Decorative sheet, manufacturing method thereof, and decorated molded body using the same

Abstract

To provide a decorative sheet and its manufacturing method capable of applying decoration with a beautiful and impressive concavoconvex pattern, as well as a decorative molding using the decorative sheet.SOLUTION: A decorative sheet 20 comprising: a top sheet portion 30; a colored pattern layer 31 provided on a back side of the top sheet portion 30 and visible from the top side of the top sheet portion 30; a metal thin film layer 32 provided on the back side of the colored pattern layer 31; and a back sheet portion 33 provided on the back side of the metal thin film layer 32, wherein a surface of the top sheet portion 30 is partially recessed to provide a concavoconvex pattern, and at least a part of a contour of the pattern in the concavoconvex pattern is arranged overlapping with at least a part of contour section of the pattern in the colored pattern layer 31.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a decorative sheet capable of providing beautiful and impressive decoration to various molded articles, a method for producing the same, and a decorated molded article using the decorative sheet. [Background technology]

[0002] Resin molded products used in cosmetic compact containers, lipstick containers, etc., are required to not only be functional, but also to have a good appearance and a design that reflects the product image. For this reason, it is important to give the container surface a unique colored pattern or a detailed textured pattern to enhance the eye-catching effect and differentiate it from other companies' products.

[0003] An example of such a decorated molded body is one in which, as shown in Figure 9, a release agent 2 is printed in a specific printing pattern on a substrate 1, and a resin ink 3 is printed thickly on the areas where the release agent 2 is not printed, thereby making the outline of the thickly printed area clearer and enhancing its lens effect (see Patent Document 1 described below).

[0004] As shown in FIG. 10(a), a lid 4 for a compact-type cosmetic container has a lid plate 8 that is fitted with a lid frame 6 provided with a hinge portion 6a for connecting to the container body, and is decorated with a complex embossed pattern (see Patent Document 2, described below). The embossed pattern on the lid plate 8 is created by forming an opaque colored layer 8b on the back surface of a transparent base layer 8a, irradiating the colored layer 8b with a laser to form a concave watermark P, and then forming a thickened portion 9 on the front surface in a position overlapping the watermark P, as shown in FIG. 10(b), a vertical cross-sectional view of the lid 4. A metallic gloss sheet 7 is sandwiched between the lid plate 8 and the lid frame 6, making the embossed pattern visible from the front surface appear more three-dimensional. Note that reference numeral 6b denotes a mirror attached to the underside of the lid frame 6.

[0005] However, these decorated molded bodies have thick portions (reference numeral 3 in Figure 9, reference numeral 9 in Figure 10) protruding from the surface side of the molded body, so if they are repeatedly handled by hand or carried in a bag with other containers, the thick portions may fall off or become damaged, making it difficult to maintain a beautiful appearance for a long period of time.

[0006] Furthermore, when forming a concave pattern (concave-convex pattern) by laser irradiation or the like, as in the case of the decorated molded body shown in Figures 10(a) and (b) above, the resin plate on which the decoration is applied needs to be somewhat thick due to issues with the strength of the processed surface on which the concave-convex pattern is formed.However, given the ``movement toward eliminating plastics,'' which has been a particularly important issue in recent years, there is a demand for thinner resins while still providing more impressive decorations.

[0007] Therefore, in order to respond to the "movement toward a plastic-free society," from the viewpoint of making the thickness of molded bodies thinner while providing impressive decoration, the use of decorative sheets such as those shown in Patent Document 3 below for decorating molded bodies is being considered. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-221030 [Patent Document 2] Japanese Patent Application Laid-Open No. 2002-177045 [Patent Document 3] Patent No. 6409153 Summary of the Invention [Problem to be solved by the invention]

[0009] The decorative sheet described in Patent Document 3, for example, as shown in Figure 11, has a colored layer 11 and a thickly protruding portion 12 provided on the underside of a transparent surface layer 10, and the protruding surface of the thickly protruding portion 12 is covered with a thin metal layer 13, so that the uneven texture of the thickly protruding portion 12 and the glossiness of the thin metal layer 13 can be seen through the colored layer 11 from the front. Reference numeral 14 denotes a white pressing layer for improving appearance, and below this, via an adjustment layer 15, an adhesive layer 16 and a release sheet 17 are provided for attaching the decorative sheet to the object to be decorated.

[0010] The decorative sheet described above has a three-dimensional appearance due to the combination of the colored layer 11, the thickened portion 12, and the metal thin film layer 13 on the inside of the sheet, but since the surface of the sheet itself is flat, there is a problem in that the three-dimensional impression is inevitably weaker than that of a decorated molded body in which a textured pattern is directly applied to the surface.

[0011] Therefore, in order to create unevenness in the decorative sheet, for example, when resin molding the object to be decorated, we considered placing the decorative sheet in a mold with an uneven surface and performing insert molding using a pin gate, but we found that the heat generated during molding would cause the metal thin film layer in the decorative sheet to flow, damaging the three-dimensional effect.We also considered applying welder processing from the front side of the decorative sheet to create unevenness, but we found that it is difficult to create an uneven shape because the resin sheets used for decorative sheets are generally hard sheets with excellent printability.

[0012] The present invention has been made in consideration of the above circumstances, and its object is to provide a decorative sheet with concave and convex shapes that is beautiful and impressive for various molded bodies, a method for manufacturing the same, and a decorated molded body using the decorative sheet. [Means for solving the problem]

[0013] In order to achieve the above object, the present invention provides the following [1] to

[15] . [1] A decorative sheet comprising a translucent surface sheet portion, a colored pattern layer provided on the back side of the surface sheet portion, visible from the front side of the surface sheet portion, and itself translucent, a metal thin film layer provided on the back side of the colored pattern layer, and having a metallic luster visible from the front side of the surface sheet portion, and a back sheet portion provided on the back side of the metal thin film layer, wherein the surface of the surface sheet portion is partially recessed to give it an uneven pattern, and at least a portion of the outline of the uneven pattern is arranged to overlap at least a portion of the outline of the pattern in the colored pattern layer. [2] The decorative sheet according to [1] above, wherein the surface side of the surface sheet portion is made of a soft sheet, and the back side of the surface sheet portion is made of a hard sheet. [3] The decorative sheet according to [2] above, wherein the thickness of the flexible sheet is 100 to 500 μm, and the thickness of the rigid sheet is 5 to 30 μm. [4] The decorative sheet according to any one of [1] to [3] above, wherein the colored pattern layer has a thick portion made of thick ink and having a thickness of 30 to 150 μm in a part thereof. [5] The decorative sheet according to any one of the above [1] to [4], wherein a white pressing layer is formed between the metal thin film layer and the back sheet portion. [6] The decorative sheet according to any one of [1] to [5] above, wherein the back sheet portion is composed of a soft sheet having a thickness of 100 to 500 μm. [7] The decorative sheet according to any one of [1] to [6] above, wherein the partially recessed portion on the surface of the top sheet portion is recessed in the thickness direction of the entire decorative sheet and protrudes downward from the back surface of the back sheet portion, thereby imparting a textured pattern to the back surface of the back sheet portion as well. [8] A method for manufacturing a decorative sheet, comprising the steps of: preparing a surface sheet portion that is translucent and has the ability to follow textured processing and is suitable for printing on its back side; printing a colored pattern on the back side of the surface sheet portion using a translucent ink to form a colored pattern layer that is visible from the front side of the surface sheet portion; forming a metal thin film layer that has a metallic luster that is visible from the front side of the surface sheet portion on the side of the colored pattern layer opposite to the side that contacts the surface sheet portion; providing a back sheet portion that has the ability to follow textured processing on the side of the metal thin film layer opposite to the side that contacts the colored pattern layer, thereby obtaining a multilayer body having a surface sheet portion, a colored pattern layer, a metal thin film layer, and a back sheet portion; and applying high-frequency welding to the multilayer body to partially recess the surface of the surface sheet portion to impart a textured pattern, wherein at least a portion of the outline of the textured pattern overlaps at least a portion of the outline of the pattern in the colored pattern layer. [9] A method for manufacturing a decorative sheet according to [8] above, wherein in the step of preparing the surface sheet portion, a soft sheet and a hard sheet are laminated via an adhesive layer to obtain a surface sheet portion having a surface side made of the soft sheet and a back side made of the hard sheet.

[10] The method for producing a decorative sheet according to [9] above, wherein the soft sheet has a thickness of 100 to 500 μm, and the hard sheet has a thickness of 5 to 30 μm.

[11] A method for producing a decorative sheet according to any one of [8] to

[10] above, wherein the step of forming the colored pattern layer combines a step of printing a colored pattern by offset printing with a step of forming a thick portion having a thickness of 30 to 150 μm by screen printing using thick ink to obtain a colored pattern layer.

[12] A method for producing a decorative sheet according to any one of [8] to

[11] above, wherein after the step of forming the metal thin film layer and before the step of obtaining the multilayer body, a step of forming a white pressing layer using white ink on the surface of the metal thin film layer opposite to the surface that comes into contact with the colored pattern layer is provided, and in the step of obtaining the multilayer body, the back sheet portion is provided on the surface of the white pressing layer opposite to the surface that comes into contact with the metal thin film layer.

[13] A method for producing a decorative sheet according to any one of [8] to

[12] above, wherein in the step of obtaining the multilayer body, a soft sheet having a thickness of 100 to 500 μm is used as the back sheet portion, and the soft sheet is laminated on the metal thin film layer or the white pressing layer via a hot melt adhesive sheet, and then the multilayer body is subjected to high-frequency welder processing, thereby imparting a textured pattern to the surface of the top sheet portion and integrating the back sheet portion with the metal thin film layer or the white pressing layer.

[14] A method for manufacturing a decorative sheet according to any one of [8] to

[13] above, wherein in the step of applying high-frequency welding to the multilayer body to impart a textured pattern, the surface of the top sheet portion is partially recessed and simultaneously the entire multilayer body is recessed in the thickness direction, causing the back surface of the back sheet portion to partially protrude downward, thereby imparting a textured pattern to the back surface of the back sheet portion as well.

[15] A decorated molded article having a decorative portion provided on at least a portion of its surface, the decorative portion being formed from the decorative sheet according to any one of [1] to [7] above. [Effects of the Invention]

[0014] That is, the decorative sheet of the present invention is a sheet in which a colored pattern layer for giving a beautiful impression and a metal thin film layer provided on the back side thereof are sandwiched between a front sheet portion and a back sheet portion, and the entire multilayer body is subjected to processing such as welding to impart a textured pattern to the surface. In particular, since the outline of the textured pattern and the outline of the pattern in the colored pattern are arranged to at least partially overlap, the textured pattern imparted to the sheet surface works in combination with the colored pattern inside the sheet to form a three-dimensional decoration with clearly defined pattern outlines, which has a high eye-catching effect.

[0015] By simply applying this decorative sheet to the desired surface of the molded body to be decorated, a textured pattern can be easily imparted directly to the surface of the molded body, resulting in a clear and beautiful textured pattern that looks as if the molded body itself had been textured. Furthermore, since this textured shape is created by partially recessing the surface of the decorative sheet and not by engraving the surface of the molded body using laser processing or the like, the uneven portions of the texture will not crack or chip. Furthermore, since the colored pattern layer and metal thin film layer that make up the colored pattern are located inside the decorative sheet, they will not deteriorate or be damaged. Therefore, the beautiful appearance of the decorative part can be maintained in good condition for a long period of time.

[0016] Furthermore, by decorating using the above-mentioned decorative sheet, there is no need to increase the thickness of the resin part that will become the processed surface, as is the case when applying textured processing to a molded body, which has the advantage of being able to reduce the amount of resin used for the entire decorated molded body.

[0017] According to the method for producing a decorative sheet of the present invention, the decorative sheet can be easily obtained by utilizing high-frequency welding.

[0018] Furthermore, as already mentioned, with the decorative molded body of the present invention using the decorative sheet, there is no need to directly texture the surface of the molded body, and an excellent decorative effect can be obtained simply by attaching this decorative sheet. Furthermore, since the thickness of the resin in the decorative part of the molded body can be reduced and the amount of resin can be significantly reduced, it is possible to provide an environmentally friendly resin product that aims to "eliminate plastic."

[0019] In the present invention, the term "translucent" does not necessarily mean completely colorless and transparent, but also includes transparency that allows the opposite side to be seen through. [Brief explanation of the drawings]

[0020] [Figure 1]1 is a perspective view showing a compact container using a decorative sheet according to one embodiment of the present invention. [Figure 2] FIG. 2 is an exploded perspective view of the lid of the compact case. [Figure 3] FIG. 2 is an explanatory diagram of the decorative sheet. [Figure 4] FIG. 2 is a schematic cross-sectional view of the decorative sheet. [Figure 5] 3 is an explanatory diagram of a design of a colored pattern used to form a colored pattern layer in the method for producing the decorative sheet. FIG. [Figure 6] 3 is an explanatory diagram of a design of a thick portion used to form a colored pattern layer in the manufacturing method of the decorative sheet. FIG. [Figure 7] FIG. 2 is an explanatory diagram of a mold design used in high-frequency welder processing in the manufacturing method of the decorative sheet. [Figure 8] FIG. 10 is a schematic vertical cross-sectional view of a decorative sheet according to another embodiment of the present invention. [Figure 9] FIG. 10 is an explanatory diagram showing an example of a conventional decorative molded body. [Figure 10] 1A and 1B are explanatory views showing another example of a conventional decorative molded body, in which (a) is an exploded perspective view of a lid body using the decorative molded body, and (b) is a longitudinal sectional view thereof. [Figure 11] 1 is a schematic longitudinal cross-sectional view showing an example of a conventional decorative sheet. DETAILED DESCRIPTION OF THE INVENTION

[0021] Next, an embodiment of the present invention will be described in detail with reference to the drawings, but the present invention is not limited to the following embodiment.

[0022] Fig. 1 is a perspective view of a compact container in which the surface of a lid 21 is decorated using a decorative sheet 20 according to one embodiment of the present invention, and Fig. 2 is an exploded perspective view of the lid 21. This compact container is comprised of a main body 22 that stores and holds cosmetics such as eyeshadow, and a lid 21 that is rotatably connected to the main body 22 via a hinge 23 (see Fig. 2), and its basic configuration as a compact container is the same as that of a typical compact container. A mirror 24 is attached to the inside surface of the lid 21.

[0023] 2, the lid body 21 is composed of a lid frame body 21a having a hinge portion 23 protruding from the rear end portion thereof, and a decorative sheet 20 for decorating the surface thereof. More specifically, a recess 25 is formed on the upper surface of the lid frame body 21a in consideration of the thickness of the decorative sheet 20, and the decorative sheet 20 is bonded and integrated into this recess 25 via an adhesive layer 26 (see FIG. 3).

[0024] On the surface of the decorative sheet 20, there is visible a pattern A made up of wide lines with a metallic luster, a shading pattern B below it that has a gradation from dark red to light orange (formed on the entire sheet surface except for the line pattern A), and a fine bubble-like embossed pattern C that can be seen through the shading pattern B (formed on the entire sheet surface except for the line pattern A and superimposed on the shading pattern B).

[0025] 3, the line pattern A is recessed in a concave shape, and this recess recesses the entire decorative sheet 20 in the thickness direction and protrudes downward from the back surface of the sheet, so that the decorative sheet 20 has an uneven shape as a whole. Note that the adhesive layer 26 is usually covered with a release sheet before the decorative sheet 20 is attached to the lid frame 21a, and when the decorative sheet 20 is attached to the lid frame 21a, the release sheet is peeled off to expose the adhesive layer 26 and attach it to the lid frame 21a. The structure of the decorative sheet 20 will be described in detail below.

[0026] <Configuration of the decorative sheet 20> As shown in Figure 4, which is a schematic cross-sectional view of the decorative sheet 20, the decorative sheet 20 comprises a translucent surface sheet portion 30, a colored pattern layer 31 provided on the back side (the lower side in the figure, the same applies below) of the surface sheet portion 30, a metal thin film layer 32 provided on the back side of the surface sheet portion 30, and a back sheet portion 33 provided on the back side of the surface sheet portion 30.

[0027] The surface sheet portion 30 comprises two layers: a first surface layer 34 made of colorless, transparent, and relatively soft polypropylene (PP); and a second surface layer 35 provided on the back side of the first surface layer 34 and made of colorless, transparent, and relatively hard polyethylene terephthalate (PET), with an adhesive layer (not shown) provided between the two layers.

[0028] The first surface layer 34 is provided with the intention of creating a textured pattern by denting the surface of this layer. It is not limited to the PP mentioned above, and any material may be used as long as it is translucent and flexible enough to conform to the textured surface when the textured surface is formed. Other than PP, other examples include polyvinyl chloride, soft polyethylene, and polyurethane. The thickness of the first surface layer 34 depends on the depth of the textured surface desired and the overall thickness of the decorative sheet 20, but is typically 50 to 1000 μm, preferably 100 to 500 μm (300 μm in the above embodiment).

[0029] Furthermore, since the PP used for the first surface layer 34 has poor printability, the second surface layer 35 is provided in consideration of the formation of the colored pattern layer 31 on its back side. The second surface layer 35 is not limited to PET, but may be made of any material that is translucent and printable. Examples include polycarbonate and polyurethane. To ensure printability, it is generally desirable for the printed surface to be non-deformable or non-moving, so the second surface layer 35 must be relatively hard, as described above. The thickness of the second surface layer 35 is preferably very thin so that it can deform in accordance with the irregularities imparted to the first surface layer 34. It is typically 1 to 100 μm, with 5 to 30 μm being preferred (12 μm in the above embodiment). If the thickness of the first surface layer 34 is T1 and the thickness of the second surface layer 35 is T2, the ratio T2:T1 is typically 1:10 to 1:100, with 1:20 to 1:30 being preferred.

[0030] However, if the first surface layer 34 is formed from a material that is suitable for printing, or if printability is imparted by applying a coating agent that improves printability to the back surface of the first surface layer 34, there is no need to provide the second surface layer 35.

[0031] The colored pattern layer 31 is composed of two layers: a first pattern layer 36 in which the shading pattern B (see Figure 2 for the pattern, the same applies below) is formed using translucent ink, and a second pattern layer 37 on the back side of the first pattern layer 36 in which the line pattern A and the grain pattern C are formed using a thickly applied portion also made using translucent thick ink.

[0032] The first pattern layer 36 is formed by forming the shading pattern B on the back surface of the second surface layer 35 by offset printing. The pattern is not limited to such a shading pattern, and examples include color patterns of various shades, patterns in which single colors are arranged in a predetermined arrangement, letters, figures, etc. The thickness of the first pattern layer 36 is not particularly limited, but is preferably not too thick in order to highlight the pattern formed by the thickened portions of the second pattern layer 37, and is, for example, 1 to 50 μm, and preferably 3 to 20 μm.

[0033] The second pattern layer 37 is formed by screen printing the line pattern A and the grain pattern C, which are made up of thickly protruding portions, on the back surface of the first pattern layer 36. The pattern is not limited to this and is set taking into consideration the overlap with the pattern made by the first pattern layer 36. The second pattern layer 37 is made up of thickly protruding portions, which give the pattern a unique shadow and emphasize a three-dimensional effect. Therefore, the thickness of the second pattern layer 37 is usually 10 to 300 μm, preferably 30 to 150 μm. However, depending on the pattern design, the second pattern layer 37 may not necessarily be provided.

[0034] The metal thin film layer 32 is formed only in the areas that overlap the thickened portions of the second pattern layer 37, and the metallic luster of the metal thin film layer 32 is visible from the front side of the decorative sheet 20, overlapping the line pattern A and the grain pattern C. The metal thin film layer 32 is formed by transferring a metal foil, and its thickness is usually 1 to 50 μm, preferably 3 to 20 μm.

[0035] A white pressing layer 38 is formed on the back surface of the metal thin film layer 32 and on the back surface of the first pattern layer 36 in the area where the metal thin film layer 32 is not formed, i.e., on the entire back surface. This white pressing layer 38 is provided to prevent the overlapping color patterns from being obscured by the colors and uneven shading of the underlying layers when viewed through the colored pattern layer 31 and metal thin film layer 32 formed on the back surface from being affected by the color and uneven shading of the underlying layers.

[0036] The back sheet portion 33 is made of a layer of relatively soft polyurethane, and is attached to the back side of the pressing layer 38 via an adhesive layer 39 (thickness: 100 μm) made of a hot melt adhesive. The back sheet portion 33 is provided to absorb the pressure applied during processing to form clear depressions on the front side of the decorative sheet 20, when processing is performed to make the portions where the line pattern A appears concave.

[0037] For the above reasons, the back sheet portion 33 is preferably relatively soft, and in addition to the polyurethane, polyvinyl chloride, soft polyethylene, etc. The thickness thereof is usually 50 to 2000 μm, and preferably 100 to 500 μm (200 μm in the above embodiment).

[0038] As described above, the decorative sheet 20 having the above structure has a concave portion on the front surface where the line pattern A appears, giving it an uneven shape as shown in FIG.

[0039] In this way, the decorative sheet 20 has a configuration in which a complex and beautiful color pattern (line pattern A + shading pattern B + grain pattern C) is sandwiched between a translucent surface sheet portion 30 and a back sheet portion 33, and is given a concave and concave pattern from the surface side of the surface sheet portion 30, by combining a colored pattern layer 31 consisting of a first pattern layer 36 and a second pattern layer 37 made of a thick portion, and a metal thin film layer 32 provided on the back side thereof.

[0040] In particular, because the outline of the uneven pattern overlaps with the outline of the line pattern A in the pattern consisting of the raised portions formed by the second pattern layer 37, the plump outline of the line pattern A visible through the surface of the decorative sheet 20 is emphasized as a step in the uneven pattern on the sheet surface, and although it is actually recessed, combined with the shadow of the step, it appears as if it is plump and raised from the surface. Furthermore, the overlapping pattern of the shading pattern B and the grain pattern C, which appears to be separated by the line pattern A, also has a unique shadow when viewed through the sheet surface due to the fine grain of the grain pattern C and the metallic luster of the metal thin film layer 32, and is visually recognized as a deep and beautiful color pattern, resulting in a highly eye-catching effect.

[0041] The uneven shape imparted to this decorative sheet 20 is formed by partially recessing the sheet surface, and is not carved into the surface of the molded body by laser processing or the like, so the uneven portions will not crack or chip. Furthermore, the colored pattern layer 31 and the metal thin film layer 32 that form the color pattern are also located inside the decorative sheet 20, so they will not deteriorate or be damaged. Therefore, the beautiful appearance of the decorative part can be maintained in good condition for a long period of time.

[0042] 1, in which the lid 21 is decorated using the decorative sheet 20, has a unique and beautiful decorative part that combines a complex color pattern with a three-dimensional effect as if the lid 21 itself were given a textured pattern, and is therefore highly eye-catching to customers. When actually used, as described above, the appearance of the beautiful decorative part is well maintained for a long period of time, demonstrating the high quality of the container.

[0043] Furthermore, as already mentioned, in the above compact container, the decorative portion of the lid body 21 is made up of the decorative sheet 20, and the thickness of the resin in the decorative portion of the lid body 21 can be reduced, so the amount of resin used in the entire lid body 21 can be significantly reduced. This makes it an environmentally friendly product that aims to eliminate plastic. Furthermore, since the lid body 21 can be designed to be thinner than one that is directly textured, it has the advantage of making the entire container lighter and more compact. Next, a method for producing the decorative sheet 20 will be described.

[0044] <Manufacturing method for decorative sheet 20> The decorative sheet 20 shown in FIG. 4 can be obtained, for example, as follows. First, a PP sheet that will become the first surface layer 34 of the surface sheet portion 30 (see Figure 4) and a PET sheet that will become the second surface layer 35 are cut to predetermined dimensions (dimensions that assume a sheet in which multiple decorative sheets 20 are arranged vertically and horizontally), and then laminated together sheet by sheet using an adhesive to obtain the surface sheet portion 30.

[0045] Next, the back side of the surface sheet portion 30, i.e., the second surface layer 35 side, is turned upward, and this surface is offset printed using translucent colored ink to form the first pattern layer 36. The design of this pattern is as shown in Figure 5, and is a shaded pattern B with a gradation from dark red to pale orange.

[0046] Next, a translucent thick ink (a colorless, transparent resin ink in this example) is screen printed on the first pattern layer 36 (upside down in FIG. 4) to form a second pattern layer 37. The design of this pattern is as shown in FIG. 6, and consists of a line pattern A and a grain pattern C.

[0047] Then, on top of the colored pattern layer 31 consisting of the first pattern layer 36 and the second pattern layer 37 (upside down in FIG. 4), the raised surfaces of the thick portions constituting the second pattern layer 37 are covered with a metal foil transfer layer to form a metal thin film layer 32. The formation area of ​​this metal thin film layer 32 overlaps with the thick portions of the second pattern layer 37, so it forms a pattern that matches the line pattern A and the grain pattern C, just like the design shown in FIG.

[0048] Next, a white pressing layer 38 is formed by silk printing using white ink on the surface on which the metal thin film layer 32 has been formed (where the first pattern layer 36 is exposed in places).

[0049] Then, a hot melt adhesive sheet that will become the adhesive layer 39 is placed on top of the polyurethane sheet that will become the back sheet portion 33, and an intermediate formed from the surface sheet portion 30 to the white pressing layer 38 is placed on top of that with the white pressing layer 38 facing downward, i.e., so that the underside of the white pressing layer 38 overlaps the hot melt adhesive sheet, and the resultant is put through a high-frequency welder processing machine to give a concave and convex pattern that is recessed from the surface of the surface sheet portion 30.

[0050] The processing conditions for the high-frequency welder are as follows, for example: [Processing conditions] Machine: Hydraulic 10 ton press / Oscillation power 7kw / Slide table type Mold: 1 block with 3 molds (area = 145mm x 98mm) made of copper Mold temperature setting: Room temperature (23°C) Pressure: approx. 2 ton / cm Oscillation output: 550mA Welding time: 5 seconds Cooling period: 3 seconds

[0051] The design of the embossed pattern (welder processing mold design) imparted by the high-frequency welding process overlaps with the line pattern A, as shown in Figure 7, and both longitudinally extending edges of each line of the line pattern A are pressed in deeper than the inner portions, making each band-like line appear more clearly. Similarly, the peripheral edge W of the entire sheet is also set to have a recess of the same depth as the line pattern A. The recesses in the peripheral edge W compress the entire sheet in the thickness direction to form a single unit, preventing peeling from the edges.

[0052] In this way, a large sheet is obtained in which a plurality of decorative sheets 20 with a concave-convex pattern are arranged in succession. Then, by cutting out decorative sheets 20 of a predetermined size from this large sheet, the decorative sheet 20 according to the above embodiment can be obtained.

[0053] Before cutting out the decorative sheet 20 from the large sheet, it is preferable to attach a double-sided adhesive sheet to the back surface of the large sheet to form the decorative sheet 20 with an adhesive layer and a release sheet. This is because, in this form, the decorative sheet 20 can be easily attached to the surface of the molded body to be decorated (in this embodiment, the lid 21 of the compact container).

[0054] In the above manufacturing method, to prepare the surface sheet portion 30, a PP sheet to become the first surface layer 34 and a PET sheet to become the second surface layer 35 are laminated sheet by sheet, but lamination by sheet is not necessarily required. A rolled PP sheet and a rolled PET sheet may be unwound and laminated together, and then cut at predetermined intervals.

[0055] Furthermore, as already mentioned, the surface sheet portion 30 does not necessarily need to be made by overlapping the first surface layer 34 and the second surface layer 35; if a sheet is prepared that has the ability to follow the uneven processing and is printable on one side, the two-layer lamination as described above is not necessary.

[0056] Furthermore, in the above manufacturing method, to obtain the colored pattern layer 31, the first pattern layer 36 was formed by offset printing, and the second pattern layer 37 consisting of the thickened portions was formed by screen printing. However, the formation of the first pattern layer 36 is not limited to offset printing, and any appropriate printing method such as gravure printing or inkjet printing can be applied. Furthermore, the pattern layer can also be formed by direct coating, or by transferring a pattern layer from a transfer sheet on which a pattern layer has been formed. Furthermore, the formation of the second pattern layer 37 can also be achieved by any method that can create thickened portions in parts.

[0057] Furthermore, the formation area of ​​the first pattern layer 36 and the formation area of ​​the second pattern layer 37 may overlap each other, or they may be set so as not to overlap each other, as shown in Figure 8. By forming the two so that they do not overlap in this way, the three-dimensional effect of the thickened portion can be further emphasized. Note that in Figure 8, the other configuration is the same as in Figure 4, and the same parts are designated by the same reference numerals.

[0058] As already mentioned, the formation of the second pattern layer 37 by the above-mentioned thickened portion is not necessarily required, but if a thickened portion is provided on the inside of the sheet to give the colored pattern layer 31 a three-dimensional appearance, this, combined with the reflection of the metallic luster of the metal thin film layer 32 on the back side, makes it possible to obtain a colored pattern with a more complex impression, which is preferable.

[0059] In the above manufacturing method, the metal thin film layer 32 on the back side of the colored pattern layer 31 is formed so as to cover only the protruding surfaces of the thickly protruding portions constituting the second pattern layer 37 of the colored pattern layer 31. However, the area where the metal thin film layer 32 is formed is not limited to the above, and the metal thin film layer 32 can be formed in any suitable pattern depending on the design of the colored pattern visible from the front side. Of course, the metal thin film layer 32 may also be formed on the entire back side of the colored pattern layer 31. The method for forming the metal thin film layer 32 is not limited to metal foil transfer, and any suitable method can be selected, such as vapor deposition, sputtering, plating, or hot stamping.

[0060] Furthermore, in the above manufacturing method, a white pressing layer 38 is provided on the back side of the metal thin film layer 32 to improve appearance, but as already mentioned, this white pressing layer 38 is not necessarily required. For example, if the joining surface of the back sheet portion 33 provided below it via the adhesive layer 39 is a white surface without irregularities or stains, this surface will serve as the white pressing layer 38, and therefore the white pressing layer 38 may not be provided.

[0061] In the above manufacturing method, the multilayer body sandwiching the colored pattern layer 31, the metal thin film layer 32, and the white pressing layer 38 between the surface sheet portion 30 and the back sheet portion 33 is subjected to high-frequency welder processing to impart a textured pattern to its surface, but the imparting of the textured pattern does not necessarily have to be by high-frequency welder processing and can also be done by embossing using a press device, etc.

[0062] However, in the present invention, it is important to arrange at least a portion of the outline of the pattern of the colored pattern layer 31 provided inside the decorative sheet 20 and at least a portion of the outline of the textured pattern imparted to its surface so that they overlap with each other, thereby highlighting the outline of the pattern of the colored pattern layer 31 and emphasizing the three-dimensional effect. For this reason, the high-frequency welding process is suitable for overlapping the outlines with high precision. Furthermore, the high-frequency welding process is suitable in that it allows precise control of the depth of the recesses in the textured pattern to be imparted.

[0063] In the present invention, "high frequency welder processing" generally refers to a process in which high frequency waves of 3 MHz to 30 GHz are used to generate dielectric heating inside an object, melt the object, and form an uneven shape.

[0064] Furthermore, in the above manufacturing method, the layers below the surface sheet portion 30 are sequentially laminated, but the decorative sheet 20 of the present invention can be produced by using, for example, the decorative sheet disclosed in the aforementioned Patent Document 3 as a sheet having the second surface layer 35 having printability, the colored pattern layer 31, and the metal thin film layer 32 (+white pressing layer 38), and overlapping the first surface portion 34 of the surface sheet portion 30 on the surface side of this decorative sheet, and overlapping the back surface sheet portion 33 on the back side of that to obtain a multilayer body, and then subjecting this to high-frequency welding processing or the like to apply a textured pattern to the surface of the first surface portion 34.

[0065] Although the above example shows the application of the present invention to a compact container, the molded article to which the present invention is applied is not limited to containers and may include various resin molded articles, or molded articles in which a resin molded article is combined with other members, etc. For example, the present invention may be widely applied to mobile phones, stationery, home appliances, various cases, etc. [Industrial Applicability]

[0066] The present invention can be used for a decorative sheet that can provide beautiful and impressive decoration with uneven surfaces to various molded bodies, a manufacturing method thereof, and a decorated molded body using the decorative sheet. [Explanation of symbols]

[0067] 20 Decorative sheet 30 Surface sheet part 31 Colored pattern layer 32 Metal thin film layer 33 Back sheet part

Claims

1. The sheet has a translucent top sheet portion, a colored pattern layer that is provided on the back side of the top sheet portion and is itself translucent and visible from the front side of the top sheet portion, a metal thin film layer that is provided on the back side of the colored pattern layer and has a metallic luster and is visible from the front side of the top sheet portion, and a back sheet portion that is provided on the back side of the metal thin film layer, the surface of the top sheet portion is partially recessed to form a concave-convex pattern, and at least a portion of the contour of the concave-convex pattern is arranged to overlap at least a portion of the contour of the pattern in the colored pattern layer; The decorative sheet is characterized in that the partially recessed portion on the surface of the top sheet portion is recessed in the thickness direction of the entire decorative sheet and protrudes downward from the back surface of the back sheet portion, thereby imparting an uneven pattern to the back surface of the back sheet portion as well.

2. A sheet material comprising a translucent surface sheet portion, a colored pattern layer provided on the back side of the surface sheet portion and visible from the front side of the surface sheet portion and itself translucent, a metal thin film layer provided on the back side of the colored pattern layer and having a metallic luster and visible from the front side of the surface sheet portion, and a back sheet portion provided on the back side of the metal thin film layer, The surface side of the surface sheet portion is made of a soft sheet, and the back side of the surface sheet portion is made of a hard sheet, the soft sheet is made of at least one selected from the group consisting of polypropylene, polyvinyl chloride, soft polyethylene, and polyurethane, and the hard sheet is made of at least one selected from the group consisting of polyethylene terephthalate and polycarbonate, The decorative sheet is characterized in that the surface of the surface sheet portion is partially recessed to provide an uneven pattern, and at least a part of the outline of the uneven pattern is arranged to overlap at least a part of the outline of the pattern in the colored pattern layer.

3. 3. The decorative sheet according to claim 2, wherein the thickness of the soft sheet is 100 to 500 μm, and the thickness of the hard sheet is 5 to 30 μm.

4. 4. The decorative sheet according to claim 1, wherein the colored pattern layer has a thick portion of 30 to 150 μm made of thick ink in a part thereof.

5. 5. The decorative sheet according to claim 1, further comprising a whitening layer formed between the metal thin film layer and the back sheet portion.

6. The back sheet portion is made of a soft sheet having a thickness of 100 to 500 μm, 6. The decorative sheet according to claim 1, wherein the soft sheet is made of at least one material selected from the group consisting of polypropylene, polyvinyl chloride, soft polyethylene, and polyurethane.

7. a step of preparing a surface sheet portion that is translucent and conforms to the textured surface processing and has printability on the back side; a step of printing a colored pattern on the back surface of the top sheet portion using a light-transmitting ink to form a colored pattern layer visible from the front surface of the top sheet portion; forming a metal thin film layer having a metallic luster visible from the surface side of the surface sheet portion on the surface of the colored pattern layer opposite to the surface contacting the surface sheet portion; a step of providing a back sheet portion having conformability to uneven processing on the surface of the metal thin film layer opposite to the side in contact with the colored pattern layer, thereby obtaining a multilayer body having a surface sheet portion, a colored pattern layer, a metal thin film layer, and a back sheet portion; and a step of applying high-frequency welding to the multilayer body to partially recess the surface of the top sheet portion to provide a textured pattern. The method for producing a decorative sheet is characterized in that at least a part of the outline of the uneven pattern is arranged to overlap at least a part of the outline of the pattern in the colored pattern layer.

8. In the step of preparing the surface sheet portion, a soft sheet and a hard sheet are laminated via an adhesive layer to obtain a surface sheet portion having a surface side made of the soft sheet and a back side made of the hard sheet, 8. The method for producing a decorative sheet according to claim 7, wherein the soft sheet is made of at least one selected from the group consisting of polypropylene, polyvinyl chloride, soft polyethylene, and polyurethane, and the hard sheet is made of at least one selected from the group consisting of polyethylene terephthalate and polycarbonate.

9. 9. The method for producing a decorative sheet according to claim 8, wherein the soft sheet has a thickness of 100 to 500 μm, and the hard sheet has a thickness of 5 to 30 μm.

10. The method for manufacturing a decorative sheet according to any one of claims 7 to 9, characterized in that in the step of forming the colored pattern layer, the colored pattern layer is obtained by combining a step of printing the colored pattern by offset printing and a step of forming a thick portion having a thickness of 30 to 150 μm by screen printing using a thick-layer ink.

11. The method for manufacturing a decorative sheet according to any one of claims 7 to 10, characterized in that after the step of forming the metal thin film layer and before the step of obtaining the multilayer body, a step of forming a white pressing layer using white ink on the surface of the metal thin film layer opposite to the surface that contacts the colored pattern layer is provided, and in the step of obtaining the multilayer body, the back sheet portion is provided on the surface of the white pressing layer opposite to the side that contacts the metal thin film layer.

12. 12. The method for manufacturing a decorative sheet according to any one of claims 7 to 11, characterized in that in the process of obtaining the multilayer body, a soft sheet having a thickness of 100 to 500 μm is used as the back sheet portion, and the soft sheet is laminated on the metal thin film layer or the white pressing layer via a hot melt adhesive sheet, and then high-frequency welding is performed on the multilayer body to impart a textured pattern to the surface of the top sheet portion and integrate the back sheet portion with the metal thin film layer or the white pressing layer.

13. A method for manufacturing a decorative sheet as described in any one of claims 7 to 12, characterized in that in the process of applying high-frequency welding processing to the multilayer body to impart an uneven pattern, the surface of the top sheet portion is partially recessed and at the same time the entire multilayer body is recessed in the thickness direction, causing the back surface of the back sheet portion to partially protrude downward, thereby imparting an uneven pattern to the back surface of the back sheet portion as well.

14. A molded body having a decorative portion provided on at least a part of its surface, wherein the decorative portion is constituted by the decorative sheet according to any one of claims 1 to 6.

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