resin coating layer 22 can be set to 12 μm or less, preferably 10 μm or less. The lower limit of the thickness of the melamine resin coating layer 22 is about 5 μm or more.

[0066] The melamine resin coating layer 22 contains a matte filler, and may have a convex portion on its surface that conforms to the shape of the matte filler. The melamine decorative sheet 10 of this embodiment has a melamine resin coating layer 22 with convex portions, which suppresses gloss and provides excellent aesthetics, and is also excellent in anti-fouling effect, making it difficult for fingerprints and the like to stick to the sheet.

[0067] The average particle size of the matte filler is preferably larger than the average film thickness of the melamine resin coating layer 22 (12 μm or less). The average particle size of the matte filler is from 3 μm to 100 μm, preferably from 5 to 70 μm, and more preferably from 5 to 50 μm.

[0068] The surface roughness (arithmetic mean height (μm) Sa) of the melamine resin coating layer 22 is 0.1 to 10 μm, preferably 0.2 to 7 μm, and more preferably 0.5 to 5 μm. If the surface roughness of the melamine resin coating layer 22 is within the above range, a decorative sheet having excellent surface gloss suppression and antifouling effects can be provided.

[0069] Furthermore, in the melamine decorative sheet 10 of this embodiment, the ratio of the area of ​​the matte filler to the surface area (100%) of the melamine resin coating layer 22 is 5 to 60%, preferably 10 to 50%, and more preferably 15 to 40%, when viewed from above on the surface having the convex portions of the melamine resin coating layer 22. If the area ratio of the matte filler is within the above range, a decorative sheet having excellent surface gloss suppression effect and anti-fouling effect can be provided.

[0070] The area ratio of the matte filler can be obtained by binarizing an image of the surface of the melamine resin coating layer 22 taken by a laser microscope and calculating the area ratio of the matte filler in the melamine resin coating layer 22 (100%).

[0071] The matte filler contains at least one selected from acrylic resin, melamine resin, and silica. Examples of the matte filler include acrylic resin particles, melamine resin particles, polystyrene resin particles, silica particles, composite particles of these resins and silica, and the like. In this embodiment, from the viewpoint of visibility of the printing layer 14, it is preferable that the matte filler contains an acrylic resin or a melamine resin.

[0072] Examples of matte fillers include Metablen (acrylic resin particles, manufactured by Mitsubishi Chemical Corporation), Tuftic (acrylic resin particles, manufactured by Toyobo Co., Ltd.), Techpolymer (acrylic resin particles, manufactured by Sekisui Chemical Co., Ltd.), Techpolymer (polystyrene resin particles, manufactured by Sekisui Chemical Co., Ltd.), silica particles (manufactured by Denka Co., Ltd.), Optobeads (manufactured by Nissan Chemical Co., Ltd., melamine resin / silica composite particles), and Eposter (melamine resin particles, manufactured by Nippon Shokubai Co., Ltd.).

[0073] If the refractive index of the matte filler is significantly different from that of the resin layer (portion of the melamine resin coating layer 22 other than the matte filler) constituting the melamine resin coating layer 22, the transparency of the melamine resin coating layer 22 decreases, and the matte effect of the melamine resin coating layer 22 is not fully exhibited, resulting in a decrease in the aesthetic appeal of the appearance. Therefore, from the viewpoint of improving the aesthetic appeal of the appearance, it is preferable to use a matte filler made of a transparent material whose refractive index difference with the resin constituting the melamine resin coating layer 22 is 0.2 or less.

[0074] Since the refractive index of the melamine resin constituting the melamine resin coating layer 22 is about 1.6, the refractive index of the matte filler is in the range of about 1.4 to 1.8.

[0075] The difference between the linear expansion coefficient of the resin constituting the melamine resin coating layer 22 and the linear expansion coefficient of the matte filler is 5×10 -5 / °C or less. Within this range, the difference in the degree of expansion and contraction in response to temperature changes between the matte filler and the resin constituting the melamine resin coating layer 22 is small, and the multiple convex portions of the melamine resin coating layer 22 can be maintained, and thus the gloss suppression effect and the stain-proofing effect can be stably obtained.

[0076] In this embodiment, the melamine resin coating layer 22 is preferably a combination in which the base resin is a melamine-based resin and the resin contained in the matte filler is an acrylic resin.

[0077] Since the thickness of the melamine resin coating layer 22 is 12 μm or less, the entire melamine decorative sheet 10 is made thin and has improved flexibility, so that it can easily conform to the shape of the application surface, such as a wall. In this embodiment, the bending resistance of the melamine decorative sheet 10 can be set to 0.5 or more and 10 or less, and preferably 1 or more and 7 or less. This prevents the melamine decorative sheet 10 from lifting up or peeling off from corners of the application surface, and allows the sheet to exert its effect particularly over time. The bending resistance test method is as follows. Test Method: The decorative sheet was pressed against a digital force gauge (manufactured by Nidec-Shimpo) in a folded state, and the displayed value was read when the distance between the folded ends of the sheet reached 2 mm (1R).

[0078] [Core 20] The winding core 20 has a columnar or cylindrical shape. In the decorative sheet roll 30 of this embodiment, the thickness of the melamine resin coating layer 22 is 12 μm or less, and the entire melamine decorative sheet 10 is thinned and has improved flexibility, so that the outer diameter of the winding core 20 can be 190 mm or less, preferably 90 mm or less. The lower limit of the outer diameter of the winding core 20 is about 60 mm or more.

[0079] By setting the outer diameter of the core 20 to 190 mm or less, the diameter of the decorative sheet roll 30 is small and the weight is reduced, which makes installation and transportation easier and also makes it possible to secure storage space.

[0080] Furthermore, because the flexibility of the melamine decorative sheet 10 is improved, the number of windings around the core 20 can be increased, and the longitudinal length of the strip-shaped melamine decorative sheet 10 can be increased to 4 m or more. The decorative sheet roll 30 of this embodiment can provide a melamine decorative sheet 10 that is long in the longitudinal direction, and the number of seams between melamine decorative sheets 10 that occur on the application surface can be reduced, improving the design of the application surface.

[0081] The length (axial length) of the core 20 is not particularly limited, but may be the same as the width of the melamine decorative sheet 10, and is preferably slightly larger from the standpoint of workability. The material constituting the winding core 20 is not particularly limited as long as it has sufficient strength, and examples of the material include metal, resin, wood, etc. Among these materials, resin is preferred from the viewpoints of strength and weight reduction.

[0082] <Method of manufacturing decorative sheet roll> The decorative sheet roll of this embodiment can be manufactured, for example, according to the process flow diagram of FIG.

[0083] First, a long transparent film (printing base material layer) 16 is supplied from a roll of the transparent film (printing base material layer) 16, and a printing layer 14 is formed on one surface of the transparent film (printing step S10). The printing layer 14 can be formed by, for example, gravure printing, inkjet printing, offset printing, or the like.

[0084] At the same time, a melamine resin coating layer 22 is formed on a surface of the transparent film (printing substrate) 16 different from the surface on which the printing layer 14 is formed. Specifically, a coating liquid containing a thermosetting resin or a thermoplastic resin is prepared (coating liquid preparation step S20). of The resin is continuously applied to a surface of the transparent film (printing substrate) 16 different from the surface on which the printing layer 14 is formed, so as to have a predetermined thickness, and then cured (resin coat layer forming step S30).

[0085] Various coating methods can be used, specifically including die coating, lip coating, gravure coating, inkjet, spin coating, bar coating, roll coating, wire bar coating, and dip coating. Transparent film 16 with printed layer 14 is continuously supplied from a long roll, and the coating and curing steps of the coating liquid can be continuously performed. Steps S10 to S30 can be continuously performed. Through the above steps, a long first laminate in which the printed layer 14, the transparent film 16, and the melamine resin coating layer 22 are laminated in this order can be obtained.

[0086] In addition, a concealing layer 12 is prepared separately and laminated onto the printed layer 14 of the first laminate obtained in the previous step (concealing layer lamination step S40).

[0087] Specifically, first, a long film that will become the concealing layer 12 is supplied from a roll, and an adhesive layer is formed on the surface of the film. The adhesive layer can be formed from a urethane resin, and has a thickness of about 1 to 10 μm. The concealing layer 12 is continuously supplied from the long roll, and the adhesive layer can be continuously formed. Then, the concealing layer 12 is continuously laminated on the surface of the printing layer 14 of the first laminate via the adhesive layer, to obtain a long second laminate.

[0088] When the concealing layer 12 is composed of a resin film and a metal vapor deposition layer, aluminum oxide, silicon oxide, silicon nitride, or silicon oxynitride is vapor deposited on one side of the resin film to form a metal vapor deposition layer. The concealing layer 12 in which the resin film and the metal vapor deposition layer are laminated can be provided as a long roll.

[0089] Next, the release layer 11 is laminated onto the concealing layer 12 of the second laminate (release layer lamination step S50). Specifically, an adhesive is applied to a release paper to prepare a release paper with an adhesive layer. The thickness of the adhesive layer is about 30 μm. The release paper can be provided as a long roll, and an adhesive layer is continuously formed on the release paper supplied from the roll, and the release paper (release layer 11) is laminated onto the surface of the resin film 12a of the second laminate via the adhesive layer. This makes it possible to obtain a long melamine decorative sheet 10 in which the melamine resin coating layer 22, the transparent film 16, the printing layer 14, the concealing layer 12, and the release layer 11 are laminated in this order.

[0090] Finally, the melamine decorative sheet 10 is passed through a slit of a specified width to adjust the thickness uniformly, and then wound around a core 20 to produce the decorative sheet roll 30 of this embodiment (decorative sheet winding step S60). In the method for producing a rolled decorative sheet of this embodiment, the above steps can be carried out continuously.

[0091] [Second embodiment] 2, the decorative sheet roll 30 of this embodiment has a structure in which a strip-shaped decorative sheet 10 is wound around a winding core 20. The decorative sheet 10 is wound in a roll shape around the winding core 20 so that a resin coating layer 22 (described later) is on the inside (the winding core 20 side) and a release layer 11 is on the outside.

[0092] A schematic cross-sectional view of the decorative material sheet constituting the decorative sheet roll is shown in Fig. 3. As shown in Fig. 3, the decorative sheet 10 of this embodiment includes, in this order, a release layer 11, a concealing layer 12, a printed layer 14, a transparent film 16, and a resin coating layer 22 containing a melamine resin or a thermoplastic resin and having a layer thickness of 12 μm or less.

[0093] In this way, by making the resin coating layer have a predetermined thickness in a decorative sheet having a specific layer structure, the decorative sheet is thin and has excellent flexibility, so that application to curved surfaces is easy and workability is excellent, and a rolled body can be manufactured by rolling up a long decorative sheet in the longitudinal direction. Therefore, the rolled body of the present invention can be applied to a wide area at once with the rolled decorative sheet, and has excellent workability in application, and the number of rolls required for the application area can be reduced, making it easy to transport and carry in.

[0094] Furthermore, by using the decorative sheet 10 of this embodiment, the length in the longitudinal direction of the strip-shaped decorative sheet 10 can be set to 4 m or more, and the outer diameter of the winding core 20 can be set to 190 mm or less in the decorative sheet roll 30. This makes it possible to provide a decorative sheet roll that is excellent in workability, and furthermore, because the outer diameter of the roll is smaller, it is easier to transport and bring in. The following describes each layer that constitutes the decorative sheet 10. Note that the release layer 11, the concealing layer 12, the printed layer 14, and the transparent film 16 are the same as those in the first embodiment, and so descriptions thereof will be omitted.

[0095] (Resin coat layer 22) The resin coating layer 22 contains a thermosetting resin or a thermoplastic resin. The thickness of the resin coating layer 22 can be 12 μm or less, and preferably 10 μm or less. The lower limit of the thickness of the resin coating layer 22 is about 5 μm or more.

[0096] Examples of the resin constituting the resin coat layer 22 include the resins exemplified for the concealing layer 12 in the first embodiment, and thermoplastic resins and melamine resins are preferred.

[0097] The resin coating layer 22 contains a matte filler, and may have protrusions on its surface that correspond to the shape of the matte filler. By providing the resin coating layer 22 with protrusions, the decorative sheet 10 of this embodiment has excellent aesthetics with suppressed gloss, and is also excellent in anti-fouling effect as it is less susceptible to fingerprints and the like.

[0098] The average particle size of the matte filler is preferably larger than the average film thickness of the resin coating layer 22 (12 μm or less). The average particle size of the matte filler is from 3 μm to 100 μm, preferably from 5 to 70 μm, and more preferably from 5 to 50 μm.

[0099] The surface roughness (arithmetic mean height (μm) Sa) of the resin coat layer 22 surface is 0.1 to 10 μm, preferably 0.2 to 7 μm, and more preferably 0.5 to 5 μm. If the surface roughness of the resin coat layer 22 surface is within the above range, a decorative sheet having excellent surface gloss suppressing effect and antifouling effect can be provided.

[0100] Furthermore, in the decorative sheet 10 of this embodiment, the ratio of the area of ​​the matte filler to the area (100%) of the surface of the resin coat layer 22 having the convex portions is 5 to 60%, preferably 10 to 50%, and more preferably 15 to 40%. If the area ratio of the matte filler is within the above range, a decorative sheet having excellent surface gloss suppression effect and anti-fouling effect can be provided.

[0101] The area ratio of the matte filler can be obtained by binarizing an image of the surface of the resin coat layer 22 taken by a laser microscope and calculating the area ratio of the matte filler in the resin coat layer 22 (100%).

[0102] The matte filler contains at least one selected from acrylic resin, melamine resin, and silica. Examples of the matte filler include acrylic resin particles, melamine resin particles, polystyrene resin particles, silica particles, composite particles of these resins and silica, and the like. In this embodiment, from the viewpoint of visibility of the printing layer 14, it is preferable that the matte filler contains an acrylic resin or a melamine resin.

[0103] Examples of matte fillers include Metablen (acrylic resin particles, manufactured by Mitsubishi Chemical Corporation), Tuftic (acrylic resin particles, manufactured by Toyobo Co., Ltd.), Techpolymer (acrylic resin particles, manufactured by Sekisui Chemical Co., Ltd.), Techpolymer (polystyrene resin particles, manufactured by Sekisui Chemical Co., Ltd.), silica particles (manufactured by Denka Co., Ltd.), Optobeads (manufactured by Nissan Chemical Co., Ltd., melamine resin / silica composite particles), and Eposter (melamine resin particles, manufactured by Nippon Shokubai Co., Ltd.).

[0104] If the refractive index of the matte filler is significantly different from that of the resin layer (portions of the resin coat layer 22 other than the matte filler) constituting the resin coat layer 22, the transparency of the resin coat layer 22 decreases, and the matte effect of the resin coat layer 22 is not fully exhibited, resulting in a decrease in the aesthetic appeal of the appearance. Therefore, from the viewpoint of improving the aesthetic appeal of the appearance, it is preferable to use a matte filler made of a transparent material whose refractive index differs from that of the resin constituting the resin coat layer 22 by 0.2 or less.

[0105] The refractive index of the resin constituting the resin coat layer 22 is about 1.4 to 1.7, and the refractive index of the preferably used melamine resin is about 1.6, so the refractive index of the matte filler is in the range of about 1.4 to 1.8.

[0106] The difference between the linear expansion coefficient of the resin constituting the resin coating layer 22 and the linear expansion coefficient of the matte filler is 5×10 -5 / ° C. or less. Within this range, the difference in the degree of expansion and contraction in response to temperature changes between the matte filler and the resin constituting the resin coating layer 22 is small, and the multiple protrusions 20a of the resin coating layer 22 can be maintained, and thus the gloss suppression effect and the antifouling effect can be stably obtained.

[0107] In this embodiment, the resin coating layer 22 is preferably a combination in which the base resin is a melamine-based resin and the resin contained in the matte filler is an acrylic resin, or a combination in which the base resin is a thermoplastic resin and the resin contained in the matte filler is a melamine-based resin.

[0108] Since the thickness of the resin coating layer 22 is 12 μm or less, the entire decorative sheet 10 is made thin and has improved flexibility, so that it can easily conform to the shape of the application surface, such as a wall. In this embodiment, the bending resistance of the decorative sheet 10 can be set to 0.5 or more and 10 or less, and preferably 1 or more and 7 or less. This prevents the decorative sheet 10 from lifting up or peeling off from corners of the application surface, and allows the decorative sheet 10 to exert its effect particularly over time. The bending resistance test method is as follows. Test Method: The decorative sheet was pressed against a digital force gauge (manufactured by Nidec-Shimpo) in a folded state, and the displayed value was read when the distance between the folded ends of the sheet reached 2 mm (1R).

[0109] [Core 20] The winding core 20 has a columnar or cylindrical shape. In the decorative sheet roll 30 of this embodiment, the thickness of the resin coat layer 22 is 12 μm or less, and the entire decorative sheet 10 is thinned and has improved flexibility, so that the outer diameter of the winding core 20 can be 190 mm or less, preferably 90 mm or less. The lower limit of the outer diameter of the winding core 20 is about 60 mm or more.

[0110] By setting the outer diameter of the core 20 to 190 mm or less, the diameter of the decorative sheet roll 30 is small, which makes it possible to provide a decorative sheet roll that is excellent in workability and is easier to transport and bring in, etc. Furthermore, the smaller outer diameter of the roll makes it possible to provide a decorative sheet roll that is easier to transport and bring in, etc. Furthermore, storage space can be secured.

[0111] Furthermore, because the flexibility of the decorative sheet 10 is improved, the number of windings around the core 20 can be increased, and the length in the longitudinal direction of the strip-shaped decorative sheet 10 can be set to 4 m or more, preferably 8 m or more, and more preferably 12 m or more. The decorative sheet roll 30 of this embodiment can provide a decorative sheet 10 that is long in the longitudinal direction, and the number of seams between the decorative sheets 10 that occur on the application surface can be reduced, improving the design of the application surface. Furthermore, it can provide a decorative sheet roll that is easy to apply to curved surfaces, has excellent application workability, and is easy to transport and carry in. The upper limit of the length of the decorative sheet 10 in the longitudinal direction is about 50 m or less, from the viewpoint of workability and construction area.

[0112] The length (length in the axial direction) of the core 20 is not particularly limited, but may be the same as the width of the decorative sheet 10, and is preferably slightly larger from the standpoint of workability. The material constituting the winding core 20 is not particularly limited as long as it has sufficient strength, and examples of the material include metal, resin, wood, paper, etc. Among these materials, resin is preferred from the viewpoints of strength and weight reduction.

[0113] <Method of manufacturing decorative sheet roll> The decorative sheet roll of this embodiment can be manufactured in the same manner as in the first embodiment according to the process flow diagram of FIG. 4, so a description thereof will be omitted.

[0114] Although the embodiments of the present invention have been described above, these are merely examples of the present invention, and various configurations other than those described above can be adopted as long as they do not impair the effects of the present invention. EXAMPLES

[0115] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these.

[0116] Example A [Materials used] The melamine resin constituting the resin coating layer 20 The melamine-based resin was synthesized by the following method. First, the raw material melamine and formalin were charged in a reaction vessel in a predetermined mixing ratio, and after adding a catalyst, the temperature was raised to the boiling point and refluxed. After confirming that the melamine had been completely dissolved, the reaction reached its end point, and the resin solid content was prepared by dehydration treatment and cooled. The melamine-based resin was synthesized by this method. Acrylic resin constituting the resin coating layer 20: Luxidia WLS-373 manufactured by DIC Corporation was used.

[0117] Matte filler constituting the resin coating layer 20 Acrylic resin particles (product name: Metablen (manufactured by Mitsubishi Chemical Corporation), average particle size: 18 μm, refractive index: 1.5, linear expansion coefficient (10 -5 / ℃):8.3) Melamine resin particles (product name: Eposter (manufactured by Nippon Shokubai Co., Ltd.), average particle size: 9 μm, refractive index: 1.68, linear expansion coefficient (10 -5 / ℃):4)

[0118] [Physical property measurement method] Average thickness of resin coating layer 20 (μm) The cross sections were observed and measured using an electron microscope (product name JSM-7401F, manufactured by JEOL Ltd.).

[0119] Surface roughness (arithmetic mean height (μm): Sa) The measurements were made using an image taken with a 20x objective lens of a laser microscope (product name: VK-X1100, manufactured by Keyence Corporation).

[0120] - Matte filler 18 area ratio (area occupancy rate) of resin coat layer 20 An image taken with a 20x objective lens of a laser microscope (product name: VK-X1100, manufactured by Keyence Corporation) was binarized, and the area ratio of the matte filler 18 in the resin coating layer 20 (100%) was calculated.

[0121] Aesthetic evaluation (matt) The decorative sheet was placed on a plaster board (manufactured by Yoshino Gypsum Co., Ltd.) so that the concealing layer 12 was in contact with the mounting plate. That is, the decorative sheet was placed on the plaster board (manufactured by Yoshino Gypsum Co., Ltd.) so that the surface opposite to the surface on which the concealing layer 12 was provided (the outer surface) faced upward. In this state, the decorative sheet was observed from the outer surface side, and its aesthetics was evaluated according to the following criteria. A: The decorative panel has an excellent appearance. B: The laminate has an excellent appearance. C: The decorative panel has a good appearance. D: The aesthetics of the decorative panel are somewhat poor. E: The aesthetics of the veneer are very poor.

[0122] ·Stain resistance evaluation The decorative sheet was treated in accordance with the stain resistance test of JIS K 6902, and the state of remaining stained material on the outer surface of the decorative sheet was confirmed and evaluated according to the following criteria. A: No traces of contaminated material were found on the outer surface of the decorative panel. B: Almost no trace of contaminated material is found on the outer surface of the decorative panel. C: A small amount of contaminated material remains on the outer surface of the decorative panel. D: Remains of contaminated material are clearly visible on the outer surface of the decorative panel. E: Significant traces of contaminated material are visible on the outer surface of the decorative panel.

[0123] ·Fingerprint resistance A fingerprint was applied to the outer surface of each of the decorative sheets of the Examples and Comparative Examples, and the outer surface was visually observed and rated according to the following criteria. A: Fingerprints are clearly less noticeable than in Comparative Example A1. B: Fingerprints are less noticeable than in Comparative Example A1. C: Fingerprints are noticeable (same or worse than Comparative Example A1).

[0124] (Example A1) First, a polyethylene terephthalate film having an ink-receiving layer was prepared as the transparent film 16. This transparent film had a thickness of 38 μm. Next, a printed layer 14 was formed in a predetermined pattern (woodgrain pattern) by an inkjet method on the surface of the transparent film 16 on which the ink receiving layer was provided. Ink containing a colorant and an acrylic resin as an ultraviolet-curable resin was used to form the printed layer 14. After the ink was ejected by the inkjet method, the ink that had landed on the transparent film 16 was irradiated with ultraviolet light to cure it. As a result, a printed layer with a thickness of 3 μm was formed.

[0125] Next, a resin composition containing 100 parts by mass of melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by mass) and 6 parts by mass of matte filler 18 (acrylic resin particles, product name: Metablen (manufactured by Mitsubishi Chemical Corporation)) was applied to the surface of the transparent film 16 opposite to the surface on which the printed layer 14 was provided, forming a coating film. The coating film was then dried for 90 seconds in a hot air dryer at 120°C to obtain a B-stage layer (resin coat layer 20 composed of a material containing B-stage curable resin (melamine resin) and matte filler 18 (acrylic resin particles)). As a result of the above, a laminate was obtained in which the printed layer 14, the transparent film 16, and the B-stage layer (the resin coat layer 20 containing the matte filler 18) were laminated together.

[0126] On the other hand, aluminum was evaporated onto the surface of a white polyvinyl chloride film (80 μm, resin film 12a) made of a material containing titanium oxide by resistance heating evaporation to form a metal evaporated layer 12b (thickness 0.1 μm), thereby obtaining a concealing layer 12. Next, the printed layer 14 of the obtained laminate was laminated on the metal deposition layer 12b of the concealing layer 12, and the obtained laminate was heated and pressurized for 40 minutes at 140° C. and 2 MPa. This resulted in a decorative sheet 10 (melamine decorative sheet) in which a resin coating layer 20 (average film thickness: 6 μm) made of a hard resin material, a transparent film 16 (thickness: 38 μm), a printed layer 14 (thickness: 3 μm), and a concealing layer 12 (thickness: 80 μm) were laminated in this order (see FIG. 1). The resin coating layer (D) had protrusions 20a on its surface, the protrusions conforming to the shape of the matte filler. The results of the aesthetic evaluation (matte) and stain resistance evaluation of the decorative sheet 10 are shown in Table 1.

[0127] (Examples A2 to A5, Comparative Example A1) A decorative sheet was produced in the same manner as in Example A1, except that the structure of each layer was changed as shown in Table 1.

[0128] [Table 1]

[0129] As shown in Table 1, the decorative sheet of Example A, which contains a matte filler in the resin coating layer and has protrusions on its surface that conform to the shape of the matte filler, was excellent in terms of aesthetics (effect of suppressing surface gloss), anti-fouling effect, and fingerprint resistance.

[0130] Example B [Example B1] A long polyethylene terephthalate (PET) film (base layer) having a length of 50 m in the longitudinal direction and a thickness of 38 μm was continuously fed from a roll of the PET film, and a 3 μm-thick printed layer was continuously formed on one side of the PET film by gravure printing. At the same time, a coating liquid containing a melamine resin (resin: manufactured by Sumitomo Bakelite Co., Ltd., solvent: water) was prepared, and the coating liquid was continuously applied by a die coating method to the side opposite to the side having the printed layer of the PET film (base layer), and then cured to laminate a resin coat layer having a thickness of 6 μm. As a result, a long first laminate was obtained in which the printed layer, the PET film (base layer), and the resin coat layer were laminated in order. Separately, a polyethylene terephthalate (PET) film (substrate layer) having a length of 50 m in the longitudinal direction and a thickness of 25 μm was continuously fed from a roll of the PET film, and aluminum oxide was deposited on one side of the PET film to produce a laminate (concealing layer) in which a metal deposition layer (thickness 0.1 μm) was laminated on the PET film. Furthermore, an adhesive layer made of a urethane resin was formed on the other side of the PET film, and the PET film was continuously laminated on the printing layer of the first laminate via the adhesive layer to obtain a long second laminate. Next, release paper was supplied from the long roll, and an adhesive was applied to the release paper to prepare a release paper with an adhesive layer.The release paper was then laminated onto the concealing layer surface of the second laminate via the adhesive layer to obtain a long decorative sheet having a length of 50 m in the longitudinal direction, in which the resin coating layer, the transparent film (base layer), the printing layer, the concealing layer, and the release layer were laminated in this order. Finally, the decorative sheet was passed through a slit to correct the sheet width to be uniform, and then wound around a core having an outer diameter of 71 mm to produce a decorative sheet roll.

[0131] [Examples B2 to B4] A decorative sheet roll was produced in the same manner as in Example B1, except that the layer structure shown in Table 2 was used.

[0132] [Comparative examples B1~B2] A decorative sheet roll was produced in the same manner as in Example B1, except that the layer structure shown in Table 2 was used and the length of each film in the longitudinal direction was 2.4 m.

[0133] [Table 2]

[0134] As shown in Table 2, the roll of Example B was wound with a decorative sheet having a longitudinal length of 4 m or more, and was excellent in workability because it could be applied to a wide area at once. Furthermore, compared to the roll of Comparative Example B, which was wound with a decorative sheet having a short longitudinal length, the roll of Example B reduced the number of rolls relative to the application area, and was easy to transport and carry in.

[0135] Example C [Example C1] A long polyethylene terephthalate (PET) film (base layer) having a length of 50 m in the longitudinal direction and a thickness of 38 μm was continuously fed from a roll of the PET film, and a 3 μm-thick printed layer was continuously formed on one side of the PET film by gravure printing. At the same time, a coating liquid containing a melamine resin (resin: manufactured by Sumitomo Bakelite Co., Ltd., solvent: water) was prepared, and the coating liquid was continuously applied by a die coating method to the side opposite to the side having the printed layer of the PET film (base layer), and then cured to laminate a resin coat layer having a thickness of 6 μm. As a result, a long first laminate was obtained in which the printed layer, the PET film (base layer), and the resin coat layer were laminated in order. Separately, a polyethylene terephthalate (PET) film (substrate layer) having a length of 50 m in the longitudinal direction and a thickness of 25 μm was continuously fed from a roll of the PET film, and aluminum oxide was deposited on one side of the PET film to produce a laminate (concealing layer) in which a metal deposition layer (thickness 0.1 μm) was laminated on the PET film. Furthermore, an adhesive layer made of a urethane resin was formed on the other side of the PET film, and the PET film was continuously laminated on the printing layer of the first laminate via the adhesive layer to obtain a long second laminate. Next, release paper was supplied from the long roll, and an adhesive was applied to the release paper to prepare a release paper with an adhesive layer.The release paper was then laminated onto the concealing layer surface of the second laminate via the adhesive layer to obtain a long decorative sheet having a length of 50 m in the longitudinal direction, in which the resin coating layer, the transparent film (base layer), the printing layer, the concealing layer, and the release layer were laminated in this order. Finally, the decorative sheet was passed through a slit to correct the sheet width to be uniform, and then wound around a core having an outer diameter of 71 mm to produce a decorative sheet roll.

[0136] [Examples C2 to C5] A decorative sheet roll was produced in the same manner as in Example C1, except that the layer structure shown in Table 3 was used.

[0137] [Comparative examples C1~C2] A decorative sheet roll was produced in the same manner as in Example C1, except that the layer structure shown in Table 3 was used and the length of each film in the longitudinal direction was 2.4 m.

[0138] TIFF0007604380000003.tif221153

[0139] As shown in Table 3, the decorative sheet of Example C had a resin coating layer thickness of 12 μm or less, so a rolled body could be manufactured by rolling up a decorative sheet 50 m long in the longitudinal direction. Furthermore, the decorative sheet was easy to apply to curved surfaces and had excellent application properties. The rolled body was wrapped with a decorative sheet 50 m long in the longitudinal direction, and was excellent in application workability because it could be applied to a wide area at once. Furthermore, compared to the rolled body of Comparative Example C, which was wrapped with a decorative sheet with a short longitudinal length, the number of rolls per application area was reduced, making it easier to transport and carry in.

[0140] This application claims priority based on Japanese Patent Application No. 2020-036669, filed March 4, 2020, Japanese Patent Application No. 2020-060642, filed March 30, 2020, and Japanese Patent Application No. 2020-060873, filed March 30, 2020, the disclosures of which are incorporated herein in their entirety. [Explanation of symbols]

[0141] 10 Decorative Sheet 12 Hidden Layer 12a Resin film 12b Metal evaporated layer 14 Printing layer 16 Transparent Film 18 Matte Filler 20, 22 Resin coating layer 20a Convex part 30 Decorative sheet roll

Claims

1. A concealment layer; A printing layer; A transparent film and A melamine resin coating layer containing a matte filler, in this order; The matte filler comprises a melamine-based resin or silica; The decorative sheet, wherein the melamine resin coating layer has a surface provided with convex portions conforming to the shape of the matte filler, and the area ratio of the matte filler on the surface is 5 to 60% when viewed from above.

2. The decorative sheet according to claim 1 , wherein the average particle size of the matte filler is greater than the average thickness of the melamine resin coating layer.

3. 3. The decorative sheet according to claim 1, wherein the surface roughness of the surface having the protrusions of the melamine resin coating layer is 0.1 to 10 μm.

4. The decorative sheet according to any one of claims 1 to 3, wherein the average particle size of the matte filler is 3 to 100 µm.

5. When the matte filler contains a melamine-based resin, 5. The decorative sheet according to claim 1, wherein the difference between the refractive index of the resin constituting the melamine resin coating layer and the refractive index of the matte filler is 0.2 or less.

6. When the matte filler contains a melamine-based resin, The difference between the linear expansion coefficient of the melamine resin constituting the melamine resin coating layer and the linear expansion coefficient of the matte filler is 10×10 －５ The decorative sheet according to any one of claims 1 to 5, wherein the temperature is 0.1 to 100°C.

7. The decorative sheet according to any one of claims 1 to 6, wherein the transparent film comprises polyethylene terephthalate.

8. The decorative sheet according to any one of claims 1 to 7, wherein the concealing layer comprises a polyvinyl chloride film.

9. A release layer; A concealment layer; A printing layer; A transparent film and a melamine resin coating layer comprising a melamine resin and a matte filler, the surface of which has a convex portion conforming to the shape of the matte filler, the matte filler occupying 5 to 60% of the surface when viewed from above; A decorative sheet roll in which a strip-shaped decorative sheet having the above components is wound around a core, The matte filler comprises a melamine-based resin or silica; A decorative sheet roll, wherein the length of the decorative sheet in the longitudinal direction is 4 m or more.

10. 10. The decorative sheet roll according to claim 9, wherein the outer diameter of the core is 190 mm or less.

11. A release layer; A concealment layer; A printing layer; A transparent film and A melamine resin coating layer containing a matte filler; A decorative sheet roll in which a strip-shaped decorative sheet having the above components is wound around a core, The matte filler comprises a melamine-based resin or silica particles; The melamine resin coating layer has a layer thickness of 12 μm or less, and has a surface having protrusions following the shape of the matte filler, and an area ratio of the matte filler on the surface is 5 to 60% when viewed from above.

12. 12. The decorative sheet roll according to claim 11, wherein the length of the strip-shaped decorative sheet in the longitudinal direction is 4 m or more, and the outer diameter of the roll core is 190 mm or less.

13. The decorative sheet roll according to any one of claims 9 to 12, wherein the transparent film comprises polyethylene terephthalate.

14. The decorative sheet roll according to any one of claims 9 to 13, wherein the concealing layer comprises polyvinyl chloride or polyethylene terephthalate.

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