Decorative sheet and method for manufacturing same

Abstract

A decorative sheet (1) comprises: a light-transmissive skin layer (3); an intermediate layer (4) disposed on the back side of the skin layer (3); and a design layer (5) disposed on the back side of the intermediate layer (4) and having a design region (50) which is decorated with a predetermined design. The skin layer (3) has a display region (30) in which the design is displayed through light that is emitted from the back side of the design region (50). The design region (50), when viewed from the front side, is disposed over the entire surface of the display region (30) without a gap, and has higher light transmittance than the intermediate layer (4).

Description

Decorative sheet and manufacturing method thereof

[0001] The present disclosure relates to a decorative sheet used in, for example, vehicle interior components, and a method for manufacturing the same.

[0002] In the field of vehicle interiors, development is progressing on decorative sheets that can switch designs visible from inside the vehicle cabin by turning on and off a backlight. For example, Patent Document 1 discloses a display device that includes a surface protective layer, a pattern layer and a gap, a substrate, a light-adjusting sheet, a light-emitting display (display), and a display control device. The surface protective layer, the pattern layer and the gap, the substrate, the light-adjusting sheet, and the light-emitting display are layered in the same order from the front side (inside the vehicle cabin) to the back side. The display control device is arranged separately from these components.

[0003] The surface protection layer is colorless and transparent. A pattern such as a wood grain vessel pattern or a marble pattern is printed on the pattern layer. The pattern layer is printed on the surface of the substrate. The voids are juxtaposed to the pattern layer. The voids correspond to the portions of the substrate surface where the pattern layer is not printed.

[0004] The display control device can adjust the light transmittance of the light-controlling sheet depending on whether the light-emitting display body is turned on or off. Specifically, the display control device can adjust the light transmittance of the light-controlling sheet so that light is transmitted when the light-emitting display body is turned on and so that light is not transmitted when the light-emitting display body is turned off.

[0005] Japanese Patent Application Laid-Open No. 2021-162723

[0006] In the display device of this document, a light-controlling sheet is essential. Furthermore, the light transmittance of the light-controlling sheet must be adjusted by a display control device. This results in a complex layer structure and electrical configuration. Furthermore, in the display device of this document, when the light-emitting display body is turned on, the pattern layer and the void portion, which are arranged side by side, work together to display the desired design on the surface of the surface protection layer.

[0007] Here, the pattern layer and the void are laminated directly behind the surface protective layer without any other layers in between. The pattern layer has low light transmittance, while the void has high light transmittance. This results in a pronounced contrast, making the boundary between the pattern layer and the void clear. Therefore, when the light-emitting display is turned off, the pattern layer and the void may be visible through the surface of the surface protective layer.

[0008] Therefore, the present disclosure aims to provide a decorative sheet and a manufacturing method thereof that has a simple layer structure and electrical structure and that can prevent the design area of ​​the design layer from being visible through the surface of the skin layer when the backlight is turned off.

[0009] (1) In order to solve the above problem, the decorative sheet of the present disclosure is a decorative sheet comprising a light-transmitting surface layer, an intermediate layer arranged on the back side of the surface layer, and a design layer arranged on the back side of the intermediate layer and having a design area on which a predetermined design is drawn, wherein the surface layer has a display area in which the design is displayed by light irradiated onto the design area from the back side, and the design area is arranged without gaps across the entire display area when viewed from the front side, and has higher light transmittance than the intermediate layer.

[0010] With this configuration, components for adjusting the light transmittance of the layer (for example, the display control device or dimming sheet in Patent Document 1) are not required. This simplifies the layer configuration and electrical configuration. Furthermore, the design area of ​​the design layer is arranged without gaps across the entire display area when viewed from the front side. Therefore, there is no boundary between the design portion and gaps in the design area. This makes it possible to prevent the design area of ​​the design layer from being visible through the surface of the skin layer when the backlight is turned off.

[0011] Let's assume that the design layer has lower light transmittance than the intermediate layer. In this case, the intermediate layer becomes more transparent than the design layer. Therefore, when the backlight is turned off, light passes through the intermediate layer and the design area of ​​the design layer is easily visible on the surface of the skin layer.

[0012] In this respect, with this configuration, the design layer has higher light transmittance than the intermediate layer, making the intermediate layer less transparent than the design layer. Therefore, when the backlight is turned off, light can be prevented from passing through the intermediate layer and appearing as if the design area of ​​the design layer is visible on the surface of the skin layer.

[0013] (1-1) In the above configuration (1), it is preferable that the skin layer has an uneven surface. With this configuration, when the backlight is off, external light can be diffused between the unevenness of the uneven surface. This makes it possible to blur the boundary of the design area of ​​the design layer (for example, if the design area of ​​the design layer has a wood grain pattern, the area where the wood grain has a distinct shade). This makes it possible to prevent the boundary of the design area from being visible through the surface of the skin layer.

[0014] (1-2) In the above-mentioned configuration (1), the design layer is preferably a printed layer on which a predetermined pattern is formed by printing. With this configuration, the variation in the thickness of the design layer can be suppressed compared to when the design layer is a coating film, for example. In addition, the thickness of the design layer can be prevented from becoming excessively thick.

[0015] (2) In the configuration described in (1) above, it is preferable that the visible light transmittance of the intermediate layer be 3% or more and 50% or less. In this disclosure, "visible light" refers to electromagnetic waves in a wavelength range that is perceived as light by the human eye. The wavelength range of visible light is, for example, 360 nm or more and 830 nm or less. Furthermore, "visible light transmittance" τ refers to the percentage of visible light that passes through a sample (e.g., an intermediate layer, a design layer, etc.). The visible light transmittance τ (%) is expressed as (I / I) × 100, where I0 is the luminous intensity of incident light and I is the luminous intensity of light that has passed through the sample. This configuration improves the visibility of the design in the design region when the backlight is on, compared to when the visible light transmittance is less than 3%. Furthermore, compared to when the visible light transmittance is more than 50%, it is possible to suppress the design in the design region from being visible through the surface of the skin layer when the backlight is off.

[0016] (3) In the configuration of (1) above, it is preferable that the visible light transmittance of the design area is 5% or more and 90% or less. This configuration can prevent the design in the design area from being visible through the surface of the skin layer when the backlight is off, compared to when the visible light transmittance is less than 5%. Furthermore, compared to when the visible light transmittance is more than 90%, it can improve the visibility of the design in the design area when the backlight is on.

[0017] (4) In the configuration of (1), it is preferable to configure the backlight to be disposed in the interior of the vehicle. With this configuration, by switching the backlight on and off, it is possible to give the interior design a dual-faceted look.

[0018] (5) In order to solve the above-mentioned problems, the manufacturing method of the decorative sheet of the present disclosure is a decorative sheet comprising a light-transmitting surface layer, an intermediate layer arranged on the back side of the surface layer, and a design layer arranged on the back side of the intermediate layer and having a design area on which a predetermined design is drawn, wherein the surface layer has a display area in which the design is displayed by light irradiated onto the design area from the back side, and the design area is arranged without gaps over the entire display area when viewed from the front side, and has higher light transmittance than the intermediate layer, characterized by comprising an intermediate layer printing step of printing the intermediate layer on the back side of the surface layer, and a design layer printing step of printing the design layer on the back side of the intermediate layer.

[0019] This configuration can suppress variations in the thickness of the intermediate layer compared to when the intermediate layer is a coating, for example. It can also suppress excessive thickness of the intermediate layer. The decorative layer has the same effect as the intermediate layer. It can also suppress misalignment in the layer direction (layer expansion direction, a direction intersecting the stacking direction) between the three layers (skin layer, intermediate layer, and decorative layer).

[0020] The decorative sheet and manufacturing method thereof of the present disclosure simplify the layer structure and electrical configuration, and also prevent the design area of ​​the design layer from being visible through the surface of the skin layer when the backlight is turned off.

[0021] Fig. 1 is a partial perspective view of a door trim in which a decorative sheet of a first embodiment is arranged. Fig. 2 is a perspective view of the inside of a frame II in Fig. 1. Fig. 3 is an exploded perspective view of the inside of a frame II in Fig. 1. Fig. 4 is a cross-sectional view in the direction IV-IV in Fig. 2. Fig. 5 is a partial cross-sectional view in the front-back direction of a decorative sheet of a second embodiment. Fig. 6 is a partial cross-sectional view in the front-back direction of a decorative sheet of a third embodiment.

[0022] Hereinafter, embodiments of the decorative sheet and the manufacturing method thereof according to the present disclosure will be described.

[0023] <First embodiment> Fig. 1 shows a partial perspective view of a door trim on which a decorative sheet of this embodiment is arranged. Fig. 2 shows a perspective view of the inside of a frame II in Fig. 1. Fig. 3 shows an exploded perspective view of the inside of a frame II in Fig. 1. Fig. 4 shows a cross-sectional view (cross-sectional view from the front to the back) taken along the line IV-IV in Fig. 2.

[0024] (Arrangement and configuration of decorative sheet) First, the arrangement and configuration of the decorative sheet of this embodiment will be described. As shown in FIG. 1 , the decorative sheet 1 is arranged on a door trim 9 in the vehicle interior. The door trim 9 is included in the concept of "interior member" in this disclosure. As shown in FIGS. 1 to 4 , the door trim 9 includes the decorative sheet 1 and a light source unit 8. The decorative sheet 1 and the light source unit 8 are layered in this order from the front side (upper side, inside the vehicle interior) to the back side (lower side, outside the vehicle interior).

[0025] As shown in Figures 3 and 4, the decorative sheet 1 comprises, from the front side to the back side, a skin layer 3, an intermediate layer 4, and a design layer 5. As shown in Figure 1, the surface (top surface) of the skin layer 3 is exposed to the interior of the vehicle. The skin layer 3 is made of synthetic leather and has a layered structure. The skin layer 3 is light-transmitting and flexible. The skin layer 3 comprises a display area 30 and a grained portion (concave and convex portion) 31 on its surface. The grained portion 31 is disposed over the entire surface of the skin layer 3. Light is irradiated onto the design area 50 (described later) from a light source unit 8 on the back side. The light causes the wood grain pattern of the design area 50 to be displayed in the display area 30.

[0026] The intermediate layer 4 is disposed on the back side of the surface layer 3. The intermediate layer 4 is made of light-transmitting ink and has a layered shape. The intermediate layer 4 is light-transmitting and flexible. The intermediate layer 4 has lower light transmittance than the surface layer 3. The intermediate layer 4 is semi-transparent with a smoky color. The intermediate layer 4 is colored and transparent.

[0027] The design layer 5 is disposed on the back side of the intermediate layer 4. The design layer 5 is made of light-transmitting ink and is layered. The design layer 5 is light-transmitting and flexible. The design layer 5 is more light-transmitting than the intermediate layer 4. The design layer 5 is colored and transparent. The design layer 5 has a design area 50 that displays a wood grain pattern when viewed from the front side. The wood grain pattern is included in the concept of "predetermined design" in this disclosure. When viewed from the front side, the design area 50, the display area 30, and the light source unit 8 overlap. When viewed from the front side, the design area 50 is disposed without gaps across the entire surface of the display area 30.

[0028] The light source unit 8 is disposed on the back side of the design layer 5 of the decorative sheet 1. The light source unit 8 includes a plurality of light sources (LEDs) 80. The plurality of light sources 80 are distributed throughout the layer-wise direction (layer expansion direction; direction intersecting the stacking direction; surface direction) of the light source unit 8. The surface of the light source unit 8 is capable of emitting light from the entire surface. Light from the light sources 80 reaches the surface of the door trim 9 via the design layer 5, intermediate layer 4, and skin layer 3.

[0029] (Function of Decorative Sheet) Next, the function of the decorative sheet of this embodiment will be described. When the light source unit 8 is off, the light source 80 is turned off. In other words, the backlight for the decorative sheet 1 is turned off. Here, the light transmittance of each layer is set in descending order of increasing transparency as follows: skin layer 3 (most transparent), design layer 5, and intermediate layer 4 (least transparent). For this reason, it is difficult for a user to view the design area 50 of the design layer 5 from the front side of the decorative sheet 1 (inside the vehicle cabin). Furthermore, it is easy for a user to view the three-dimensional shape of the grained portion 31 of the display area 30 of the skin layer 3 and the color of the intermediate layer 4 together from the front side of the decorative sheet 1 (inside the vehicle cabin).

[0030] When the light source unit 8 is on, the light source 80 is lit. In other words, the backlight for the decorative sheet 1 is lit. By first passing through the design layer 5 closest to the light source unit 8, the light from the light source unit 8 preferentially displays the color scheme of the design area 50 (i.e., the wood grain pattern), making it easier for the user to see the wood grain pattern. In this way, the decorative sheet 1 can display two types of designs in the display area 30 depending on whether the light source unit 8 is on or off.

[0031] (Method of Manufacturing Decorative Sheet) Next, a method of manufacturing the decorative sheet of this embodiment will be described. The method of manufacturing the decorative sheet 1 includes an intermediate layer printing step and a design layer printing step. This manufacturing method is carried out with the decorative sheet 1 shown in FIGS. 1 to 4 turned upside down. In the intermediate layer printing step, an intermediate layer 4 is printed on the back surface (top surface) of the skin layer 3 with the grained portion 31 using a silk screen printer. If the intermediate layer 4 has a multi-layer structure (for example, a structure having a top layer (transparent layer) and a back layer (colored layer)), each layer is printed in order. In the design layer printing step, a design layer 5 is printed on the back surface (top surface) of the intermediate layer 4 using a silk screen printer. If the design layer 5 has a multi-layer structure (for example, a structure in which multiple layers are stacked to form a wood grain pattern when viewed from the front), each layer is printed in order.

[0032] (Effects) Next, the effects of the decorative sheet of this embodiment and its manufacturing method will be described. The decorative sheet 1 of this embodiment does not require components for adjusting the light transmittance of the intermediate layer 4 or the design layer 5 (for example, the display control device or light-adjusting sheet described in Patent Document 1). This simplifies the layer structure and electrical configuration. Furthermore, the design area 50 of the design layer 5 is disposed without gaps across the entire display area 30 when viewed from the front side. Therefore, there is no boundary between the design portion (wood grain pattern portion) and gaps in the design area 50. This prevents the design area 50 of the design layer 5 from being visible through the surface of the skin layer 3 when the backlight (light source unit 8) is turned off.

[0033] Let us assume that the design layer 5 has lower light transmittance than the intermediate layer 4. In this case, the intermediate layer 4 becomes more transparent than the design layer 5. Therefore, when the backlight is turned off, the design area 50 (i.e., the wood grain pattern) of the design layer 5 is likely to be visible through the intermediate layer 4 and on the surface of the skin layer 3.

[0034] In this regard, in the decorative sheet 1 of this embodiment, the design layer 5 has higher light transmittance than the intermediate layer 4. Therefore, the intermediate layer 4 is less transparent than the design layer 5. Therefore, when the backlight is turned off, it is possible to prevent the design area 50 of the design layer 5 from being transmitted through the intermediate layer 4 and being visible on the surface of the skin layer 3.

[0035] The surface of the skin layer 3 has a textured portion 31. Therefore, when the backlight is off, external light can be diffused between the irregularities of the textured portion 31. This makes it possible to blur the boundary of the design area 50 of the design layer 5 (the portion where the wood grain pattern of the design area 50 has a distinct shading of wood grain). This makes it possible to prevent the boundary of the design area 50 from being visible through the surface of the skin layer 3. The skin layer 3 is colorless and transparent, and has higher light transmittance than the design layer 5 and the intermediate layer 4. Therefore, the textured portion 31 is mainly visible when the backlight is off.

[0036] The design layer 5 is a printed layer with a wood grain pattern formed by printing. Therefore, compared to when the design layer 5 is a coating or the like, it is possible to suppress variations in the thickness (thickness in the front-to-back direction) of the design layer 5. In addition, it is possible to suppress the thickness of the design layer 5 from becoming excessively thick.

[0037] The visible light transmittance of the intermediate layer 4 is 8%. That is, the visible light transmittance of the intermediate layer 4 is in the range of 3% to 50%. Therefore, compared to when the visible light transmittance is less than 3%, the visibility of the wood grain pattern in the design area 50 when the backlight is on can be improved. Also, compared to when the visible light transmittance is more than 50%, the visibility of the wood grain pattern in the design area 50 when the backlight is off can be reduced. The method for measuring visible light transmittance will be described below. First, in a dark room with no lighting, a LED light source (luminance 3000 cd / m ２The sample is placed on the sample holder and the LED light source is turned on. Next, the luminous intensity of the incident light, I0, and the luminous intensity of the light that has passed through the sample, I, are measured using a color luminance meter (manufactured by Konica Minolta, Inc., model number CS-160) at a position 1000 mm away from the measurement point of the sample (a circular portion with a diameter of approximately 4 mm). Thereafter, the visible light transmittance is calculated from the measurement results using the formula: visible light transmittance τ (%) = (I / I0) × 100.

[0038] The visible light transmittance of the design area 50 (measured using the above-described measurement method) is 55%. That is, the visible light transmittance of the design area 50 is in the range of 5% to 90%. Therefore, compared to when the visible light transmittance is less than 5%, the design of the design area 50 is less likely to be visible through the surface of the skin layer 3 when the backlight is off. Furthermore, compared to when the visible light transmittance is more than 90%, the visibility of the design of the design area 50 when the backlight is on is improved.

[0039] The decorative sheet 1 is disposed on the door trim 9. Therefore, by switching the backlight on and off, it is possible to give the door trim 9 a dual-faceted design and texture. Specifically, when the light source unit 8 is off, a leather-like design can be displayed on the door trim 9, and when the light source unit 8 is on, a wood-grain-like design can be displayed on the door trim 9.

[0040] The manufacturing method of the decorative sheet 1 includes an intermediate layer printing step and a design layer printing step. Therefore, compared to when the intermediate layer 4 is a coating, for example, the variation in the thickness of the intermediate layer 4 can be suppressed. Also, the thickness of the intermediate layer 4 can be prevented from becoming excessively thick. The design layer 5 has the same effect as the intermediate layer 4. Also, the positional deviation in the layer direction between the three layers (skin layer 3, intermediate layer 4, and design layer 5) can be suppressed.

[0041] Second Embodiment The decorative sheet and manufacturing method thereof of this embodiment differ from the decorative sheet and manufacturing method thereof of the first embodiment in that a flexible layer is additionally disposed. Here, only this difference will be described.

[0042] Figure 5 shows a partial cross-sectional view of the decorative sheet of this embodiment in the front-to-back direction. Note that parts corresponding to those in Figure 4 are indicated by the same reference numerals. As shown in Figure 5, a flexible layer 6 is interposed between the design layer 5 and the light source unit 8. The flexible layer 6 is disposed on the back side of the design layer 5. The flexible layer 6 is made of a thermoplastic elastomer and has flexibility, light transparency, and light diffusion properties. Light from the light source 80 is diffused in the layer-wise direction by the flexible layer 6. As a result, the entire surface of the flexible layer 6 emits light.

[0043] The decorative sheet and manufacturing method thereof of this embodiment and the decorative sheet and manufacturing method thereof of the first embodiment have similar effects in common parts of the configuration. The decorative sheet 1 of this embodiment includes a flexible layer 6. This ensures flexibility when a user touches the door trim 9 (see FIG. 1). Furthermore, the light from the light source 80 can be diffused along the layer. This allows the light source unit 8 to emit light evenly across the entire surface when viewed from the front side.

[0044] Third Embodiment The decorative sheet and manufacturing method thereof of this embodiment differ from the decorative sheet and manufacturing method thereof of the second embodiment in that a base layer is additionally disposed. Here, only this difference will be described.

[0045] Fig. 6 shows a partial cross-sectional view of the decorative sheet of this embodiment taken from the front and back. The same reference numerals are used to denote portions corresponding to those in Fig. 5. As shown in Fig. 6, a base layer 7 is interposed between the flexible layer 6 and the light source unit 8. The base layer 7 is disposed on the back side of the flexible layer 6. The base layer 7 is made of resin and is light-transmitting and flexible.

[0046] The decorative sheet and manufacturing method thereof of this embodiment and the decorative sheet and manufacturing method thereof of the second embodiment have similar effects in terms of the common configuration. The decorative sheet 1 of this embodiment includes a base layer 7. The base layer 7 is harder than the other layers (skin layer 3, intermediate layer 4, design layer 5, and flexible layer 6). This ensures the shape retention of the decorative sheet 1.

[0047] <Others> The decorative sheet and the manufacturing method thereof according to the present disclosure have been described above. However, the embodiments are not limited to the above-described embodiments. Various modifications and improvements that can be made by those skilled in the art are also possible.

[0048] (Configuration) The configuration of the area other than the design area 50 of the design layer 5 is not particularly limited. The area other than the design area 50 may be arranged without gaps across the entire area other than the display area 30 when viewed from the front side. Furthermore, gaps (voids, recesses, etc.) may be arranged in the area other than the design area 50.

[0049] There are no particular limitations on the number, position, size, shape, etc. of the display area 30 and the design area 50. There are no particular limitations on the layer structure of each layer (skin layer 3, intermediate layer 4, design layer 5, flexible layer 6, and base layer 7). They may have a single-layer structure or a multi-layer structure. Another layer may be interposed between two adjacent layers in the front-to-back direction (excluding the flexible layer 6 and base layer 7). Furthermore, another layer may be disposed on the front side of the skin layer 3.

[0050] There are no particular limitations on the area of ​​each layer when viewed from the front side. For example, when viewed from the front side, the intermediate layer 4 and the design layer 5 may be disposed on a portion of the skin layer 3. When viewed from the front side, the design layer 5 may be disposed on a portion of the intermediate layer 4. When viewed from the front side, the intermediate layer 4 may be disposed on a portion of the design layer 5.

[0051] The positions and number of light sources 80 in the light source unit 8 are not particularly limited. A single light source 80 may include multiple LEDs. In this case, the colors of the multiple LEDs may be different. For example, if a single light source 80 includes three LEDs of red, green, and blue, it can emit white light in addition to red, green, and blue.

[0052] The design of the design area 50 of the design layer 5 is not particularly limited. Preferably, the design should be different from the design (color, etc.) of the intermediate layer 4. This makes it easier to give the design displayed in the display area 30 a dual-faceted appearance depending on whether the backlight is on or off.

[0053] Examples of designs for the design area 50 include designs that include one or more of the following: patterns (wood grain, marble, stone wall, polka dots, stripes, checkerboard patterns, etc.), characters (alphabet, hiragana, katakana, kanji, numbers, braille, etc.), shapes (polygons, circles, etc.), and symbols (buttons for operating devices, icons indicating the status of devices, etc.).

[0054] The color of the design displayed in the display area 30 of the skin layer 3 may be a single color or multiple colors. The color may be expressed in the display area 30 by one or more selected from each layer and the light source unit 8. The light transmittance of each layer is not particularly limited. It may be colored transparent, translucent, or the like. The color (hue, saturation, brightness) of each layer and the light source 80 is not particularly limited. The skin layer 3 does not need to have an uneven portion such as a grained portion 31. The surface of the skin layer 3 may be, for example, a smooth surface.

[0055] There are no particular limitations on the brightness of the light source 80. There are no particular limitations on the type, number, or location of the light source 80. The light source 80 may be an organic EL sheet, an inorganic EL sheet, a phosphorescent sheet, or the like. Furthermore, the light source unit 8 may include the light source 80 and a light guide plate (e.g., an acrylic plate).

[0056] The type of interior member on which the decorative sheet 1 is to be disposed is not particularly limited. Examples include door trim 9, seats, armrests, floors, ceilings, instrument panels, glove boxes, steering wheels, center consoles, and cash registers. The surface of the interior member (the surface of the skin layer 3) may be flat or curved. The orientation of the interior member (the orientation of the front and back directions of the decorative sheet 1) is not particularly limited. That is, the front and back direction may be vertical, horizontal, or a direction intersecting the vertical and horizontal directions. The decorative sheet 1 may also be disposed in interior members of transportation equipment other than vehicles (such as motorcycles, ships, and aircraft) and buildings (such as buildings and houses). The decorative sheet 1 may also be disposed in exterior members (such as the exterior walls of transportation equipment and buildings).

[0057] (Regarding Materials) The material of the skin layer 3 is not particularly limited. Examples include synthetic leather, resin, elastomer, nonwoven fabric, and various fabrics (woven fabrics, knitted fabrics, etc.). Specific examples of synthetic leather, resin, and elastomer include acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. Examples of nonwoven fabric and various fabrics include polyester, polypropylene, nylon, and cotton. The skin layer 3 may contain a colorant (such as colored polyethylene), a light diffusing agent (such as silicone, acrylic, or titanium oxide), or a light absorbing agent (such as titanium black or carbon black).

[0058] There are no particular limitations on the material of the intermediate layer 4. Examples include resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. The intermediate layer 4 may contain the aforementioned colorant, light diffusing agent, and light absorbing agent.

[0059] There are no particular limitations on the material of the design layer 5. Examples include resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. The design layer 5 may contain the aforementioned colorants, light diffusing agents, and light absorbing agents.

[0060] There are no particular limitations on the material of the flexible layer 6. Examples include elastomers such as styrene-based thermoplastic elastomers, olefin-based thermoplastic elastomers, and dynamically crosslinked thermoplastic elastomers, and foams such as polyurethane foam.

[0061] There are no particular limitations on the material of the base layer 7. Examples include resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer.

[0062] When each layer has light diffusibility, the method for imparting the light diffusibility is not particularly limited. For example, a light diffusing agent (such as silicone, acrylic, or titanium oxide) having a refractive index different from that of a transparent base material may be dispersed in the base material.

[0063] The method for laminating each layer is not particularly limited. Screen printing (such as silk screen printing), gravure printing, inkjet printing, flexographic printing, etc. may be used. Furthermore, each layer may be laminated by adhesion, pressure bonding, pasting, vapor deposition, welding, painting, etc. Another film-like layer (such as the design layer 5) may be adhered to the back surface of any layer (such as the intermediate layer 4). Furthermore, another layer (such as the intermediate layer 4) may be painted on the back surface of any layer (such as the skin layer 3).

[0064] 1: Decorative sheet, 3: Skin layer, 30: Display area, 31: Textured portion, 4: Intermediate layer, 5: Design layer, 50: Design area, 6: Flexible layer, 7: Base layer, 8: Light source portion, 80: Light source, 9: Door trim (interior member)

Claims

1. A decorative sheet comprising a light-transmissive epidermal layer, an intermediate layer disposed on the back side of the epidermal layer, and a design layer disposed on the back side of the intermediate layer and having a design region with a predetermined design, wherein the epidermal layer has a display region where the design is displayed by light irradiated from the back side to the design region, the design region is disposed without gaps across the entire surface of the display region when viewed from the front side, and has a higher light transmittance than the intermediate layer.

2. The decorative sheet according to claim 1, wherein the visible light transmittance of the intermediate layer is 3% or more and 50% or less.

3. The decorative sheet according to claim 1, wherein the visible light transmittance of the design region is 5% or more and 90% or less.

4. The decorative sheet according to claim 1, which is disposed on an interior member of a vehicle.

5. A method for manufacturing a decorative sheet, which comprises a light-transmissive epidermal layer, an intermediate layer disposed on the back side of the epidermal layer, and a design layer disposed on the back side of the intermediate layer and having a design region with a predetermined design, wherein the epidermal layer has a display region where the design is displayed by light irradiated from the back side to the design region, the design region is disposed without gaps across the entire surface of the display region when viewed from the front side, and has a higher light transmittance than the intermediate layer, the method comprising an intermediate layer printing step of printing the intermediate layer on the back surface of the epidermal layer, and a design layer printing step of printing the design layer on the back surface of the intermediate layer.

Images