Resin laminate and method for producing resin laminate

Abstract

To provide a resin laminate capable of suppressing occurrence of a gate mark defect.SOLUTION: A decorative panel 10 includes a surface material 1, a base material 3, a decorative layer 2, and an ink flow prevention layer 4, in which the surface material 1 is formed of a transparent resin material, the base material 3 is formed of a resin material, the decorative layer 2 is arranged between the surface material 1 and the base material 3 and has ink, and the ink flow prevention layer 4 is arranged between the base material 3 and the decorative layer 2.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a resin laminate and a method for manufacturing the resin laminate.

Background Art

[0002] In recent years, many techniques for decorating resin molded products have been developed. For example, Patent Document 1 discloses that by sandwiching a colored layer with an inorganic polymer layer, ink flow of the colored layer can be prevented, and the occurrence of defects in in-mold molded products can be suppressed.

[0003] Further, Patent Document 2 discloses an in-mold transfer foil capable of suppressing ink flow of a transfer layer or the like in the vicinity of a gate portion during transfer and stably performing desired transfer over the entire transfer corresponding portion.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, for example, when creating a decorative panel or the like, when a base material is formed by injection molding on a decorative layer by inkjet printing, the ink of the decorative layer may be washed away by the injected resin, resulting in gate mark defects.

[0006] The present invention has been made in view of the above problems, and an object thereof is to provide a resin laminate and a method for manufacturing the resin laminate capable of suppressing the occurrence of gate mark defects.

Means for Solving the Problems

[0007] In order to achieve the above object, the resin laminate according to the first invention includes a surface material, a base material, a decorative layer, and an ink flow prevention layer. The surface material is formed of a transparent resin material. The base material is formed of a resin material. The decorative layer is disposed between the surface material and the base material and has ink. The ink flow prevention layer is disposed between the base material and the decorative layer.

[0008] By disposing the ink flow prevention layer in this way, even when the base material is formed by injection molding, the resin hits the ink flow prevention layer and the flow rate of the resin material is relaxed, so that the occurrence of gate mark defects can be suppressed.

[0009] The resin laminate according to the second invention is the resin laminate according to the first invention, wherein the ink flow prevention layer is disposed at a position facing the gate for injecting the resin material in the resin material outflow direction during the molding of the base material.

[0010] As a result, the resin injected from the gate hits the ink flow prevention layer once, so that the ink in the decorative layer is less likely to be washed away with the resin flow, and the occurrence of gate mark defects can be suppressed.

[0011] The resin laminate according to the third invention is the resin laminate according to the first or second invention, wherein the ink flow prevention layer is colorless and transparent, the same color as the base material, or the same color as the portion of the decorative layer where the ink flow prevention layer is disposed.

[0012] As a result, even when the ink flow prevention layer is provided, the decoration of the resin laminate can be unaffected.

[0013] The resin laminate according to the fourth invention is the resin laminate according to any one of the first to third inventions, wherein the ink flow prevention layer is composed of ink or a thermoplastic resin.

[0014] Inks can be those based on known technologies. For example, UV or EB curable inks (citation: Journal of the Imaging Society of Japan, Vol. 49, No. 5, Hardening characteristics of UV inkjet and Polymer, Vol. 34, November issue (1985), Electron beam curable resin) that contain monomers as the main component and one or more of other additives such as oligomers, colorants, dispersants, photoinitiators, surfactants, etc. Or, for example, penetration, evaporation, drying, acid polymerization drying, and thermosetting inks obtained by dissolving (or dispersing) known colorants (dyes or pigments) together with a binder resin in a solvent (or dispersion medium) may also be used.

[0015] Also, thermoplastic resins such as Teflon and thermosetting resins such as epoxy resins may be used. These may be used in combination. An adhesive layer may be provided and fixed on at least one side of these.

[0016] This can suppress the occurrence of gate mark defects because even when the ink in the ink flow prevention layer is washed away with the injection of the resin, the ink in the decorative layer is not washed away.

[0017] The resin laminate according to the fifth invention is the resin laminate according to any one of the first to fourth inventions, and the ink flow prevention layer has a thickness of 10 μm or more. This can reduce the influence on the decorative layer due to the injection of the resin.

[0018] The resin laminate according to the sixth invention is the resin laminate according to any one of the first to fifth inventions, and the thickness of the decorative layer is 10 μm or more. This can reduce the influence on the decorative layer due to the injection of the resin.

[0019] The resin laminate according to the seventh invention is the resin laminate according to any one of the first to sixth inventions, and the thickness of the surface material is 0.1 mm or more.

[0020] In this way, by setting the thickness of the surface material to 0.1 mm or more, long-term durability (abrasion resistance) can be ensured. This can reduce the influence on the decorative layer due to the injection of the resin.

[0021] The resin laminate according to the eighth invention is the resin laminate according to the first invention, wherein the ink flow prevention layer has a plurality of layers with different diameters. The diameters of the plurality of layers become smaller as the distance from the decorative layer increases.

[0022] This can suppress the occurrence of gate mark defects because when the resin hits the ink flow prevention layer, the flow rate of the resin material is relaxed.

[0023] The resin laminate according to the ninth invention is the resin laminate according to the eighth invention, wherein the layer at the position farthest from the decorative layer among the plurality of layers of the ink flow prevention layer is arranged at a position facing the gate for injecting the resin material in the outflow direction of the resin material during the molding of the base material.

[0024] This can suppress the occurrence of gate mark defects because the resin injected from the gate hits the thickest part of the ink flow prevention layer once, making it difficult for the ink on the decorative layer to be washed away with the flow of the resin.

[0025] The method for manufacturing a resin laminate according to the tenth invention includes a decorative layer forming step, an ink flow prevention layer forming step, and a base material molding step. The decorative layer forming step forms a decorative layer by discharging ink onto the surface of a surface material formed of a transparent resin material. The ink flow prevention layer forming step forms an ink flow prevention layer at a position facing the gate for injecting the resin material when forming the base material on the side opposite to the surface material of the decorative layer. The base material molding step injects the resin material to mold the base material.

[0026] By arranging the ink flow prevention layer in this way, even when the base material is formed by injection molding, since the resin hits the ink flow prevention layer, the occurrence of gate mark defects can be suppressed.

[0027] In addition, since the resin ejected from the gate hits the ink flow prevention layer once, it becomes difficult for the ink in the decorative layer to be washed away with the flow of the resin, and the occurrence of gate mark defects can be suppressed.

Advantages of the Invention

[0028] According to the present invention, it is possible to provide a resin laminate and a method for manufacturing the resin laminate capable of suppressing the occurrence of gate mark defects.

Brief Description of the Drawings

[0029]

Figure 1

Figure 2

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Figure 8

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Figure 10

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Figure 16

Figure 17

[0030] Hereinafter, a decorative panel, which is an example of the resin laminate of the present invention, and a method for manufacturing the decorative panel will be described in detail with reference to the drawings.

[0031] [1. Configuration] (1-1. Overview of the decorative panel 10) Fig. 1 is a perspective view of the decorative panel 10 of the present embodiment. Fig. 2 is a cross-sectional view of the decorative panel 10 of the present embodiment. Note that the perspective view of Fig. 1 includes a partial cross-sectional view.

[0032] Also, in the following description, the up-down direction coincides with the up-down direction in Fig. 2, but is not limited thereto, and the direction may change depending on the position where the decorative panel 10 is arranged.

[0033] The decorative panel 10 (an example of the resin laminate) of the present embodiment is used, for example, for floor materials and the like. The decorative panel 10 includes a surface material 1, a decorative layer 2, a substrate 3, and an ink flow prevention layer 4.

[0034] The surface material 1 is formed of a transparent resin material. The substrate 3 is formed of a resin material. The decorative layer 2 is disposed between the surface material 1 and the substrate 3. The ink flow prevention layer 4 is disposed on the substrate 3 side of the decorative layer 2.

[0035] (1-2. Surface material 1) FIG. 3 is a perspective view of the surface material 1 seen from above. FIG. 4 is a perspective view of the surface material 1 seen from below. FIG. 5 is a cross-sectional view of the surface material.

[0036] The surface material 1 has a plate-shaped main body portion 11 and a side wall portion 12. The main body portion 11 is formed in a rectangular shape. The side wall portion 12 is formed to incline in a flared shape from the periphery of the main body portion 11. The main body portion 11 and the side wall portion 12 are integrally formed. The surface material 1 has an upper surface 1a (which can also be called the surface) and a lower surface 1b (which can also be called the back surface).

[0037] On the lower surface 1b of the surface material 1, a recess 1c surrounded by the lower surface 11b (which can also be called the back surface) of the main body portion 11 and the inner wall surface 12b of the side wall portion 12 is formed.

[0038] From the viewpoints of wear and cost, the thickness W1 of the surface material 1 is preferably, for example, 0.1 mm or more.

[0039] The surface material 1 is not particularly limited as long as it is formed of a transparent resin material, and it is more preferably formed of a resin material with high transparency.

[0040] As the material of the surface material 1, for example, it can be formed of at least one selected from acrylic resins such as acrylonitrile-styrene copolymers, polyolefin resins such as polyethylene, polycarbonate resins, polycarbonate resin, or polyester resins such as polyethylene terephthalate.

[0041] (1-3. Decorative layer) The decorative layer 2 is formed with various patterns, colors, etc., and decorates the decorative panel 10. The decorative layer 2 is formed on the lower surface 1b of the surface material 1 as shown in FIG. 2. The decoration by the decorative layer 2 can be visually recognized from the outside through the transparent surface material 1.

[0042] The decorative layer 2 can be printed on the lower surface 1b of the surface material 1 by an inkjet printer in a non-contact manner. In this case, it may be printed directly on the lower surface 1b of the surface material 1, or it may be printed after performing a primer treatment or a discharge treatment on the lower surface 1b of the surface material 1 to improve adhesiveness. Further, these treatments may be performed on the decorative layer 2 after printing.

[0043] The ink ejected by the inkjet printer uses ink based on known techniques. For example, a UV or EB curable ink containing a monomer as a main component and one or more of other additives such as an oligomer, a colorant, a dispersant, a photoinitiator, and a surfactant (citation: Journal of the Imaging Society of Japan, Vol. 49, No. 5, Curing Characteristics of UV Inkjet and Polymer, Vol. 34, November issue (1985), Electron Beam Curing Resin).

[0044] Alternatively, for example, a penetration, evaporation, drying, acid polymerization drying, or thermosetting ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) together with a binder resin in a solvent (or dispersion medium) may be used. These may be used in combination.

[0045] The decorative layer 2 is formed by printing on the lower surface 1b of the surface material 1 by an inkjet printer. The film thickness W3 of the decorative layer 2 (see FIG. 8 described later) is preferably 10 μm or more.

[0046] (1-4. Substrate 3) FIG. 6 is a perspective view of only the substrate 3 seen from above. FIG. 7 is a perspective view of the substrate 3 seen from below. FIG. 8 is a partial enlarged view of FIG. 2.

[0047] As shown in the figure, the substrate 3 supports the surface material 1. The substrate 3 is disposed on the surface 2b opposite to the surface 2a on the surface material 1 side of the decorative layer 2 as shown in FIG. 8.

[0048] The substrate 3 is formed by insert molding on the surface 2b of the decorative layer 2 and an ink flow prevention layer 4 described later as shown in FIG. 6.

[0049] The base material 3 has a base portion 31 and a convex portion 32. The base portion 31 is formed in a rectangular plate shape. The convex portion 32 is rectangular and is formed on the upper surface of the base portion 31.

[0050] The convex portion 32 is formed in a shape that fits into the concave portion 1c of the surface material 1, and is formed in a trapezoidal shape in a cross-sectional view. The convex portion 32 has an upper surface 321 having the same shape as the lower surface 11b of the main body portion 11 of the surface material 1, and side surfaces 322 that extend downward in a flared shape from the upper surface 321.

[0051] The side surfaces 322 are formed in the same shape as the inner wall surface 12b of the side wall portion 12 of the surface material 1. Such a convex portion 32 and the concave portion 1c of the surface material 1 form a raised portion on the decorative panel 10. Further, a concave portion 321a is formed on the upper surface 321 in the shape of an ink flow prevention layer 4 described later.

[0052] The base material 3 is formed of a resin material, and this resin material is not particularly limited. For example, a material that is easily elastically deformed to absorb the impact received by the decorative panel 10 is preferable.

[0053] Such a material can be formed from at least one resin material selected from, for example, vinyl chloride-based resins such as PVC, olefin-based resins such as polyethylene, acrylic resins such as acrylonitrile-styrene copolymers, or ABS resins. Further, from the viewpoint of the adhesiveness with the ink of the decorative layer 2, it is preferable to be formed of a resin material having polarity.

[0054] (1-5. Ink flow prevention layer 4) As shown in FIG. 8, the ink flow prevention layer 4 is formed on the surface 2b of the decorative layer 2. The ink flow prevention layer 4 prevents the ink flow of the decorative layer 2 when the base material 3 is formed on the surface 2b of the decorative layer 2 by injection molding.

[0055] The ink flow prevention layer 4 is preferably formed to be colorless and transparent, the same color as the base material 3, or the same color as the portion of the decorative layer 2 where the ink flow prevention layer 4 is disposed. Here, the portion of the decorative layer 2 where the ink flow prevention layer 4 is disposed is the portion 2c shown in FIG. 8, which is the portion in contact with the ink flow prevention layer 4.

[0056] The ink flow prevention layer 4 is formed using known inks. For example, a UV or EB curable ink containing a monomer as a main component and one or more of other additives such as an oligomer, a colorant, a dispersant, a photoinitiator, and a surfactant (citation: Journal of the Imaging Society of Japan, Vol. 49, No. 5, Curing Characteristics of UV Inkjet and Polymer, Vol. 34, November issue (1985), Electron Beam Curing Resin).

[0057] Alternatively, for example, penetration, evaporation, drying, acid polymerization drying, or thermosetting ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) together with a binder resin in a solvent (or dispersion medium) may be used. These may be used in combination.

[0058] Alternatively, for example, penetration, evaporation, drying, acid polymerization drying, or thermosetting ink obtained by dissolving (or dispersing) a known colorant (dye or pigment) together with a binder resin in a solvent (or dispersion medium) may be used. Also, a thermoplastic resin such as Teflon or a thermosetting resin such as an epoxy resin may be used. These may be used in combination.

[0059] The ink flow prevention layer 4 can be formed by an inkjet printer. When the ink flow prevention layer 4 is formed to be the same color as the portion 2c of the decorative layer 2, the ink flow prevention layer 4 can be formed by increasing the thickness of the portion 2c when the decorative layer 2 is formed by an inkjet printer.

[0060] As shown in FIG. 8, the ink flow prevention layer 4 is formed such that the radius a from the intersection point P1 of the extension line L1 in the resin injection direction at the center of the gate 210 and the decorative layer 2 is, for example, about 1 time the radius b of the gate 210.

[0061] Further, for example, the radius a of the ink flow prevention layer 4 is formed to be 0.75 mm or more, and the radius b of the gate 210 at this time is 0.75 mm.

[0062] The thickness W3 of the ink flow prevention layer 4 is preferably 10 μm or more. As shown in FIG. 8, the ink flow prevention layer 4 is preferably disposed at a position facing the gate 210 of the resin material when the base material 3 is insert-molded. Thereby, the resin material discharged from the gate 210 is once applied to the ink flow prevention layer 4, and the flow rate of the resin material can be slowed down, so that the ink flow of the decorative layer 2 can be prevented.

[0063] Further, the ink flow prevention layer 4 only needs to face the gate 210 in the injection direction A of the resin material. As shown in FIG. 9, the position of the gate 210 may be formed obliquely with respect to the surface of the base material 3.

[0064] <2. Manufacturing method of the decorative panel 10> Next, the manufacturing method of the decorative panel 10 of the present embodiment will be described.

[0065] FIG. 10 is a flowchart showing the manufacturing method of the decorative panel 10 of the present embodiment. FIGS. 11(a), 11(b), 12(a), 12(b), and 13 are cross-sectional views for explaining the manufacturing method of the decorative panel 10.

[0066] First, in step S10, as shown in FIG. 11(a), the ink 130 is discharged from the inkjet printer 120 onto the lower surface 1b of the surface material 1, and the ink is applied to the lower surface 1b. As shown in FIG. 11(b), the decorative layer 2 and the ink flow prevention layer 4 are formed.

[0067] Next, in step S20, the base material 3 is formed on the decorative layer 2 and the ink flow prevention layer 4 by insert molding.

[0068] Specifically, as shown in Fig. 12(a), the surface material 1, the decorative layer 2, and the ink flow prevention layer 4 are arranged in the mold 200. The mold 200 has a first mold 201 and a second mold 202.

[0069] A gate 210 for injecting a resin material into the mold is formed in the first mold 201. The surface material 1, the decorative layer 2, and the ink flow prevention layer 4 are arranged in the second mold 202. In this embodiment, two gates 210 are formed and provided so as to face each of the two ink flow prevention layers 4.

[0070] As shown in Fig. 12(b), after the surface material 1, the decorative layer 2, and the ink flow prevention layer 4 are arranged in the second mold 202, the first mold 201 and the second mold 202 are closed. Then, the resin material is injected into the mold 200 from the gate 210, and as shown in Fig. 13, the base material 3 is formed. And the produced decorative panel 10 is taken out from the mold 200.

[0071] <3. Example> Next, the decorative panel of this embodiment will be described using examples.

[0072] In the examples, when the thickness W2 of the decorative layer 2 was changed to 10 μm, 20 μm, and 40 μm using a decorative panel 10' without the ink flow prevention layer 4 as shown in Fig. 14, the base material 3 was formed by insert molding and the occurrence of gate mark defects was verified.

[0073] The gate radii in Examples 1 and 2 and Comparative Example 1 are the same and are set to 0.75 mm. Also, the radii of the ink flow prevention layers in Examples 1 and 2 are set to 0.75 mm. Fig. 15 is a diagram showing a table of the results of Examples 1 and 2 and Comparative Example 1.

[0074] The determination of gate mark defects was made by visually checking that the ink of the decorative layer 2 was flowing (the base material 3 was exposed) at a position 50 cm away from the decorative panel 10'.

[0075] In Example 1, the thickness of the decorative layer 2 was set to 20 μm, the temperature of the resin material was set to 230°C, and the resin material was filled in a filling time of 0.5 s. As a result, as shown in FIG. 14, no gate mark defect occurred.

[0076] In Example 2, the thickness of the decorative layer 2 was set to 40 μm, the temperature of the resin material was set to 230°C, and the resin material was filled in a filling time of 0.5 s. As a result, as shown in FIG. 14, no gate mark defect occurred.

[0077] In Comparative Example 1, the thickness of the decorative layer 2 was set to 10 μm, the temperature of the resin material was set to 230°C, and the resin material was filled in a filling time of 0.5 s. As a result, as shown in FIG. 15, a gate mark defect with a diameter of about 5 mm occurred.

[0078] From the above, it can be seen that by increasing the film thickness of the decorative layer 2, the occurrence of gate mark defects due to ink flow can be suppressed. Therefore, by forming the ink flow prevention layer 4, since the combined thickness of the ink flow prevention layer 4 and the decorative layer 2 becomes thick, ink flow can be suppressed.

[0079] Thus, it was confirmed that when the thickness of the ink flow prevention layer was doubled under the same conditions of the gate radius, the gate mark defect disappeared.

[0080] <4. Features, etc.> (4-1) The decorative panel 10 (an example of a resin laminate) of the present embodiment includes a surface material 1, a base material 3, a decorative layer 2, and an ink flow prevention layer 4. The surface material 1 is formed of a transparent resin material. The base material 3 is formed of a resin material. The decorative layer 2 is disposed between the surface material 1 and the base material 3 and has ink. The ink flow prevention layer 4 is disposed between the base material 3 and the decorative layer 2.

[0081] By disposing the ink flow prevention layer 4 in this manner, even when the base material is formed by injection molding, since the resin hits the ink flow prevention layer 4, the occurrence of gate mark defects can be suppressed.

[0082] (4-2) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the ink flow prevention layer 4 is disposed at a position facing in the resin material outflow direction with respect to the gate 210 through which the resin material is injected during the molding of the base material 3.

[0083] As a result, since the resin injected from the gate 210 hits the ink flow prevention layer 4 once, the ink of the decorative layer 2 is less likely to be washed away along with the resin flow, and the occurrence of gate mark defects can be suppressed.

[0084] (4-3) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the ink flow prevention layer 4 is colorless and transparent, the same color as the base material 3, or the same color as the portion 2c of the decorative layer 2 where the ink flow prevention layer 4 is disposed.

[0085] As a result, even when the ink flow prevention layer 4 is provided, the decoration of the decorative panel 10 can be unaffected.

[0086] (4-4) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the ink flow prevention layer 4 is composed of ink or a thermoplastic resin As a result, even when the ink of the ink flow prevention layer 4 is washed away along with the resin injection, the ink of the decorative layer 2 is not washed away, so the occurrence of gate mark defects can be suppressed.

[0087] Note that ink, a thermoplastic resin, or a thermosetting resin may be used. These may be used in combination. An adhesive layer may be provided on at least one side of these and fixed.

[0088] (4-5) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the ink flow prevention layer 4 has a thickness of 10 μm or more. Thereby, the influence on the decorative layer due to the injection of the resin can be reduced.

[0089] (4-6) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the thickness of the decorative layer 2 is 10 μm or more.

[0090] (4-7) In the decorative panel 10 (an example of a resin laminate) of the present embodiment, the thickness of the surface material 1 is 0.1 mm or more.

[0091] In this way, by setting the thickness of the surface material to 0.1 mm or more, long-term durability (abrasion resistance) can be ensured.

[0092] (4-8) The manufacturing method of the decorative panel 10 (an example of a resin laminate) of the present embodiment includes step S10 (an example of a decorative layer forming step), step S10 (an example of an ink flow prevention layer forming step), and step S20 (an example of a base material molding step). In step S10, S20 (an example of a decorative layer forming step), ink is discharged onto the lower surface 1b (an example of a surface) of the surface material 1 formed of a transparent resin material to form the decorative layer 2. In step S10 (an example of an ink flow prevention layer forming step), the ink flow prevention layer 4 is formed at a position facing the gate 210 through which the resin material is injected when forming the base material 3 on the side opposite to the surface material 1 of the decorative layer 2. In step S20 (an example of a base material molding step), the resin material is injected to mold the base material 3.

[0093] By disposing the ink flow prevention layer 4 in this way, even when the base material 3 is formed by injection molding, since the resin hits the ink flow prevention layer 4, the occurrence of gate mark defects can be suppressed.

[0094] In addition, since the resin injected from the gate 210 once hits the ink flow prevention layer 4, the ink in the decorative layer 2 is less likely to be washed away along with the flow of the resin, and the occurrence of gate mark defects can be suppressed.

[0095] <5. Other Embodiments> As described above, the embodiments of the resin laminate and the method for manufacturing the resin laminate according to the present invention have been described. However, the present invention is not limited to the above embodiments, and can be appropriately modified without departing from the spirit thereof.

[0096] (A) In the above embodiment, the side wall portion 12 is formed on the surface material 1. However, the side wall portion may not be provided and the surface material 1 may be plate-shaped. In this case, the decorative panel may not have a raised center. FIG. 16 is a cross-sectional view showing a non-raised decorative panel 20.

[0097] As shown in FIG. 16, the decorative panel 20 has a surface material 21, a decorative layer 22, a base material 23, and an ink flow prevention layer 4. The surface material 21 is plate-shaped and does not have the recess 1c provided in the surface material 1. Further, the decorative layer 22 is formed over the entire surface of the surface material 21 on the side of the base material 23 among the two surfaces. The base material 23 is formed in a plate shape and does not have convex portions 32 or the like as compared with the base material 23. The ink flow prevention layer 4 is formed at a position corresponding to the gate during injection molding of the base material 23.

[0098] (B) In the above embodiment, two gates 210 are formed, but the number is not limited to two, and the location is not limited to the location shown in FIG. 12(b) either.

[0099] (C) The ink flow prevention layer 4 has a cylindrical shape, but is not limited thereto, and may have a square column shape or the like. Further, the thickness W3 may not be constant, and the tip surface on the side of the base material 3 may be inclined.

[0100] (D) In the above embodiment, the decorative layer 2 and the ink flow prevention layer 4 are formed simultaneously, but they may also be formed separately. That is, after forming the decorative layer 2 with an inkjet printer, the ink flow prevention layer 4 may be formed with an inkjet printer.

[0101] (E) The ink flow prevention layer 4 provided on the decorative panel of the above embodiment is formed with a constant diameter in the thickness direction, but it is not limited to this. For example, an ink flow prevention layer with different diameters in the thickness direction may be provided.

[0102] For example, an ink flow prevention layer 4' as shown in FIGS. 17(a) and (b) may be used. FIG. 17(a) is a cross-sectional view showing the vicinity of the ink flow prevention layer 4' of the decorative panel 10'. FIG. 17(b) is a plan view of the ink flow prevention layer 4' viewed from the base material 3 side.

[0103] The ink flow prevention layer 4' of the decorative panel 10' has a plurality of layers 41, 42, 43, and 44. The layers 41, 42, 43, and 44 are arranged in this order from the decorative layer 2 side. That is, the layer 41 is arranged on the decorative layer 2, the layer 42 is arranged on the layer 41, the layer 43 is arranged on the layer 42, and the layer 44 is arranged on the layer 43.

[0104] The layers 41, 42, 43, and 44 are formed such that the diameter becomes smaller as they are farther from the decorative layer 2. Also, the centers of the layers 41, 42, 43, and 44 are arranged on the extension line L1 in the resin injection direction of the center of the gate 210. As a result, the resin injected from the gate 210 hits the layer 44, which is the farthest from the decorative layer 2 and has the thickest position in the ink flow prevention layer 4, so that ink flow can be more effectively prevented.

[0105] Note that the radius a of the layer 44 is more preferably equal to or greater than the radius b of the gate 210. Also, the ink flow prevention layer 4' is not limited to four layers and may have two or more layers.

[0106] (F) Further, within the scope not departing from the gist of the present invention, it is possible to appropriately replace the components in the above-described embodiments with well-known components.

Industrial Applicability

[0107] The resin laminate of the present invention has an effect of suppressing the occurrence of gate mark defects and is useful as a decorative panel or the like.

Explanation of Signs

[0108] 1: Surface material 1a: Upper surface 1b: Lower surface 1c: Recess 2: Decorative layer 2a: Surface 2b: Surface 2c: Portion 3: Base material 4: Ink flow prevention layer 10: Decorative panel 10´: Decorative panel 11: Main body part 11b: Lower surface 12: Side wall part 12b: Inner wall surface 31: Base part 32: Protrusion 120: Inkjet printer 130: Ink 200: Mold 201: First mold 202: Second mold 210: Gate 321: Upper surface 321a: Recess 322: Side surface

Claims

1. A surface material formed of a transparent resin material, having a plate-shaped main body portion, a side wall portion formed to incline in a flared manner from the periphery of the main body portion, and a recess formed by the main body portion and the side wall portion; A base material disposed on the recess side of the surface material, formed of the resin material of the surface material, and covering the end face of the side wall portion; A decorative layer disposed between the surface material and the base material and formed by discharging ink inside the recess; An ink flow prevention layer disposed between the base material and the decorative layer; The ink flow prevention layer is disposed at a position facing the outflow direction of the resin material at the gate where the resin material is injected during the molding of the base material; The ink flow prevention layer has a thickness of 10 μm or more; The thickness of the decorative layer is 10 μm or more; A resin laminate.

2. The ink flow prevention layer is colorless and transparent, the same color as the base material, or the same color as the portion of the decorative layer where the ink flow prevention layer is disposed; The resin laminate according to Claim 1.

3. The ink flow prevention layer is composed of ink or a thermoplastic resin; The resin laminate according to Claim 1 or 2.

4. The thickness of the surface material is 0.1 mm or more; The resin laminate according to any one of Claims 1 to 3.

5. The ink flow prevention layer has a plurality of layers with different diameters; The diameters of the plurality of layers become smaller as they are farther from the decorative layer; The resin laminate according to Claim 1.

6. Among the plurality of layers of the ink flow prevention layer, the layer at the position farthest from the decorative layer is disposed at a position facing the outflow direction of the resin material at the gate where the resin material is injected during the molding of the base material; The resin laminate according to Claim 5.

7. The ink is UV or EB curable ink; The surface material, the decorative layer, and the ink flow prevention layer are formed without stretching; The resin laminate according to any one of Claims 1 to 6.

8. A decorative layer forming step of discharging ink inside the recess of a surface material formed of a transparent resin material, having a plate-shaped main body portion, a side wall portion formed to incline in a flared manner from the periphery of the main body portion, and a recess formed by the main body portion and the side wall portion, to form a decorative layer; An ink flow prevention layer forming step of forming an ink flow prevention layer at a position facing in the outflow direction of the resin material at a gate for injecting a resin material when forming a base material on the side opposite to the surface material of the decorative layer; A base material forming step of injecting the resin material to form the base material, and comprising: The base material covers an end face of the side wall portion; The ink flow prevention layer has a thickness of 10 μm or more; The thickness of the decorative layer is 10 μm or more; A method for manufacturing a resin laminate.

9. The ink is a UV or EB curable ink; No stretching is performed on the surface material, the decorative layer, and the ink flow prevention layer; The method for manufacturing a resin laminate according to Claim 8.

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