Cosmetic sheet, cosmetic board, and method for manufacturing cosmetic sheet

Abstract

To provide a decorative sheet having higher designability.SOLUTION: A decorative sheet includes: a belt-like sheet base material; and a pattern layer 6 arranged on one surface side of the sheet base material and including a plurality of print patterns 8 aligned and repeatedly printed in a constant pitch p along a longer direction of the sheet base material, in which patterns continue across a boundary 9 of neighboring print patterns 8. Furthermore, the pattern layer 6 is a plate-less printed layer. The pitch p of the print patterns 8 is 2500 mm or more.SELECTED DRAWING: Figure 2

Description

Technical Field

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

Background Art

[0002] Conventionally, a decorative sheet having a base material and a pattern layer disposed on one surface side of the base material has been proposed (see, for example, Patent Document 1). As a method for forming the pattern layer, generally, a gravure printing method is used in which a cylinder plate is rotated and ink filled in the cells of the cylinder plate is transferred to repeatedly print a plurality of printed patterns at a constant pitch on one surface of the base material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when the gravure printing method is used, the pitch of the printed pattern is determined by the circumference of the cylinder plate used. Therefore, for example, when the decorative sheet is used for a large-area portion such as a wall or a floor, the same printed pattern may repeatedly appear many times, which may result in a monotonous design. The present invention has been made paying attention to the above problems, and an object thereof is to provide a decorative sheet, a decorative board, and a method for manufacturing a decorative sheet with higher design.

Means for Solving the Problems

[0005] In order to solve the above problems, a decorative sheet according to one aspect of the present invention includes: (a) a strip-shaped sheet base material; and (b) a pattern layer disposed on one surface side of the sheet base material, in which a plurality of printed patterns repeatedly printed at a constant pitch along the longitudinal direction of the sheet base material are arranged, and the patterns are continuous across the boundaries of adjacent printed patterns. The pattern layer is a plate-less printing layer, and the pitch of the printed patterns is 2500 mm or more. In addition, a decorative board according to one aspect of the present invention includes: (a) the above-described decorative sheet; and (b) a substrate provided on the surface of the decorative sheet on the side of the sheet base material.

[0006] In addition, a method for manufacturing a decorative sheet according to one aspect of the present invention is a method for manufacturing a decorative sheet in which (a) a plurality of printed patterns are repeatedly printed at a constant pitch along the longitudinal direction of a strip-shaped sheet base material on one surface side of the sheet base material to form a pattern layer, and (b) the repeated printing of the printed patterns is performed by a plate-less printing method such that the pitch becomes 2500 mm or more and the patterns are continuous across the boundaries of adjacent printed patterns.

Advantages of the Invention

[0007] According to one aspect of the present invention, it is possible to provide a decorative sheet, a decorative board, and a method for manufacturing a decorative sheet with higher design properties.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0009] Hereinafter, a decorative sheet, a decorative board, and a method for manufacturing a decorative sheet according to an embodiment of the present invention will be described with reference to the drawings. The present invention is not limited to the following embodiments, and it is possible to make modifications such as design changes based on the knowledge of those skilled in the art, and forms with such modifications are also included in the scope of the present invention. Also, each drawing is exaggerated appropriately for easy understanding.

[0010] (Configuration) As shown in FIG. 1, a decorative board 1 according to an embodiment of the present invention includes a decorative sheet 2 and a substrate 3 provided on the back surface 2b of the decorative sheet 2 (the surface on the sheet base material 5 side of the decorative sheet 2). An adhesive layer 4 is formed between the decorative sheet 2 and the substrate 3. The material of the adhesive layer 4 may be any adhesive as long as it can adhere the decorative sheet 2 and the substrate 3. For example, reactive adhesives, solution adhesives, and hot melt adhesives can be mentioned.

[0011] (Decorative Sheet) The decorative sheet 2 includes a sheet base material 5, a pattern layer 6 formed on the surface 5a side (one surface side of the sheet base material 5) of the sheet base material 5, and a transparent resin layer 7 formed on the surface 6a side of the pattern layer 6. In FIG. 1, a case where the pattern layer 6 is in contact with the surface 5a of the sheet base material 5 and the transparent resin layer 7 is in contact with the surface 6a of the pattern layer 6 is illustrated. Note that other layers may be provided between the sheet base material 5 and the pattern layer 6, between the pattern layer 6 and the transparent resin layer 7, and on the surface 6a side of the pattern layer 6.

[0012] (Sheet Base Material) As the sheet base material 5, a strip-shaped substrate can be adopted. For example, paper, film-like synthetic resin, film-like rubber, non-woven fabric, and metal foil can be mentioned. Examples of paper include thin paper, titanium paper, and resin-impregnated paper. Examples of synthetic resin include vinyl chloride, polyethylene, polypropylene, polybutylene, polystyrene, polycarbonate, polyester, polyamide, ethylene-vinyl acetate copolymer, polyvinyl alcohol, and acrylic. Examples of rubber include ethylene-propylene copolymer rubber, ethylene-propylene-diene copolymer rubber, styrene-butadiene copolymer rubber, styrene-isoprene-styrene block copolymer rubber, styrene-butadiene-styrene block copolymer rubber, and polyurethane. Examples of non-woven fabric include organic non-woven fabric and inorganic non-woven fabric. Examples of metal foil include aluminum foil, iron foil, gold foil, and silver foil. The thickness of the sheet base material 5 is preferably 20 μm to 250 μm from the viewpoints of workability and cost.

[0013] (Pattern layer) The pattern layer 6 is a printing layer for imparting design properties to the decorative board 1 or the decorative sheet 2. As shown in FIG. 2, a plurality of printed patterns 8 repeatedly printed at a constant pitch p in the longitudinal direction of the sheet base material 5 are arranged in the pattern layer 6. As the printed pattern 8, for example, a wood grain pattern, a stone grain pattern, a cloth grain pattern, an abstract pattern, a geometric pattern, characters, symbols, or a combination thereof can be adopted. FIG. 2 illustrates the case where a geometric pattern composed of a plurality of oval patterns is used. Also, the printed pattern 8 is set such that the pattern has continuity at the boundary 9 of the adjacent printed patterns 8. In FIG. 2, the oval pattern at the lower end of the printed pattern 8 (also denoted as "8a") located on the upper side in FIG. 2 and the oval pattern at the upper end of the printed pattern 8 (also denoted as "8b") located on the lower side in FIG. 2 are connected without interruption at the boundary 9 to form an oval pattern (pattern). Thereby, in the pattern layer 6, the pattern is continuous across the boundary 9 of the adjacent printed patterns 8. The pitch p of the printed pattern 8 is preferably 2500 mm or more. More preferably, it is 3000 mm or more, and even more preferably, it is 5000 mm or more. Thereby, for example, even when the decorative board 1 or the decorative sheet 2 is used for a large area portion such as a wall or a floor, it is possible to suppress the repeated appearance of the same printed pattern 8, suppress the monotony of the design property, and improve the design property.

[0014] Further, as a method for forming the pattern layer 6, for example, a plate - less printing method can be adopted. Examples of the plate - less printing method include an ink - jet method and an electrophotographic method. That is, the pattern layer 6 may be a plate - less printing layer (ink - jet printing layer) formed by the ink - jet method, or a plate - less printing layer (electrophotographic printing layer) formed by the electrophotographic method.

[0015] As shown in FIG. 3, in the ink - jet method, ink is ejected and printed while scanning the print head 10 in a direction orthogonal to the conveyance direction of the sheet base material 5. When the scanning is completed, after performing a one - step forward feed in the conveyance direction so that no gap is generated, printing is repeated while scanning again. In the repeated printing of the printed pattern 8 by the ink - jet method, the pitch p is 2500 mm or more, and the original image of the printed pattern 8 is processed so that the pattern is continuous across the boundary 9 between adjacent printed patterns 8. Based on the processed original image, the print head 10 is controlled. Thereby, by operating the print head 10, a pattern layer 6 is obtained by the ink - jet method (plate - less printing method) in which the pitch p is 2500 mm or more and the pattern is continuous across the boundary 9 between adjacent printed patterns 8. That is, in the present embodiment, it can also be said that the repeated printing of the printed pattern 8 is performed by the ink - jet method (plate - less printing method) such that the pitch p is 2500 mm or more and the pattern is continuous across the boundary 9 between adjacent printed patterns 8. The ink may be any ink as long as it is printable on the sheet base material 5. For example, ultraviolet - curable ink and aqueous ink can be mentioned. In particular, compared with aqueous ink, ultraviolet - curable ink does not require large - scale equipment such as a dryer, and can be cured by ultraviolet irradiation immediately after coating, so that simplification of the manufacturing process and shortening of the manufacturing time are possible.

[0016] (Transparent resin layer) The transparent resin layer 7 is a resin layer for protecting the pattern layer 6 and imparting good surface physical properties. As the material of the transparent resin layer 7, for example, a resin having at least such transparency as to be able to see through the pattern layer 6 can be adopted. For example, a vinyl chloride film or a polyolefin film can be adopted. Examples of the material (polyolefin-based resin) of the polyolefin film include a polypropylene-based resin and a polyethylene-based resin. Most suitable for general use is a polypropylene-based resin, that is, a homopolymer or copolymer having propylene as a main component.

[0017] (Substrate) As the substrate 3, a plate-shaped member can be adopted. For example, a wooden substrate, a fibrous substrate, an inorganic substrate, a metal substrate, a synthetic resin substrate, or a combination thereof (composite, laminate) can be mentioned. Examples of the wooden substrate include a wood veneer, plywood, laminated wood, particle board, medium density fiberboard, and hard fiberboard. Examples of the fibrous substrate include paperboard, woven fabric, non-woven fabric, resin-impregnated paper, and resin-impregnated cloth. Examples of the inorganic substrate include a gypsum board, a slate board, a calcium silicate board, a slag gypsum board, a wood wool cement board, a slag cement board, a lightweight foam concrete board, and a glass fiber reinforced concrete board. Examples of the metal substrate include a steel plate, a brass plate, an aluminum plate, a duralumin plate, and a stainless steel plate. Examples of the synthetic resin substrate include an acrylic resin plate, a styrene resin plate, an ABS resin plate, a polycarbonate resin plate, a nylon resin plate, a polystyrene resin plate, a polypropylene resin plate, a polyester resin plate, and a glass fiber reinforced plastic plate.

[0018] Here, for example, in the conventional decorative sheet 2 in which the pattern layer 6 is formed by the gravure printing method as shown in FIG. 4, the pitch p of the printed pattern 8 is determined by the circumference of the cylinder plate 11 used. Therefore, for example, when the decorative sheet 2 is used for a large area such as a wall or a floor, the same printed pattern 8 may appear repeatedly, and the design may become monotonous. Also, for example, if a cylinder plate 11 with a large circumference is used to print a printed pattern 8 with a long pitch p, inconveniences may occur in various parts such as production efficiency and cylinder management. Most of the cylinder plates 11 have a pitch p of the printed pattern 8 of 1250 mm.

[0019] On the other hand, in the decorative sheet 2 and the decorative board 1 according to the present embodiment, since the pattern layer 6 is a plate-less printing layer, that is, a printing layer formed by the plate-less printing method, the cylinder plate 11 is not required, and a printed pattern 8 (long repeat pattern) with a long pitch p can be formed. Therefore, the printed pattern 8 can be 2500 mm or more. For example, when the decorative sheet 2 is used for a large area such as a wall or a floor, the number of times the same printed pattern 8 appears repeatedly can be reduced, and the design can be improved. Thereby, the decorative sheet 2 and the decorative board 1 with higher design can be provided. Also, for example, a long pattern or a large single picture combining a plurality of patterns that could not be reproduced in the conventional decorative sheet 2 in which the pattern layer 6 is formed by the gravure printing method can be constructed.

Example

[0020] Hereinafter, examples and comparative examples of the decorative sheet 2 according to the embodiment of the present invention will be described. Note that the present invention is not limited to the following examples. (Example 1) First, as the sheet base material 5, a PVC film (Vinylban by Bandoh Chemical Co., Ltd.) was prepared. Subsequently, on one surface (surface 5a) of the sheet base material 5, the printed pattern 8 was repeatedly printed by an inkjet method to form the pattern layer 6. The pitch p of the printed pattern 8 was set to 2500 mm. Also, in the repeated printing of the printed pattern 8, the original image used for controlling the print head 10 was processed so that the pattern was continuous across the boundaries of the adjacent printed patterns 8 (hereinafter also referred to as "top-bottom processing"). As the ink, UV ink (by Mimaki Engineering Co., Ltd.) was used. Subsequently, a transparent vinyl film was thermocompression-bonded to the surface 6a of the pattern layer 6 to form the transparent resin layer 7. By such a procedure, a vinyl floor sheet (decorative sheet 2) was produced. (Example 2) In Example 2, the pitch p of the printed pattern 8 was set to 3000 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0021] (Comparative Example 1) In Comparative Example 1, the pitch p of the printed pattern 8 was set to 1250 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1. (Comparative Example 2) In Comparative Example 2, the pitch p of the printed pattern 8 was set to 625 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0022] (Comparative Example 3) In Comparative Example 3, the top-bottom processing of the printed pattern 8 was omitted. That is, in the repeated printing of the printed pattern 8, the original image used for controlling the print head 10 was not processed. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1. (Comparative Example 4) In Comparative Example 4, the top-bottom processing of the printed pattern 8 was omitted. Also, the pitch p of the printed pattern 8 was set to 3000 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0023] (Comparative Example 5) In Comparative Example 5, the top-bottom processing of the printed pattern 8 was omitted. Also, the pitch p of the printed pattern 8 was set to 1250 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1. (Comparative Example 6) In Comparative Example 6, the top-bottom processing of the printed pattern 8 was omitted. Also, the pitch p of the printed pattern 8 was set to 625 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0024] (Comparative Example 7) In Comparative Example 7, the repeated printing of the printed pattern 8 was performed by the gravure printing method, and otherwise, under the same conditions as in Example 1, an attempt was made to produce the decorative sheet 2. However, most of the metal rolls (cylinders) for manufacturing the cylinder plate 11 had a circumference of 1250 mm, and it was not easy to obtain a cylinder with a circumference of 2500 mm, so the decorative sheet 2 of Comparative Example 7 could not be produced.

[0025] (Comparative Example 8) In Comparative Example 8, the repeated printing of the printed pattern 8 was performed by the gravure printing method. Also, the pitch p of the printed pattern 8 was set to 1250 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1. (Comparative Example 9) In Comparative Example 9, the repeated printing of the printed pattern 8 was performed by the gravure printing method. Also, the pitch p of the printed pattern 8 was set to 625 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0026] (Comparative Example 10) In Comparative Example 10, the repeated printing of the printed pattern 8 was performed by the gravure printing method, the top-bottom processing of the printed pattern 8 was omitted, and otherwise, under the same conditions as in Example 1, an attempt was made to produce the decorative sheet 2. However, it was not easy to obtain a cylinder (metal roll for manufacturing the cylinder plate 11) with a circumference of 2500 mm, so the decorative sheet 2 of Comparative Example 11 could not be produced.

[0027] (Comparative Example 11) In Comparative Example 11, the repeated printing of the printed pattern 8 was performed by the gravure printing method. Also, the top-bottom processing of the printed pattern 8 was omitted. Further, the pitch p of the printed pattern 8 was set to 1250 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1. (Comparative Example 12) In Comparative Example 12, the repeated printing of the printed pattern 8 was performed by the gravure printing method. Also, the top-bottom processing of the printed pattern 8 was omitted. Further, the pitch p of the printed pattern 8 was set to 625 mm. Otherwise, the decorative sheet 2 was produced under the same conditions as in Example 1.

[0028] (Evaluation of designability) Performance evaluation of the designability was conducted on the decorative sheets 2 of Example 1, Example 2, and Comparative Examples 1 to 12. In the evaluation of designability, when the designability was "excellent", it was marked as "◎", when it was "good", it was marked as "○", when it was "fair", it was marked as "△", and when it was "poor", it was marked as "×". (Evaluation results) The evaluation results of the designability are shown in Table 1.

Table 1

[0029] As shown in Table 1, in the decorative sheets 2 of Examples 1 and 2, since the pitch p (2500 mm, 3000 mm) of the printed pattern 8 is large, the repetition frequency of the same pattern is low, and the evaluation result of the designability is excellent "◎". Also, for the decorative sheets 2 of Comparative Examples 1 and 8, since the pitch p (1250 mm) is smaller than that of the decorative sheets 2 of Examples 1 and 2, the repetition frequency of the same pattern is higher than that of the decorative sheets 2 of Examples 1 and 2. Also, since the pitch p is the same as the pitch currently widely used, the evaluation result of the designability is good "○" (sufficiently practical but inferior to excellent "○"). Further, in the decorative sheets 2 of Comparative Examples 2 and 9, since the pitch p (625 mm) of the printed pattern 8 is smaller than 1250 mm, the repetition frequency of the same pattern is high, and the evaluation result of the designability is fair "△". Also, in the decorative sheets 2 of Comparative Examples 3 to 6, 11, and 12, since the top-bottom processing of the printed pattern 8 is not performed, the pattern is interrupted at the boundary 9 of the adjacent printed patterns 8, and the designability is unacceptable "×". Note that in Comparative Examples 7 and 10, a cylinder with a circumference of 2500 mm (a metal roll for manufacturing the cylinder plate 11) could not be obtained, resulting in non-evaluable "-". Therefore, it was confirmed that the decorative sheets 2 of Examples 1 and 2 are superior in designability compared to the decorative sheets 2 of Comparative Examples 1 to 12.

Explanation of Signs

[0030] 1‥·Decorative board, 2‥·Decorative sheet, 3‥·Substrate, 4‥·Adhesive layer, 5‥·Sheet base material, 6‥·Pattern layer, 7‥·Transparent resin layer, 8‥·Printed pattern, 9‥·Boundary, 10‥·Printing head, 11‥·Cylinder plate

Claims

1. A strip-shaped sheet substrate, which is provided on one surface side of the sheet substrate, and a plurality of printed patterns repeatedly printed at a constant pitch along the longitudinal direction of the sheet substrate are arranged side by side, and a pattern layer in which the patterns are continuous across the boundaries of the adjacent printed patterns, wherein the pattern layer is a plate-less printing layer, and the pitch of the printed patterns is 2500 mm or more, the thickness of the sheet substrate is 20 μm to 250 μm, and all of the plurality of printed patterns are the same printed pattern A decorative sheet.

2. The plate-less printing layer is an inkjet printing layer The decorative sheet according to Claim 1.

3. The decorative sheet according to Claim 1 or 2, and a substrate provided on the surface on the sheet substrate side of the decorative sheet, A decorative board comprising the same.

4. A method for manufacturing a decorative sheet, in which a plurality of printed patterns are repeatedly printed at a constant pitch along the longitudinal direction of a strip-shaped sheet substrate on one surface side of the sheet substrate to form a pattern layer, wherein the repeated printing of the printed patterns is performed by a plate-less printing method such that the pitch becomes 2500 mm or more and the patterns are continuous across the boundaries of the adjacent printed patterns, the thickness of the sheet substrate is 20 μm to 250 μm, and all of the plurality of printed patterns are the same printed pattern A method for manufacturing a decorative sheet.

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