Method for manufacturing decorative sheets and decorative sheets

Abstract

To provide a method for manufacturing a decorative sheet which has texture closer to a genuine texture and has excellent designability, and a decorative sheet.SOLUTION: A method for manufacturing a decorative sheet includes: a step (Fig. 2(a)) of forming a pattern layer (5) where a pattern is drawn using a predetermined material having more light absorptivity with respect to infrared rays than a transparent thermoplastic resin layer (6); a step (Fig. 2(b)) of stacking the transparent thermoplastic resin layer (6) and a surface protective layer (7) on the pattern layer (5) in this order; a step (Fig. 2(c)) of irradiating the layers with infrared rays after the lamination step; and a step (Fig. 2(d)) of impressing an embossing plate to the surface protective layer (7), after irradiation with infrared rays.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] Decorative sheets have been developed and evolved in the process of the development of housing construction as an industry. Originally, materials suitable for regional characteristics such as wood and stone have been used for housing, but with the development of the housing industry, industrialization has advanced, and the conversion from natural materials to artificial materials has been carried out. In recent years, the extensive use of high-quality wood and stone may lead to deforestation and environmental problems, which is also one of the factors expanding the demand for decorative sheets. For example, decorative materials obtained by laminating decorative sheets on wood-based substrates such as plywood, MDF (medium density fiberboard), particle board, resin substrates, inorganic non-combustible substrates, metal substrates, etc. are widely used (see, for example, Patent Document 1). In addition, as the design of decorative sheets, the surfaces of wood, stone, etc. are often imitated.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, compared with real wood, stone, etc., the surface texture of decorative sheets tends to be flat. Actual wood and stone have differences in unevenness and texture differences from place to place due to differences in surface materials and structures, etc. In parts with different textures, the colors are often different, but this is not expressed in decorative sheets, and in terms of design, expensive real ones are much superior.

[0005] This invention has been made in view of the above-mentioned points, and aims to provide a method for manufacturing a decorative sheet and a decorative sheet that has a texture closer to the real thing and excellent design. [Means for solving the problem]

[0006] To solve the above problems, one aspect of the present invention provides a method for manufacturing a decorative sheet comprising a base layer, a pattern layer, a transparent resin layer, and a surface protection layer, and having an embossed shape that is in harmony with the pattern of the pattern layer, comprising the steps of: forming a pattern layer on which a pattern is drawn using a predetermined material that has greater light absorption to a predetermined wavelength of light than the transparent resin layer; laminating the transparent resin layer and the surface protection layer in that order on the pattern layer; irradiating with light of a predetermined wavelength whose power is stronger than the power of light of other wavelengths after the lamination step; and pressing an embossing plate for forming an embossed shape onto the surface protection layer after the irradiating step.

[0007] Another aspect of the present invention provides a method for manufacturing a decorative sheet having an embossed shape that conforms to a pattern, comprising the steps of: laminating a pattern layer, a transparent resin layer, and a surface protection layer in that order on one side of a colored resin layer; forming a pattern layer that conforms to a pattern on the other side of the colored resin layer using a predetermined material that has greater light absorption to a predetermined wavelength than the colored resin layer; irradiating the sheet with light of a predetermined wavelength whose power is stronger than that of light of other wavelengths, after the lamination step and the step of forming the pattern layer; and pressing an embossing plate for forming an embossed shape onto the surface protection layer after the step of irradiating with light.

[0008] Another aspect of the present invention provides a decorative sheet having a base layer, a pattern layer, a transparent resin layer, and a surface protection layer, wherein the pattern layer has a pattern formed using a predetermined material which has greater light absorption properties to predetermined wavelengths of light than the transparent resin layer, and the transparent resin layer and surface protection layer are sequentially laminated on the pattern layer, and an embossed portion is formed on the surface protection layer at a position that overlaps with a portion formed of the predetermined material in a plan view.

[0009] Furthermore, another aspect of the present invention provides a decorative sheet having a pattern layer, comprising: a pattern layer, a transparent resin layer, and a surface protection layer sequentially laminated on one side of a colored resin layer; and a pattern layer laminated on the other side of the colored resin layer, wherein a predetermined material having greater light absorption properties for a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern on the pattern layer, and an embossed portion is formed on the surface protection layer at a position that overlaps with a portion formed of the predetermined material in a plan view. [Effects of the Invention]

[0010] According to one aspect of the present invention, it is possible to provide a decorative sheet that has a texture similar to the surface texture of wood, stone, and other building materials, and that has excellent design properties. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic cross-sectional view showing an example of a decorative sheet produced by the method for manufacturing a decorative sheet according to the first embodiment of the present invention. [Figure 2] This is a schematic process diagram illustrating an example of the manufacturing procedure for a decorative sheet according to the first embodiment. [Figure 3] This is a schematic cross-sectional view showing another example of a decorative sheet produced by the decorative sheet manufacturing method according to the second embodiment of the present invention. [Figure 4] This is a schematic process diagram illustrating an example of the manufacturing procedure for a decorative sheet according to the second embodiment. [Figure 5] This is a schematic cross-sectional view showing another example of a decorative sheet produced by the method for manufacturing a decorative sheet according to the third embodiment of the present invention. [Figure 6] This is a schematic process diagram illustrating an example of the manufacturing procedure for a decorative sheet according to the third embodiment. [Modes for carrying out the invention]

[0012] Embodiments of this technology will be described below with reference to the drawings. In these embodiments, decorative sheets and decorative materials for floors or joinery will be used as examples, but decorative sheets for use in other parts may also be used. Here, the drawings are schematic, and the relationship between thickness and planar dimensions, the ratio of the thickness of each layer, etc., may differ from reality. Furthermore, the embodiments shown below illustrate configurations for realizing the technical idea of ​​the present invention, and the technical idea of ​​the present invention is not limited to the materials, shapes, and structures of the components described below. The technical idea of ​​the present invention can be modified in various ways within the technical scope defined by the claims described in the patent claims.

[0013] A method for manufacturing a decorative sheet according to one embodiment of the present invention comprises a base layer, a pattern layer, a transparent resin layer, and a surface protection layer, and having an embossed shape that is in harmony with the pattern of the pattern layer, comprising the steps of: forming a pattern layer on which the pattern is drawn using a predetermined material which has greater light absorption to a predetermined wavelength than the transparent resin layer; laminating the transparent resin layer and the surface protection layer on the pattern layer in that order; irradiating with light whose power of light of the predetermined wavelength is stronger than the power of light of other wavelengths after the lamination step; and pressing an embossing plate for forming the embossed shape onto the surface protection layer after the irradiating with light.

[0014] Furthermore, another embodiment of the present invention provides a method for manufacturing a decorative sheet having an embossed shape that conforms to a pattern, comprising the steps of: laminating a pattern layer, a transparent resin layer, and a surface protection layer in that order on one side of a colored resin layer; forming a pattern layer that conforms to the pattern on the other side of the colored resin layer using a predetermined material that has greater light absorption properties to a predetermined wavelength than the colored resin layer; irradiating the sheet with light whose power of the predetermined wavelength is stronger than the power of light of other wavelengths, after the lamination step and the pattern layer formation step; and pressing an embossing plate for forming the embossed shape onto the surface protection layer after the irradiating step.

[0015] Furthermore, a decorative sheet according to another embodiment of the present invention is a decorative sheet having a base layer, a pattern layer, a transparent resin layer, and a surface protection layer, wherein the pattern layer has a pattern formed using a predetermined material which has greater light absorption properties to predetermined wavelengths of light than the transparent resin layer, and the transparent resin layer and the surface protection layer are sequentially laminated on the pattern layer, and an embossed portion is formed on the surface protection layer at a position that overlaps with the portion formed of the predetermined material in a plan view.

[0016] Furthermore, a decorative sheet according to another embodiment of the present invention is a decorative sheet having a pattern layer, comprising: a pattern layer, a transparent resin layer, and a surface protection layer sequentially laminated on one side of a colored resin layer; and a pattern layer laminated on the other side of the colored resin layer, wherein a predetermined material having greater light absorption properties for a predetermined wavelength than the colored resin layer is arranged in synchronization with the pattern on the pattern layer, and an embossed portion is formed on the surface protection layer at a position that overlaps with the portion formed by the predetermined material in a plan view.

[0017] [First Embodiment] First, a first embodiment of the present invention will be described. The cosmetic sheet 1 formed by the method for manufacturing a cosmetic sheet according to the first embodiment of the present invention is, as shown in FIG. 1, composed of a colored thermoplastic resin layer (base material layer) 2, a pattern layer 5 including a pattern portion 3 for expressing gloss and matte, a transparent thermoplastic resin layer (transparent resin layer) 6, and a surface protective layer 7 laminated in this order. An embossed portion (embossed shape) 7a is formed on the transparent thermoplastic resin layer 6 and the surface protective layer 7. The pattern portion 3 for expressing gloss and matte is arranged at a position in the pattern layer 5 where it is desired to synchronize with the embossed portion 7a. Synchronization means that at least a part of the pattern portion 3 for expressing gloss and matte and the embossed portion 7a overlap in a plan view. In FIG. 1, further, the case where a primer layer 8 is provided on the surface of the colored thermoplastic resin layer 2 opposite to the surface on which the pattern layer 5 is formed is illustrated.

[0018] 〔Colored thermoplastic resin layer (base material layer)〕 The colored thermoplastic resin layer 2 as a base material includes, for example, polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-acrylic acid ester copolymer, ionomer, acrylic ester, methacrylic ester, etc. Among them, polyolefin-based resins can be preferably used in terms of environmental compatibility, processability, and price. The grade and composition of the resin can be selected in consideration of other factors such as ease of sheeting, printing suitability, and suitability for bending.

[0019] As the colored thermoplastic resin layer 2, the hue can be appropriately selected as the base color of the pattern layer 5. The colored thermoplastic resin layer 2 can be colored, for example, by mixing a colorant such as a pigment or kneading it during sheeting of the thermoplastic resin. Alternatively, before providing the pattern portion 3 for expressing gloss and matte, a coloring layer can be provided by using a coating or printing method as a solid ink layer to color it. Although a colored thermoplastic resin is used as the base material layer, the base material layer may not be colored and may be colorless and transparent.

[0020] [Handle for creating a glossy finish] The gloss-matte pattern section 3 is formed of a material that absorbs light of a predetermined wavelength, for example, a material that absorbs infrared rays. Alternatively, the gloss-matte pattern section 3 is formed of a material containing carbon black ink, for example, a urethane-based printing ink. The gloss-matte pattern section 3 is provided as part of the pattern layer 5 and is formed at a position that should be synchronized with the embossed section 7a, or in other words, at the position where the embossed section 7a should be formed. For example, if the pattern layer 5 has a wood grain pattern, the gloss-matte pattern section 3 is positioned to overlap with the wood grain grooves of the pattern layer 5.

[0021] [Picture layer] The pattern layer 5 is a printed layer on which a pattern is printed in order to give the decorative sheet 1 an aesthetic appeal. Known printing methods can be used to form the pattern layer 5. The printing method is not particularly limited, but considering productivity and pattern quality, gravure printing is preferred. For example, if the colored thermoplastic resin layer 2 can be prepared in a rolled state, printing for the formation of the pattern layer 5 can be performed using a roll-to-roll printing device. Other printing methods include, for example, offset printing, screen printing, flexographic printing, electrostatic printing, inkjet printing, and transfer printing from a transfer sheet. When using such printing methods, the pattern of the pattern layer 5 can be formed by multicolor printing using ordinary yellow, red, blue, and black process colors, or by multicolor printing using spot colors, where plates are prepared for each color that makes up the pattern.

[0022] Furthermore, the pattern of pattern layer 5 can be any pattern, taking into consideration its aesthetic appeal as flooring or joinery. For example, if one imagines a floor made of stone such as marble, the pattern could be a marble grain. Alternatively, for example, if a wood-based pattern is used, various wood grains or cork patterns could be used. In addition to patterns of natural materials, artificial patterns such as geometric patterns or other artificial patterns based on these motifs can also be used. Other examples of patterns include wood grain patterns composed of the springwood and autumnwood regions of the annual ring cross-section, and the vessel parts, leather grain patterns, stone grain patterns of stone materials such as marble, granite, and sandstone, sand grain patterns, tile patterns, brick patterns, cloth patterns, geometric figures, letters, symbols, abstract patterns, floral patterns, landscapes, and characters.

[0023] The pattern layer 5 has a gloss-matte pattern section 3 made of a material containing black ink, and a non-gloss-matte pattern section 5a, forming a single layer that creates a single pattern. The gloss-matte pattern section 3 is positioned in the pattern of the pattern layer 5 to be synchronized with the embossed section 7a. The printing ink for the pattern section 5a, which produces a non-glossy matte finish, is a mixture of a solvent and solid components such as a colorant and binder resin.

[0024] Examples of solvents include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water. A single solvent may be used alone, or two or more may be used in combination.

[0025] Examples of binder resins include chlorine-based resins, urethane resins, acrylic urethane resins, acrylic resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins (nitrified cotton), and cellulose acetate resins. Examples of chlorine-based resins include polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, ethylene-vinyl chloride copolymers, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-(meth)acrylic copolymers, polypropylene chloride, and chlorinated polypropylene. Here, (meth)acrylic means acrylic or methacrylic. The binder resin may be a single type or a combination of two or more types.

[0026] Examples of colorants include inorganic pigments such as carbon black, iron black, titanium white (titanium dioxide), antimony white, lead yellow, titanium yellow, reddish-brown, cadmium red, ultramarine, and cobalt blue; and organic pigments such as quinacridone red, isoindolinone yellow, and phthalocyanine blue. The colorants may be used individually or in combination of two or more. Here, the solvent contained in the printing ink eventually evaporates. Therefore, the pattern portion 5a for producing a non-glossy matte finish is mainly formed from solid components such as colorants and binder resins.

[0027] Furthermore, the printing ink for the pattern portion 5a for non-glossy matte finish may also contain other components such as stabilizers, plasticizers, catalysts, and curing agents. The printing ink should be selected according to the printing method. In particular, it is preferable to select an ink considering its adhesion to the colored thermoplastic resin layer 2, printability, and weather resistance as a flooring or joinery material. The thickness of the pattern layer 5 can be adjusted as appropriate considering the decorative properties required for the pattern layer 5 and the three-dimensional moldability of the decorative sheet 1. The thickness of the pattern layer 5 is usually 1 μm or more and 1 mm or less, preferably 2 μm or more and 0.1 mm or less, and more preferably 2 μm or more and 50 μm or less.

[0028] To improve the adhesion between the pattern layer 5 and the transparent thermoplastic resin layer 6, an adhesive layer (not shown) may be provided on the side of the pattern layer 5 that is in contact with the transparent thermoplastic resin layer 6. By strengthening this adhesion, the decorative sheet 1 can be given the ability to bend to follow curved and right-angle surfaces. The resin used for the adhesive layer (not shown) is not particularly limited. For example, a two-component curing urethane resin can be used. Alternatively, the adhesive resin may be bonded to the pattern layer 5 with a urethane adhesive. For applying the resin used for the adhesive layer (not shown), for example, a coating apparatus or a gravure printing apparatus can be used.

[0029] Furthermore, a glossy layer (not shown) may be provided between the pattern layer 5 and the transparent thermoplastic resin layer 6 for the purpose of suitably imparting design effects such as a sense of depth and brightness to the decorative sheet 1. The glossy layer (not shown) preferably contains a glossy pigment and a binder resin. Examples of glossy pigments include pearl pigments and metallic pigments. In particular, pearl pigments are preferred because they can suppress a decrease in the light transmittance of the glossy layer, and therefore do not impair the visibility of the pattern layer 5.

[0030] Pearl pigments are pigments that can impart a pearly luster. For example, they include those in which the surface of the matrix particles is coated with a metal oxide. Scale-like particles such as mica are preferred as the matrix particles. Examples of metal oxides include titanium, iron, zirconium, silicon, aluminum, and cerium oxides. The metal oxide may be used alone or in combination of two or more types. Specific examples include oxide-coated micas such as titanium mica, iron oxide-coated mica, iron oxide-coated titanium mica, Prussian blue-coated titanium mica, Prussian blue-iron oxide-coated titanium mica, chromium oxide-coated titanium mica, carmine-coated titanium mica, organic pigment-coated titanium mica, titanium oxide-coated mica, and titanium oxide-coated synthetic mica; oxide-coated glass powders such as titanium oxide-coated glass powder and iron oxide-coated glass powder; oxide-coated metal particles such as titanium oxide-coated aluminum powder; scale-like foil pieces such as basic lead carbonate, lead hydrogen arsenate, and bismuth chloride oxide; and fish scales, shell fragments, and pearl fragments.

[0031] Examples of metallic pigments include pigments made from metals such as aluminum, brass, stainless steel, tin, zinc, copper, nickel, gold powder, and silver, as well as alloys of these metals. Metallic pigments may be used individually or in combination of two or more types. From the viewpoint of providing excellent design effects, the average particle size of the lustrous pigment is preferably 40 μm or less, and more preferably 30 μm or less, when forming a lustrous layer using gravure printing. From a similar viewpoint, the ratio of [average particle size of lustrous pigment / thickness of lustrous layer] is preferably 0.01 or more and 15 or less, and more preferably 0.5 or more and 10 or less. In this specification, "average particle size" refers to the value that can be determined as the mass average value D50 in particle size distribution measurement by laser light diffraction.

[0032] Furthermore, examples of binder resins include thermoplastic resins and cured products of curable resin compositions, with cured products of curable resin compositions being preferred from the viewpoint of durability. Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation-curable resin compositions. From the viewpoint of interlayer adhesion, cured products of thermosetting resin compositions are preferred. Examples of thermosetting resin compositions used in the glossy layer include polyester resin compositions, epoxy resin compositions, polyurethane resin compositions, aminoalkyd resin compositions, melamine resin compositions, guanamine resin compositions, urea resin compositions, and thermosetting acrylic resin compositions. These thermosetting resin compositions consist of monomers and / or prepolymers constituting each resin, and curing agents added as needed. As for the ionizing radiation-curable resin composition used in the glossy layer, the same as the ionizing radiation-curable resin composition for the surface protective layer 7 described later can be used.

[0033] The content of the lustrous pigment in the lustrous layer is preferably 10 parts by mass or more and 90 parts by mass or less, and more preferably 50 parts by mass or more and 80 parts by mass or less, per 100 parts by mass of binder resin. By having a content of 10 parts by mass or more of lustrous pigment, sufficient gloss can be imparted, and by having a content of 90 parts by mass or less, the impairment of the visibility of the pattern layer described later can be suppressed. From a similar viewpoint, the thickness of the lustrous layer is preferably 1 μm or more and 30 μm or less, and more preferably 5 μm or more and 20 μm or less.

[0034] The glossy layer can form any pattern depending on the desired design. Examples include wood grain, leather, stone, sand, tile, brick, fabric, geometric figures, letters, symbols, abstract patterns, floral patterns, landscapes, characters, etc. Furthermore, it is preferable that the pattern has variations in shade to enhance the design effect. While variations in shade may be formed by the size or thickness of the dots, it is preferable to form them by the density of the dots (i.e., the size of the dots is uniform and the shade is formed by the density of the dots). The glossy layer can be formed, for example, using a coating solution containing a glossy pigment and a binder resin, by general-purpose printing methods such as gravure printing. When the shading of the glossy layer is formed by the density of halftone dots, the halftone dots on the printing plate can be formed using an FM (frequency modulation) screen.

[0035] [Transparent thermoplastic resin layer] The transparent thermoplastic resin layer 6 is a resin layer that protects the pattern layer 5 and imparts good surface properties to the decorative sheet 1, thereby adding thickness and depth to the design and improving its weather resistance and abrasion resistance. For example, vinyl chloride resin, acrylic resin, and polyolefin resins (polypropylene resin, polyethylene resin) can be used as materials for the transparent thermoplastic resin layer 6. Polyolefin resins are particularly preferred considering environmental compatibility, processability, and cost. Furthermore, the grade and composition of the resin can be selected considering not only environmental compatibility, processability, and cost, but also ease of sheeting, printability, and suitability for bending. Regarding suitability for bending, it is important to select a resin that prevents whitening and cracking at the bent areas. A lamination method can be used to form the transparent thermoplastic resin layer 6. Furthermore, for example, when forming the transparent thermoplastic resin layer 6 and an adhesive layer (not shown) simultaneously, a method of co-extrusion can be used to form both layers simultaneously.

[0036] [Surface protective layer] The surface protection layer 7 is a layer that imparts surface properties such as abrasion resistance to the decorative sheet 1. The surface protection layer 7 is also a layer that adjusts the gloss of the surface of the decorative sheet 1. The surface protection layer 7 may be a single layer or a multi-layer layer. For example, the surface protection layer 7 may consist of two layers, a first surface protection layer (not shown) and a second surface protection layer (not shown), in that order on top of the transparent thermoplastic resin layer 6. When providing a surface protection layer 7 consisting of a first surface protection layer (not shown) and a second surface protection layer (not shown), each layer may be applied using one of the known coating devices, heat drying devices, or ionizing radiation irradiation devices, depending on the type of curable resin, and the coating film may be cured. The surface protection layer 7 mainly consists of a curable resin. That is, it is preferable that the resin component of the surface protection layer 7 is substantially composed of a curable resin. Substantially means, for example, 80 parts by mass or more when the total resin is 100 parts by mass. The surface protection layer 7 may optionally contain weather resistant agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, etc.

[0037] As the material for the surface protective layer 7, for example, an ionizing radiation-curable resin or a two-component curable urethane resin can be used. The ionizing radiation-curable resin is not particularly limited. For example, a transparent resin mainly composed of a prepolymer (including oligomers) and / or monomer containing a radically polymerizable double bond in its molecule that can undergo polymerization crosslinking reactions by irradiation with ionizing radiation such as infrared rays, ultraviolet rays, or electron beams can be used. These prepolymers or monomers can be used individually or in combination. Specifically, examples of prepolymers or monomers include compounds having radically polymerizable unsaturated groups such as (meth)acryloyl groups and (meth)acryloyloxy groups, or cationic polymerizable functional groups such as epoxy groups in their molecules. Polyene / thiol-based prepolymers formed by a combination of polyene and polythiol are also preferred. Here, (meth)acryloyl group means acryloyl group or methacryloyl group.

[0038] Examples of prepolymers having radically polymerizable unsaturated groups include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, and silicone (meth)acrylate. Their molecular weights are preferably around 250 to 100,000. Furthermore, examples of monomers having radically polymerizable unsaturated groups include monofunctional monomers such as methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, and phenoxyethyl (meth)acrylate. Examples of polyfunctional monomers include diethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, trimethylpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate.

[0039] Furthermore, examples of prepolymers having cationic polymerizable functional groups include epoxy resins such as bisphenol-type epoxy resins and novolac-type epoxy compounds, and vinyl ether resins such as fatty acid-based vinyl ethers and aromatic vinyl ethers. Furthermore, examples of polyene-based prepolymers include polyurethanes with allyl alcohol added to both ends, such as diols and diisocyanates. Examples of thiol-based prepolymers include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate.

[0040] As the ionizing radiation, for example, electromagnetic waves or charged particles having energy capable of curing molecules in an ionizing radiation-curable resin (composition) can be used. As the curing reaction, for example, a cross-linking curing reaction can be used. As the ultraviolet light source, for example, light sources such as ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black lights, and metal halide lamps can be used. The wavelength of the ultraviolet light is preferably between 190 nm and 380 nm. As the electron beam source, for example, electron beam accelerators such as Cockcroft-Walton type, Van de Graft type, resonant transformer type, insulated core transformer type, linear type, Dynamitron type, and high-frequency type can be used. In particular, those capable of irradiating electrons with energy between 100 keV and 1000 keV (more preferably electrons with energy between 100 keV and 300 keV) are preferred.

[0041] Furthermore, the two-component curing urethane resin is not particularly limited. For example, a resin containing a polyol component having an OH group as the main component and an isocyanate component as the curing agent can be used. Examples of polyol components having an OH group include acrylic polyols, polyester polyols, polyether polyols, and epoxy polyols. Examples of isocyanate components include tolylene diisocyanate, hexamethylene diisocyanate, and metaxylene diisocyanate.

[0042] [Light of a specified wavelength] As mentioned above, the gloss matte pattern section 3 is formed of a material that absorbs light of a predetermined wavelength. The predetermined wavelength of light refers to, for example, infrared rays, ultraviolet rays, visible light, electron beams, X-rays, and ion beams.

[0043] [Embossed area] An embossed portion 7a consisting of a raised and recessed pattern is formed on the surface of the surface protection layer 7 to impart a given design. Examples of raised and recessed patterns include wood grain grooves, stone surface irregularities (such as granite cleavage surfaces), fabric surface textures, pearlescent finishes, sand textures, hairline finishes, and fine grooves. This embossed portion 7a is provided so that its raised and recessed pattern is in harmony with the pattern of the pattern layer 5. For example, embossing can be used to form the raised and recessed pattern. The method of embossing is not particularly limited. For example, a known sheet-fed embossing machine or a rotary embossing machine can be used.

[0044] [Primer layer] The primer layer 8 is a base layer that improves the adhesion and corrosion resistance between the colored thermoplastic resin layer 2 and the substrate (not shown) to which the decorative sheet 1 is attached. The primer layer 8 is provided on the side of the colored thermoplastic resin layer 2 opposite to the gloss-matt pattern portion 3. The primer layer 8 is formed using, for example, a polyester resin, organic additives, pigments, etc. Rust-preventive pigments may be added to the primer layer 8 to improve corrosion resistance. The thickness of the primer layer 8 is, for example, in the range of 1 μm to 10 μm.

[0045] [Method for manufacturing decorative sheets] Next, an example of a method for manufacturing a decorative sheet according to this embodiment will be described with reference to Figure 2. First, a colored thermoplastic resin layer 2 is formed. For example, PBT (polybutylene terephthalate resin) is used to form a layer with a thickness of 50 μm (Figure 2(a)). Next, a pattern area 3 for gloss matte finish and a pattern area 5a for non-gloss matte finish are formed to create the pattern layer 5. For example, using a urethane-based black ink containing carbon black, the pattern area 3 for gloss matte finish is formed in the pattern of the pattern layer 5 at a position that aligns with the embossed area 7a, and the pattern area 5a for non-gloss matte finish is formed in other areas.

[0046] Next, a transparent thermoplastic resin layer 6, for example, PP (polypropylene) with a thickness of 38 μm, is laminated on top of the pattern layer 5, and then a surface protection layer 7 is laminated on top of the transparent thermoplastic resin layer 6 (Figure 2(b)). Then, infrared light (irradiation light) is applied to the laminate formed by these layers from the surface protection layer 7 side (Figure 2(c)), and immediately after infrared irradiation, an embossing plate such as an embossing roll is pressed onto the surface of the surface protection layer 7 (Figure 2(d)).

[0047] Here, since the pattern portion 3 for gloss matte finish is formed of black ink having infrared absorption properties, when the laminate is irradiated with infrared light, the portion of the surface protective layer 7 that overlaps with the pattern portion 3 for gloss matte finish in a plan view is more prone to softening than the portion that overlaps with the non-gloss matte finish pattern portion 5a. In other words, after infrared irradiation, the surface protective layer 7 and the transparent thermoplastic resin layer 6 have portions that soften easily and portions that do not soften easily. Therefore, when an embossing plate is pressed onto the surface protective layer 7 in this state, the softened portions are more prone to forming irregularities, while the portions that do not soften easily are less prone to forming irregularities. As a result, irregularities are more easily formed in the softened portions, i.e., the portions that overlap with the pattern portion 3 for gloss matte finish in a plan view. Consequently, an embossed portion 7a with an irregular shape synchronized with the pattern portion 3 for gloss matte finish is more easily formed only at the position of the surface protective layer 7 that overlaps with the pattern portion 3 for gloss matte finish in a plan view.

[0048] Next, a primer layer 8 is formed on the side of the colored thermoplastic resin layer 2 opposite to the side on which the pattern layer 5 is formed (Figure 2(e)). This forms the decorative sheet 1 shown in Figure 1. Furthermore, the timing for pressing the embossing plate onto the surface protective layer 7 after infrared irradiation is not limited to immediately after infrared irradiation; any timing that allows for the selective formation of uneven surfaces in the areas softened by infrared irradiation is acceptable. Furthermore, other steps may be included between the step of creating the surface protective layer 7 and the step of performing infrared irradiation; in short, the infrared irradiation should be performed while the surface protective layer 7 is formed.

[0049] [Effects of the First Embodiment] (1) According to the manufacturing method of the decorative sheet 1 of this embodiment, after irradiating the entire surface protective layer 7 with infrared light, an embossing plate is pressed onto the surface protective layer 7, thereby embossing the portion of the surface protective layer 7 that overlaps with the gloss matte pattern portion 3 in a plan view. In other words, even without high-precision positioning of the area on the surface protective layer 7 where the embossing plate is pressed, an embossed portion can be easily formed only at the desired location. As a result, a decorative sheet with excellent design can be easily obtained.

[0050] (2) Furthermore, since the pattern portion 3 for producing the gloss matte effect is provided in synchronization with the pattern of the pattern layer 5, the embossed portion 7a can be formed at a position synchronized with the pattern of the pattern layer 5, that is, the gloss matte effect can be easily produced at a position synchronized with the pattern. Furthermore, a transparent thermoplastic resin layer 6 and a surface protection layer 7 are laminated on a pattern layer 5 in which a pattern is formed using a material with lower infrared light absorption than the pattern portion 3, which has infrared absorption properties, and an embossed portion 7a is formed on the surface protection layer 7 at a position that overlaps with the pattern portion 3 when viewed from above, so that the pattern portion 3 made with black ink can be seen as part of the pattern.

[0051] (3) Furthermore, since the gloss matte finish is achieved by creating irregularities in the surface protective layer 7 itself, it is possible to suppress the occurrence of the gloss matte pattern coming off. For this reason, a synchronized gloss matte finish can be achieved even in flooring materials, for example.

[0052] [Variation] In the above embodiment, a case was described in which a material containing black ink is used as the pattern portion 3 for producing a gloss matte finish, and the surface protective layer 7 is partially softened by infrared irradiation. However, the embodiment is not limited to this. The surface protective layer 7 may also be partially softened by using a material containing any ink consisting of a component that absorbs light of a predetermined wavelength, and a light source that irradiates with light of the predetermined wavelength.

[0053] [Second Embodiment] Next, a second embodiment of the present invention will be described. In the first embodiment described above, the pattern portion 3 for gloss matte appearance is made part of the pattern layer 5, and a pattern layer 5 is provided in which the pattern portion 3 for gloss matte appearance and the pattern portion 5a for non-gloss matte appearance form a single pattern. However, in the second embodiment, as shown in Figure 3, the pattern portion 31 for gloss matte appearance is provided on top of the main pattern layer 5b. In other words, the pattern layer 51 according to the second embodiment comprises a main pattern layer 5b and a pattern layer 5c laminated on top of the main pattern layer 5b. The pattern layer 5c consists only of the pattern portion 31 for gloss matte appearance, which is arranged in synchronization with the embossed portion 7a. The pattern of the pattern layer 51 is mainly formed by the main pattern layer 5b, and the pattern layer 5c, i.e., the pattern portion 31 for gloss matte appearance, is made of a material that allows the main pattern layer 5b to be seen. Specifically, unlike the gloss matte pattern section 3 of the first embodiment described above, the gloss matte pattern section 31 is made of a material having infrared absorption properties, rather than a material containing black ink, and is formed using a colorless, transparent or relatively transparent light-colored ink. The infrared absorption properties can be inorganic materials such as tin-doped indium oxide (ITO), antimond-doped tin oxide (ATO), lanthanum hexaboride (LaB6), cesium-doped tungsten oxide, etc., as well as organic materials such as near-infrared absorbing materials, infrared absorbing materials, and phthalocyanine-based materials, and existing materials having infrared absorption properties. In other words, the gloss matte pattern section 31 is formed with a visible ink in the main pattern layer 5b.

[0054] The decorative sheet 11 according to the second embodiment is formed by laminating a main pattern layer 5b on a colored thermoplastic resin layer 2, forming a pattern layer 5c on the main pattern layer 5b with a gloss-matt pattern portion 31, and laminating a transparent thermoplastic resin layer 6 on the pattern layer 5c. In other words, the transparent thermoplastic resin layer 6 is laminated on the main pattern layer 5b and the gloss-matt pattern portion 31 so as to fill the gaps between the gloss-matt pattern portions 3 and cover their upper surfaces.

[0055] Furthermore, after laminating the surface protection layer 7 on the transparent thermoplastic resin layer 6, the laminate formed by these layers is subjected to infrared irradiation. When infrared irradiation is performed, in a plan view, the portion of the surface protection layer 7 that overlaps with the gloss-matt pattern portion 31 softens relatively, while the portion that overlaps with the portion where the gloss-matt pattern portion 31 is not formed softens relatively little. As a result, after infrared irradiation, by pressing an embossing plate onto the surface protection layer 7, an embossed portion 7a is formed in the portion that overlaps with the gloss-matt pattern portion 31 in a plan view, which is relatively easy to soften. In this way, even when the gloss-matt pattern portion 31 is laminated on the main pattern layer 5b, the same effects and advantages as in the first embodiment can be obtained. Furthermore, since the gloss matte pattern portion 31 is formed using a material that is colorless and transparent or a light color that is relatively transparent, even when the gloss matte pattern portion 31 is laminated on the main pattern layer 5b, the pattern of the main pattern layer 5b can be seen by passing through the gloss matte pattern portion 3.

[0056] In the case of Figure 3, since the gloss-matt pattern portion 31 is laminated on top of the main pattern layer 5b, the pattern of the pattern layer 51 can be selected without considering the placement of the gloss-matt pattern portion 31. Furthermore, since the gloss-matt pattern portion 31 does not obstruct the visibility of the main pattern layer 5b, the gloss-matt effect can be easily achieved without reducing the visibility of the pattern on the pattern layer 51.

[0057] Figure 4 shows an example of the manufacturing procedure for a decorative sheet 11 created by forming a gloss-matt pattern portion 3 on the main pattern layer 5b. As shown in Figure 4, a main pattern layer 5b having a predetermined pattern is formed (Figure 4(a)), and on top of that, a gloss-matt pattern portion 31 is formed at a position corresponding to a predetermined pattern in the pattern of the main pattern layer 5b, forming a pattern layer 5c (Figure 4(b)). Subsequently, a transparent thermoplastic resin layer 6 is laminated on the main pattern layer 5b including the gloss-matt pattern portion 31 (Figure 4(c)). After laminating a surface protection layer 7 on the transparent thermoplastic resin layer 6 (Figure 4(d)), infrared irradiation is performed (Figure 4(e)), and an embossing plate is pressed onto the surface protection layer 7 (Figure 4(f)). This makes it possible to create an embossed portion 7a that is in sync with the gloss-matt pattern portion 31, and by providing a primer layer 8, the decorative sheet 11 is created (Figure 4(g)). This makes it possible to create an embossed portion 7a that is in sync with the pattern portion 31 for producing a gloss matte finish, and by applying the primer layer 8, a decorative sheet 11 is created (Figure 4(g)).

[0058] [Third Embodiment] In the second embodiment described above, the case in which the gloss-matt pattern portion 31 is provided on the main pattern layer 5b was explained. However, in the decorative sheet 12 according to the third embodiment, as shown in Figure 5, the gloss-matt pattern portion 32 is provided on the side of the colored thermoplastic resin layer 2 opposite to the main pattern layer 5b. In other words, the pattern layer 52 according to the third embodiment is formed only from the main pattern layer 5b. The same reference numerals are used for the same parts as in the first and second embodiments, and their detailed descriptions are omitted.

[0059] [Pattern layer] The pattern layer 8a consists only of a gloss-matt pattern portion 32 arranged in synchronization with the embossed portion 7a. The gloss-matt pattern portion 32 is formed of a material that absorbs light of a predetermined wavelength, similar to the gloss-matt pattern portion 3 in the first embodiment described above, for example, a material that absorbs infrared rays. Specifically, the gloss-matt pattern portion 32 is formed of a material containing a black ink having carbon black, for example, a urethane-based printing ink. The gloss-matt pattern portion 32 is positioned in synchronization with the pattern of the main pattern layer 5b. For example, if the main pattern layer 5b is a wood grain pattern, the gloss-matt pattern portion 32 is formed at a position that overlaps with the wood grain grooves of the main pattern layer 5b in a plan view. The thickness of the gloss-matte pattern portion 32 should be such that it is possible to soften the transparent thermoplastic resin layer 6 and the surface protective layer 7 to the extent that an uneven surface can be sufficiently formed on the surface protective layer 7 during the embossing process described later. Furthermore, in order to obtain a sufficient gloss-matte effect, it is preferable that the difference in gloss between the area where the gloss-matte pattern portion 32 is formed and the area where it is not formed is 5 or more, that is, it is preferable that the image density level is 60% or more.

[0060] [Light of a specified wavelength] As described above, the gloss matte pattern portion 32 is formed of a material that absorbs light of a predetermined wavelength. Examples of light of a predetermined wavelength include infrared rays, ultraviolet rays, visible light, electron beams, X-rays, and ion beams.

[0061] [Method for manufacturing decorative sheets] Next, an example of a method for manufacturing the decorative sheet 12 according to the third embodiment will be described with reference to Figure 6. First, a colored thermoplastic resin layer 2 is formed (Figure 6(a)). Next, a main pattern layer 5b is printed on the colored thermoplastic resin layer 2 using, for example, a urethane-based printing ink, and then a transparent thermoplastic resin layer 6 is laminated on top of the main pattern layer 5b. Finally, a surface protection layer 7 is laminated on top of the transparent thermoplastic resin layer 6.

[0062] Next, a pattern layer 8a is formed by creating a gloss-matte pattern portion 32 on the side of the colored thermoplastic resin layer 2 opposite to the main pattern layer 5b (Figure 6(b)). Next, a primer layer 8, made of, for example, a polyester resin, is laminated on the colored thermoplastic resin layer 2 containing the gloss matte-producing stalk portions 32, filling the gaps between the gloss matte-producing stalk portions 32 and covering their upper surfaces (Figure 6(c)). Next, the entire laminate, in which these layers are stacked, is irradiated with infrared light (irradiation light) from the surface protection layer 7 side (Figure 6(d)), and immediately after infrared irradiation, an embossing plate such as an embossing roll is pressed onto the surface of the surface protection layer 7 (Figure 6(e)). This forms the embossed portion 7a and the decorative sheet 12.

[0063] Here, the pattern portion 32 for creating a gloss matte finish is formed of black ink having infrared absorption properties. Therefore, when the laminate is irradiated with infrared light, the portion of the surface protective layer 7 that overlaps with the pattern portion 32 for creating a gloss matte finish in a plan view is more prone to softening than the portion that does not overlap with the pattern portion 32. In other words, after infrared irradiation, the transparent thermoplastic resin layer 6 and the surface protective layer 7 have portions that soften easily and portions that do not soften easily. Therefore, when an embossing plate is pressed onto the transparent thermoplastic resin layer 6 and the surface protective layer 7 in this state, irregularities are more easily formed in the softened portions, and irregularities are less easily formed in the portions that do not soften easily. Therefore, irregularities are more easily formed in the softened portions of the transparent thermoplastic resin layer 6 and the surface protective layer 7, that is, in the portions that overlap with the pattern portion 32 for creating a gloss matte finish in a plan view. Therefore, in a plan view, embossed portions 7a consisting of uneven shapes synchronized with the gloss-matt pattern portion 32 are easily formed only at positions that overlap with the gloss-matt pattern portion 32 of the transparent thermoplastic resin layer 6 and the surface protective layer 7.

[0064] This makes it possible to form an embossed portion 7a in a position synchronized with the main pattern layer 5b, meaning that an embossed portion 7a synchronized with the main pattern layer 5b can be easily created without performing high-precision positioning operations. Furthermore, the timing for pressing the embossing plate onto the transparent thermoplastic resin layer 6 and the surface protective layer 7 after infrared irradiation is not limited to immediately after infrared irradiation, but is acceptable as long as it is at a timing that allows for the selective formation of uneven surfaces in the areas softened by infrared irradiation by pressing the plate onto the surface of the transparent thermoplastic resin layer 6 and the surface protective layer 7. Furthermore, other steps may be included between the step of creating the surface protective layer 7 and the step of performing infrared irradiation. In short, the infrared irradiation should be performed while the transparent thermoplastic resin layer 6 and the surface protective layer 7 are formed.

[0065] [Effects of the Third Embodiment] The decorative sheet 12 according to the third embodiment can easily form embossed portions at desired positions, and can obtain the same effects and advantages as those of the first and second embodiments. Furthermore, in the decorative sheet 12 according to the third embodiment, since the pattern portion 32 for producing a gloss matte finish is provided in the lower layer of the colored thermoplastic resin layer 2, the visibility of the pattern portion 32 for producing a gloss matte finish is reduced when the decorative sheet 12 is viewed from the surface protective layer 7 side. As a result, although a highly concentrated black ink with infrared absorption properties is used as the pattern portion 32 for producing a gloss matte finish, it is possible to suppress the visibility of the pattern portion 32 for producing a gloss matte finish when the decorative sheet 12 is viewed from the surface protective layer 7 side. Therefore, even if a dark-colored pattern is not used as the main pattern layer 5b, it is possible to suppress the visibility of the pattern portion 32 for producing a gloss matte finish. As a result, it becomes possible to use a light-colored pattern as the main pattern layer 5b, and the constraints on pattern expression caused by the main pattern layer 5b due to the provision of the pattern portion 32 for producing a gloss matte finish can be suppressed.

[0066] Furthermore, a colored thermoplastic resin layer 2 and a main pattern layer 5b are laminated on a pattern layer 5d consisting of a gloss-matt pattern portion 32 using a high-density black ink with infrared absorption properties, and a transparent thermoplastic resin layer 6 and a surface protection layer 7 are also laminated. An embossed portion 7a is formed in the surface protection layer 7 at a position that overlaps with the gloss-matt pattern portion 32 in a plan view. As a result, the visibility of the gloss-matt pattern portion 32 using black ink can be reduced, and the influence of the gloss-matt pattern portion 32, which is useful in the manufacturing process of the decorative sheet 12, on the appearance of the decorative sheet 12 can be suppressed. As a result, a highly aesthetic decorative sheet 12 can be obtained in which the pattern of the main pattern layer 5b and the embossed portion 7a are in sync. [Examples]

[0067] (Example 1) A laminate was created comprising: a colored thermoplastic resin layer 2 made of a 50 μm thick PBT layer; a pattern layer 5 made of a pattern portion 3 for producing a gloss-matt finish, which is pattern-printed with black ink made of urethane-based printing ink, and a pattern portion 5a for producing a non-gloss-matt finish, which is formed adjacent to the gloss-matt finish portion 3 and uses urethane-based printing ink; a transparent thermoplastic resin layer 6 made of a 38 μm thick PP layer; and a surface protection layer 7 mainly composed of an acrylic resin composition. The transparent thermoplastic resin layer 6 was formed by laminating it onto the pattern layer 5. After forming the surface protective layer 7, the laminate was heated with an infrared heater, and then an embossed portion 7a was formed by pressing an embossing roll against the surface protective layer 7. A primer layer 8 was then formed to obtain the decorative sheet 1 shown in Figure 1.

[0068] (Example 2) A laminate was created consisting of a colored thermoplastic resin layer 2 made of a 50 μm thick PBT layer, a main pattern layer 5b formed using a urethane-based ink, a gloss-matt pattern section 31 with a transparent ink containing an infrared-absorbing material that was pattern-printed, a transparent thermoplastic resin layer 6 made of a 38 μm thick PP layer, and a surface protection layer 7 mainly composed of an acrylic resin composition. The transparent thermoplastic resin layer 6 was formed by laminating it onto the main pattern layer 5b, and after forming the surface protection layer 7, the laminate was heated with an infrared heater, and then an embossed section 7a was formed by pressing an embossing roll against the surface protection layer 7, and then a primer layer 8 was formed to obtain the decorative sheet 11 shown in Figure 3.

[0069] (Example 3) A laminate was created by laminating a colored thermoplastic resin layer 2, which consists of a 50 μm thick PBT layer, a main pattern layer 5b made of urethane-based printing ink, a transparent thermoplastic resin layer 6 made of a 38 μm thick PP layer, and a surface protection layer 7 mainly composed of an acrylic resin composition, in this order, onto one side of the colored thermoplastic resin layer 2. The transparent thermoplastic resin layer 6 was formed by laminating it onto the main pattern layer 5b. Furthermore, a pattern of black ink made of urethane-based printing ink was printed onto the other surface of the colored thermoplastic resin layer 2 to form a gloss-matt pattern portion 32, and a primer layer 8 was formed on the colored thermoplastic resin layer 2 including this gloss-matt pattern portion 32 to obtain a laminate. After forming the primer layer 8, the laminate was heated with an infrared heater, and then an embossed portion 7a was formed by pressing an embossing roll against the surface protective layer 7, thereby obtaining the decorative sheet 12 shown in Figure 5.

[0070] (Comparative Example 1) A colored thermoplastic resin layer 2 consisting of a 50 μm thick PBT layer was prepared as the base material, and a sheet consisting only of the base material was obtained. Furthermore, as an embodiment corresponding to a sub-concept of Example 2, we obtained the decorative sheet 11 shown in Examples 4 to 9.

[0071] (Example 4) Except for using lanthanum hexaboride (LaB6) as an infrared absorbing material to form the gloss matte pattern 31, the decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2 above. (Example 5) The decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2, except that a transparent ink made of a urethane-based printing ink containing cesium-doped tungsten oxide (CWO, manufactured by Sumitomo Metal Mining Co., Ltd.) as an infrared-absorbing material was used to form the pattern portion 31 for gloss-matt appearance.

[0072] (Example 6) The decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2, except that a transparent ink made of a urethane-based printing ink using antimond-doped tin oxide (ATO) as an infrared-absorbing material was used to form the pattern portion 31 for producing a glossy matte finish. (Example 7) The decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2, except that a transparent ink consisting of a urethane-based printing ink using tin-doped indium oxide (ITO) as an infrared-absorbing material was used to form the pattern portion 31 for producing a glossy matte finish.

[0073] (Example 8) The decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2, except that a transparent ink made of a urethane-based printing ink using the near-infrared absorbing material OPTLION (manufactured by Toyo Visual Solutions Co., Ltd.) was used as the infrared absorbing material to form the pattern portion 31 for gloss matte appearance. (Example 9) The decorative sheet 11 shown in Figure 3 was obtained in the same manner as in Example 2, except that a transparent ink made of urethane-based printing ink using the infrared absorbing material EX-Color series (manufactured by Nippon Shokubai Co., Ltd.) was used as the infrared absorbing material to form the pattern portion 31 for gloss matte appearance.

[0074] 〔evaluation〕 The infrared transmittance was measured for each decorative sheet from Examples 1 to 9 and the raw material from Comparative Example 1. The infrared transmittance was measured by the method described below. For each decorative sheet from Examples 1 to 9 and the raw material of Comparative Example 1, the color difference, gloss level, and gloss level difference were obtained. The method used for obtaining these values ​​is described below. The results are shown in Tables 1 and 2.

[0075] [Infrared transmittance measurement] Infrared transmittance was measured for the decorative sheets of Examples 1 to 9 and the raw material of Comparative Example 1, each with different image density levels. Specifically, an ultraviolet-visible spectrophotometer UV3600 manufactured by SHIMADZU was used to measure the infrared transmittance at a wavelength of 2000 nm. [Color difference measurement] Based on the infrared transmittance measurement results, the color difference was measured between the decorative sheets of Examples 1 to 9 and the raw material of Comparative Example 1. Specifically, the color difference ΔE relative to the standard plate was calculated using a Konica Minolta Japan CR-400 color difference meter.

[0076] [Glossiness measurement] For the decorative sheets of Examples 1 to 9, the surface protective layer 7 after embossing was measured for specular gloss at an incident angle of 85° using a micro-TRI-gloss manufactured by BYK. The specular gloss of the raw material of Comparative Example 1 was measured using the same procedure. [Difference in gloss level] The difference between the gloss level of each decorative sheet from Examples 1 to 9, measured by gloss measurement, and the gloss level of the raw material from Comparative Example 1 was calculated. The difference in gloss level was used to confirm whether or not a gloss-matte finish was achieved.

[0077] [Table 1]

[0078] [Table 2]

[0079] 〔result〕 In all of Examples 1 to 9, although there were slight differences in glossiness, the difference in glossiness from the original material was around 5. In other words, in all of the examples, the decorative sheet with the embossed portion 7a formed on it had a glossiness difference of around 5, satisfying the glossiness difference of 3 that is generally noticeable, thus confirming that a gloss-matte finish can be obtained. Furthermore, in Examples 2 to 9, the color difference from the standard sheet was kept low, indicating that the pattern portion for creating the gloss-matte finish could not be easily seen. [Explanation of symbols]

[0080] 1, 11, 12 Decorative sheets 2 Colored thermoplastic resin layer 3, 31, 32 Handle section for gloss matte finish 4. Concealing solid layer 5, 51, 52 Image layers 5a Handle for non-gloss matte finish 5b Main image layer 5c pattern layer 6 Transparent thermoplastic resin layer 7 Surface protective layer 7a Embossed area 8. Primer layer 8a Pattern layer

Claims

1. A method for manufacturing a decorative sheet comprising a base layer, a pattern layer, a transparent resin layer, and a surface protective layer, wherein the decorative sheet has an embossed shape that is in harmony with the pattern of the pattern layer, The process of forming the pattern layer, A step of laminating the transparent resin layer and the surface protective layer on the pattern layer in this order, A step of forming a gloss matte pattern portion, which is provided at a position synchronized with the pattern on the pattern layer and is made of black ink having a greater infrared absorption effect than the transparent resin layer, The process of irradiating with infrared light after the process of laminating the transparent resin layer and the surface protective layer and the process of forming the gloss matte pattern portion, The process of irradiating with infrared light, followed by the process of pressing the embossing plate for forming the embossed shape onto the surface protective layer to form the embossed shape, A method for manufacturing decorative sheets, characterized by comprising the following features.

2. The method for manufacturing a decorative sheet according to Claim 1, characterized in that the black ink contains carbon black.

3. The method for manufacturing a decorative sheet according to claim 1 or 2, characterized in that the pattern portion for creating a glossy matte finish is formed on the side of the pattern layer opposite to the side on which the transparent resin layer is provided.

4. A base layer and The pattern layer, A transparent resin layer and a surface protective layer are laminated in this order on top of the aforementioned pattern layer, A gloss matte pattern portion is provided in a position that is synchronized with the pattern on the pattern on the pattern on any of the upper layer, the middle layer, or the layer below the pattern, and is made of black ink that has a greater infrared absorption effect than the transparent resin layer, A decorative sheet characterized by comprising an embossed shape formed on the surface protective layer at a position that overlaps with the gloss-matt pattern portion in a plan view.

5. The decorative sheet according to claim 4, characterized in that the gloss matte pattern portion is provided on the side of the pattern layer opposite to the side on which the transparent resin layer is provided.

Images