Decorative sheet, decorative member, and method for producing decorative sheet

Abstract

Provided are: a decorative sheet in which deterioration in physical properties can be significantly inhibited even when a recycled material is applied to a resin material; a decorative member; and a method for producing the decorative sheet. In a decorative sheet (10), a colored resin layer (11) which is made of a polyolefin resin having a light-blocking property, a pattern layer (12) on which a pattern has been formed, and a transparent resin layer (14) which is made of a polyolefin resin having a light-transmitting property are layered in the stated order. The decorative sheet is characterized in that: the colored resin layer (11) is a mixture of a virgin resin raw material and a recycled resin raw material; and the proportion of the recycled resin raw material to the resin raw material obtained by mixing the virgin resin raw material and the recycled resin raw material is 10-80 mass%.

Description

Cosmetic sheet, cosmetic member, and method for manufacturing a cosmetic sheet

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

[0002] Cosmetic sheets for decorating the surfaces of the interior and exterior of buildings, furniture, household appliances, etc. have a structure in which various resin layers are laminated. Virgin materials are usually applied to the resin materials constituting such cosmetic sheets, but in recent years, recycled materials have begun to be applied in consideration of the environment.

[0003] Japanese Patent Application Laid-Open No. 10-180920

[0004] However, in a cosmetic sheet in which a recycled material is applied to a resin material, the physical properties such as hardness may be reduced. For this reason, an object of the present invention is to provide a cosmetic sheet, a cosmetic member, and a method for manufacturing a cosmetic sheet that can greatly suppress a decrease in physical properties even when a recycled material is applied to a resin material.

[0005] The cosmetic sheet according to the present invention for solving the above-described problems is a cosmetic sheet in which a colored resin layer made of a polyolefin resin having light-shielding properties, a pattern layer on which a pattern is formed, and a transparent resin layer made of a polyolefin resin having light-transmitting properties are laminated in this order. The colored resin layer is a mixture of a virgin resin raw material and a recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material obtained by mixing the virgin resin raw material and the recycled resin raw material is 10% by mass or more and 80% by mass or less.

[0006] Further, the cosmetic sheet according to the present invention is preferably the above-described cosmetic sheet in which the polyolefin resin of the colored resin layer is a polyethylene resin or a polypropylene resin.

[0007] Furthermore, in the decorative sheet according to the present invention, the transparent resin layer is preferably a mixture of virgin resin raw material and recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material mixed with the virgin resin raw material is 10% by mass or more and 80% by mass or less.

[0008] Furthermore, in the decorative sheet according to the present invention, it is preferable that the polyolefin resin in the transparent resin layer is polyethylene resin or polypropylene resin.

[0009] Furthermore, in the decorative sheet according to the present invention, it is preferable that the proportion of the recycled resin raw material in the colored resin layer and the transparent resin layer to the total is 10% by mass or more and 80% by mass or less.

[0010] On the other hand, the decorative member according to the present invention is characterized by comprising a base material and the above-mentioned decorative sheet attached to the base material.

[0011] Furthermore, the method for manufacturing a decorative sheet according to the present invention is the method for manufacturing a decorative sheet as described above, characterized by comprising: a colored resin layer forming step of mixing the virgin resin raw material and the recycled resin raw material of the polyolefin resin and mixing a coloring agent to form the colored resin layer such that the content of the recycled resin raw material of the polyolefin resin in the colored resin layer is 10% by mass or more and 80% by mass or less; a pattern layer forming step of providing the pattern layer on the colored resin layer; and a transparent resin layer forming step of providing the transparent resin layer with the pattern layer interposed between it and the colored resin layer.

[0012] Furthermore, in the method for manufacturing a decorative sheet according to the present invention, it is preferable that the transparent resin layer formation step is a step of mixing the virgin resin raw material of the polyolefin resin and the recycled resin raw material so that the content of recycled resin raw material of the polyolefin resin in the transparent resin layer is 10% by mass or more and 80% by mass or less, thereby forming and providing the transparent resin layer.

[0013] Furthermore, in the method for manufacturing a decorative sheet according to the present invention, it is preferable that the colored resin layer forming step and the transparent resin layer forming step are steps in which the recycled resin raw material of the polyolefin resin and the virgin resin raw material are mixed, respectively, so that the proportion of the recycled resin raw material of the colored resin layer and the transparent resin layer in the entire decorative sheet is 10% by mass or more and 80% by mass or less.

[0014] According to the present invention, since the colored resin layer contains 10% to 80% by mass of recycled resin raw materials, even when recycled materials are applied to the resin material, the deterioration of physical properties can be significantly suppressed.

[0015] This is a cross-sectional view showing the schematic configuration of the main embodiment of a decorative member that utilizes a decorative sheet according to the present invention.

[0016] Embodiments of the decorative sheet, decorative member, and method for manufacturing the decorative sheet according to the present invention will be described with reference to the drawings. It should be noted that the present invention is not limited to the embodiments described below with reference to the drawings, and various technical matters described in each embodiment can be combined or replaced as needed.

[0017] [Main Embodiments] Embodiments of the decorative sheet, decorative member, and method for manufacturing the decorative sheet according to the present invention will be described with reference to Figure 1.

[0018] <Overall structure of the decorative sheet> As shown in Figure 1, a pattern layer 12 is provided on a colored resin layer 11 containing a coloring agent to have light-shielding properties. A light-transmitting transparent resin layer 14 is provided on the pattern layer 12 via a light-transmitting transparent adhesive layer 13. A light-transmitting transparent surface protection layer 15 is provided on the transparent resin layer 14. A base layer 16 is provided on the back surface (bottom surface in Figure 1) of the colored resin layer 11.

[0019] In other words, the colored resin layer 11, the pattern layer 12, and the transparent resin layer 14 are laminated in this order. In Figure 1, 10a is an embossed surface with a raised and recessed shape. In this embodiment, the decorative sheet 10 is composed of these layers 11 to 16, etc.

[0020] <Colored resin layer 11> The colored resin layer 11 is a layer for providing opacity, and is a polyolefin resin containing a coloring agent such as an organic pigment or an inorganic pigment. The polyolefin resin is preferably polyethylene resin or polypropylene resin. As the coloring agent, inorganic pigments are preferred, and examples include calcium carbonate, titanium dioxide, carbon black, silica, chromium, antimony, titanium composites, and various other oxides.

[0021] The colored resin layer 11 may contain various additives as needed, such as fillers, ultraviolet absorbers, light stabilizers, heat stabilizers, antioxidants, antistatic agents, lubricants, flame retardants, antibacterial agents, antifungal agents, friction reducers, light scattering agents, and gloss adjusters. The colored resin layer 11 preferably has a thickness of 0.1 μm or more and 10 μm or less.

[0022] The colored resin layer 11 is made of polyolefin resin, which is a mixture of virgin resin raw materials and recycled resin raw materials. Here, virgin resin raw materials are resin raw materials newly manufactured from fossil fuels and have no history of use such as molding or processing. On the other hand, recycled resin raw materials have a history of use such as molding or processing, and are collected and recycled to be manufactured again as resin raw materials.

[0023] The recycled resin raw materials mentioned above can be divided into post-industrial recycled (PIR) resin raw materials and post-consumer recycled (PCR) resin raw materials. PIR resin raw materials are manufactured by recovering so-called "waste materials" that were used in molding and processing at molding plants, etc., but were discarded during the manufacturing process and did not circulate in the consumer market as products, and then recycling them to produce new resin raw materials. PCR resin raw materials are manufactured by recovering resin products that have been circulated and used in the consumer market, and then recycling them to produce new resin raw materials.

[0024] Since PIR resin raw materials are recovered from factories and other sources and recycled, their origin can be clearly identified, and processability and quality can be relatively easily guaranteed compared to PCR resin raw materials. Since PCR resin raw materials are recovered from the consumer market and recycled, they can contribute significantly to reducing the environmental burden compared to PIR resin raw materials. In the decorative sheet 10 according to this embodiment, both PIR resin raw materials and PCR resin raw materials can be used as recycled resin raw materials for the colored resin layer 11, but considering that it will be used for a relatively long period of time, it is preferable to use PIR resin raw materials.

[0025] The colored resin layer 11 has a ratio of recycled resin material to a resin material mixture of virgin resin material of 10% by mass or more and 80% by mass or less. If the ratio is less than 10% by mass, the reliance on petroleum becomes too high, and if it exceeds 80% by mass, it tends to cause a decrease in physical properties such as surface hardness and processability.

[0026] <Pattern Layer 12> The pattern layer 12 is a layer for providing design elements and is formed from printing ink or the like. Such printing ink is obtained, for example, by dissolving or dispersing a coloring agent such as a pigment or dye together with a binder resin in a suitable diluting solvent.

[0027] Examples of pigments include condensed azo, insoluble azo, quinacridone, isoindoline, anthraquinone, imidazolon, cobalt, phthalocyanine, carbon, titanium dioxide, iron oxide, mica, and other pearl pigments. Examples of binder resins include urethane resins, acrylic resins, vinyl chloride acetate resins, polyimide resins, nitrated cotton, and mixtures thereof.

[0028] The pattern layer 12 can exhibit various functions by containing functional additives such as extender pigments, plasticizers, dispersants, surfactants, tackifiers, adhesion aids, drying agents, curing agents, curing accelerators, and curing retarders. Any pattern can be applied to the pattern layer 12, such as wood grain patterns, stone patterns, fabric patterns, abstract patterns, geometric patterns, letters, symbols, solid colors, or combinations thereof.

[0029] The pattern layer 12 preferably has a thickness in the range of 0.1 μm to 10 μm. Such a pattern layer 12 can be formed, for example, by printing a pattern with printing ink using various printing methods such as gravure printing or offset printing.

[0030] <Transparent Adhesive Layer 13> The transparent adhesive layer 13 adheres the pattern layer 12 to the transparent resin layer 14 and has transparency such as colorless, colored, or semi-transparent so that the pattern layer 12 can be seen. Transparent adhesives made of resin such as urethane, acrylic, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer, polyester, and polyolefin are used for the transparent adhesive layer 13. Preferably, the thickness of the transparent adhesive layer 13 is 30 μm or more and 100 μm or less.

[0031] <Transparent Resin Layer 14> The transparent resin layer 14 is made of polyolefin resin containing an ultraviolet absorber (UVA) and a light stabilizer (HALS), and has transparency such as colorless, colored, or semi-transparent, allowing the pattern layer 12 to be seen. The polyolefin resin is preferably polyethylene resin or polypropylene resin. Examples of UVA include triazine-based and benzophenone-based types. Examples of HALS include N-OR type hindered amine-based types.

[0032] Examples of triazine compounds include 2-(4,6-diphenyl-1,3,5-triazine-2-yl)-5-[(hexyl)oxy]-phenol, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2,4-bis(2,4-dimethylphenyl)-6-(2-hydroxy-4-isooctyloxyphenyl)-s-triazine, and mixtures, modified products, polymers, and derivatives thereof.

[0033] Examples of benzophenone compounds include octabenzone, its modified products, polymers, and derivatives.

[0034] Examples of hindered amines include bis(2,2,6,6-tetramethyl-1-(octyloxy)-4-piperidinyl) decandioate and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidine-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine.

[0035] The transparent resin layer 14 preferably contains 0.1% to 5% by mass of UVA and 0.1% to 5% by mass of HALS based on its total mass. The transparent resin layer 14 preferably has a thickness of 30 μm to 100 μm.

[0036] The transparent resin layer 14, like the colored resin layer 11, is made of polyolefin resin mixed from virgin resin raw materials and recycled resin raw materials. In the decorative sheet 10 according to this embodiment, both PIR resin raw materials and PCR resin raw materials can be used as the recycled resin raw materials for the transparent resin layer 14, but considering that it will be used for a relatively long period of time, it is preferable to use PIR resin raw materials.

[0037] The transparent resin layer 14 has a ratio of recycled resin material to the resin material, which is a mixture of virgin resin material and recycled resin material, of 10% by mass or more and 80% by mass or less. If it is less than 10% by mass, the reliance on petroleum becomes too high, and if it exceeds 80% by mass, it tends to cause a decrease in physical properties such as surface hardness and processability, which is undesirable.

[0038] <Surface Protection Layer 15> The surface protection layer 15 is a layer for protecting the surface and has transparency such as colorless, colored, or semi-transparent so that the pattern layer 12 can be seen. The surface protection layer 15 is made of a resin material such as polyester resin, acrylic resin, or fluororesin, and contains weather-resistant additives such as UVA, HALS, and antioxidants. Examples of UVA include triazine-based and benzophenone-based UVA as described above. Examples of HALS include hindered amine-based UVA as described above. Examples of antioxidants include hindered phenol-based UVA.

[0039] Examples of hindered phenols include pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and 2,2-thiodiethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate].

[0040] The surface protective layer 15 preferably contains 0.1% to 5% by mass of UVA and 0.1% to 5% by mass of HALS based on its total mass. The surface protective layer 15 preferably has a thickness of 0.1 μm to 10 μm.

[0041] <Base layer 16> The base layer 16 is a layer for protecting the colored resin layer 11 and improving the adhesion to the substrate, and is composed of a known resin paint for base, etc. containing epoxy resin, polyester resin, urethane resin, melamine resin, alkyd resin, phenol resin, acrylic resin, etc. The base layer 16 can be formed, for example, by applying a resin paint by various coating methods such as the roll coating method. The base layer 16 preferably has a thickness of 0.1 μm or more and 10 μm or less.

[0042] <Decorative sheet 10> And in the decorative sheet 10, the proportion of the mass of the recycled resin raw material of the colored resin layer 11 and the transparent resin layer 14 in the total mass is 10% by mass or more and 80% by mass or less. If it is less than 10% by mass, the oil dependence will be high, and if it exceeds 80% by mass, it will easily cause deterioration of physical properties such as surface hardness and workability, which is not preferable.

[0043] <Overall configuration of the decorative member> As shown in FIG. 1, in the decorative sheet 10, the base layer 16 is attached on the substrate 101 via the adhesive layer 102. In this embodiment, the decorative member 100 is constituted by such a substrate 101, adhesive layer 102, decorative sheet 10, etc.

[0044] <Substrate 101> As the material of the substrate 101, metal-based materials such as steel plates and aluminum plates, wood-based materials such as wood veneers, plywood, laminated wood, particle boards, hard fiber boards, medium density fiber boards (MDF), etc., resin-based materials such as PVC resin, etc. can be applied.

[0045] <Adhesive layer 102> For the adhesive layer 102, for example, adhesives such as urethane-based, acrylic-based, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer-based, polyester-based, etc. can be applied. In particular, a two-component curing type urethane-based adhesive obtained by blending polyester polyol and polyisocyanate is preferable.

[0046] <Manufacturing method of the decorative sheet 10 and the decorative member 100> Next, the manufacturing method of the decorative sheet 10 and the decorative member 100 according to the present embodiment as described above will be explained.

[0047] First, a virgin resin raw material of a polyolefin resin such as a polyethylene resin or a polypropylene resin and a recycled resin raw material are mixed, and a resin material mixed with a colorant and various additives is heated and melted and extruded into a film shape to obtain a colored resin layer 11 (colored resin layer forming step). At this time, the mixing amount of the recycled resin raw material is adjusted so that the content of the recycled resin raw material of the polyolefin resin in the colored resin layer 11 is 10% by mass or more and 80% by mass or less.

[0048] Then, a pattern layer 12 is provided on the colored resin layer 11 by printing a pattern with printing ink (pattern layer forming step). On the other hand, a base layer 16 is provided on the back surface of the colored resin layer 11 by applying a resin paint (base layer forming step).

[0049] Also, a virgin resin raw material of a polyolefin resin such as a polyethylene resin or a polypropylene resin and a recycled resin raw material are mixed, and while a resin material mixed with various additives is heated and melted and extruded into a film shape, an embossing plate is pressed to obtain a transparent resin layer 14 having an emboss 10a on the surface. At this time, the mixing amount of the recycled resin raw material is adjusted so that the content of the recycled resin raw material of the polyolefin resin in the transparent resin layer 14 is 10% by mass or more and 80% by mass or less.

[0050] Then, after a transparent adhesive made of resin is applied on the pattern layer 12 to provide a transparent adhesive layer 13, the transparent resin layer 14 is superposed and adhered on the transparent adhesive layer 13, so that the transparent resin layer 14 is provided so as to interpose the pattern layer 12 between the transparent resin layer 14 and the colored resin layer 11 (transparent resin layer forming step). Finally, a liquid obtained by mixing a polyester resin, an acrylic resin, a fluorine resin, etc. and a weather-resistant additive, etc. in a solvent is applied on the transparent resin layer 14 and dried and cured to provide a surface protection layer 15 having an emboss 10a on the surface (surface protection layer forming step).

[0051] In the colored resin layer formation process and the transparent resin layer formation process, recycled polyolefin resin raw materials are mixed in such a way that the proportion of recycled resin raw materials in the colored resin layer 11 and the transparent resin layer 14 to the entire decorative sheet 10 is between 10% by mass and 80% by mass. The decorative sheet 10 according to this embodiment is manufactured in this manner.

[0052] Next, an adhesive layer 102 is formed by applying an adhesive to the base layer 16 of the decorative sheet 10, and then the decorative sheet 10 is attached to the base material 101 by bonding it to the adhesive layer 102. In this manner, the decorative member 100 according to this embodiment is manufactured.

[0053] <Effects> In the decorative sheet 10 and decorative member 100 according to this embodiment, although the colored resin layer 11 contains 10% to 80% by mass of recycled resin raw materials, the physical properties such as hardness and bendability can be made to the same level as when only virgin resin raw materials are used (see [Examples] below for details).

[0054] Therefore, according to this embodiment, even when recycled materials are applied to the resin material, the deterioration of physical properties can be significantly suppressed.

[0055] Furthermore, even though the transparent resin layer 14 contains 10% to 80% by mass of recycled resin raw materials, its physical properties such as hardness can be made to be at the same level as when only virgin resin raw materials are used. Therefore, it is possible to increase the amount of recycled material used while significantly suppressing the deterioration of physical properties.

[0056] Furthermore, since the proportion of recycled resin raw materials in the colored resin layer 11 and the transparent resin layer 14 to the entire decorative sheet 10 is between 10% by mass and 80% by mass, it is possible to reliably suppress a significant decrease in physical properties even when recycled materials are applied to the resin material.

[0057] [Other Embodiments] In the embodiments described above, the case of a decorative sheet 10 and decorative member 100 provided with a surface protective layer 15 was explained, but the present invention is not limited thereto. In other embodiments, for example, depending on the conditions of the environment in which it is used, it is also possible to provide a decorative sheet and decorative member in which the surface protective layer 15 is omitted.

[0058] Furthermore, although the above-described embodiment described the case of a decorative sheet 10 and decorative member 100 provided with a base layer 16, the present invention is not limited to this. In other embodiments, for example, depending on conditions such as the type of base material 101 and adhesive layer 102, it is also possible to provide a decorative sheet and decorative member in which the base layer 16 is omitted.

[0059] Furthermore, while the above-described embodiment described a case of a so-called dry laminate decorative sheet 10 and decorative member 100 in which the pattern layer 12 and the transparent resin layer 14 are bonded together with a transparent adhesive layer 13, the present invention is not limited to this. As another embodiment, for example, a resin material is prepared by mixing virgin resin raw material and recycled resin raw material of polyolefin resin, along with various additives, and then heating and melting the resin material and extruding it into a film shape while directly laminating and bonding the transparent resin layer 14 onto the pattern layer 12 on the colored resin layer 11. In other words, it is also possible to omit the transparent adhesive layer 13 and use a so-called extruded laminate decorative sheet and decorative member in which the pattern layer 12 and the transparent resin layer 14 are joined together.

[0060] Examples of the decorative sheet, decorative component, and method for manufacturing the decorative sheet according to the present invention will be described in detail. However, the present invention is not limited to the following examples described in detail.

[0061] [Preparation of Reference Specimens and Test Specimens] <Reference Specimen> A colored resin layer (60 μm thick) is obtained by mixing additives (UVA and HALS) with virgin polypropylene resin raw material in the proportions shown below, along with a coloring agent, heating and melting, and extruding into a film shape (colored resin layer formation step).

[0062] 《Colored Resin Layer》 ・UVA: 0.25% by mass of "Chinubin (registered trademark) 326 (product number)" manufactured by BASF Japan Co., Ltd. ・HALS: 0.5% by mass of "Chinubin (registered trademark) XT55 (product number)" manufactured by BASF Japan Co., Ltd.

[0063] Then, a pattern layer is created by applying corona discharge treatment to one side of the colored resin layer and then printing a pattern using a printing ink with a urethane resin binder (pattern layer formation process). On the other hand, a base layer is created by applying corona discharge treatment to the other side of the colored resin layer and then coating it with a urethane resin paint (base layer formation process).

[0064] Furthermore, a transparent resin layer (60 μm thick) is obtained by mixing a virgin resin raw material of transparent polypropylene resin with additives (UVA and HALS) in the proportions shown below, heating and melting the mixture, and extruding it into a film shape.

[0065] 《Transparent Resin Layer》 ・Polypropylene resin 99% by mass ・UVA BASF Japan Co., Ltd. "Chinubin (registered trademark) 326 (product number)" 0.5% by mass ・HALS BASF Japan Co., Ltd. "Chinubin (registered trademark) XT55 (product number)" 0.5% by mass

[0066] Then, a transparent adhesive made of acrylic resin is applied to the pattern layer (5 g / m²). ２ - After drying to create a transparent adhesive layer, a transparent resin layer is layered on top of the transparent adhesive layer and bonded, thereby creating a transparent resin layer with a pattern layer interposed between it and the colored resin layer (transparent resin layer formation step).

[0067] Next, a solution is prepared by mixing a two-component curing acrylic resin (main component and hardener) and additives (UVA and HALS) in the solvent (ethyl acetate) in the proportions shown below, and then coating the transparent resin layer (6 g / m²). ２ - A surface protective layer is formed by drying and curing (surface protective layer formation step). In this way, a standard specimen of the decorative sheet was prepared.

[0068] Surface protective layer: • Two-component curing acrylic resin 90% by mass Main component: Methyl methacrylate (80) / Cyclohexyl methacrylate (20) 90% by mass Hardener: Mitsui Chemicals, Inc. "Takenate (registered trademark) D170 (product number)" 10% by mass • UVA BASF Japan Co., Ltd. "Chinubin (registered trademark) 329 (product number)" 6% by mass • HALS BASF Japan Co., Ltd. "Chinubin (registered trademark) 292 (product number)" 4% by mass

[0069] Then, a two-component curing adhesive "BA-10L" (with hardener "BA-11B") manufactured by Japan Coating Resin Co., Ltd. was applied to the base layer of the standard body to form an adhesive layer, and then the decorative sheet was attached by bonding it to the wood-based substrate MDF. In this way, the standard body for the decorative component was manufactured.

[0070] <Test Specimen 1> Test specimen 1 of a decorative sheet (recycled resin material as a percentage of the total: 5% by mass) and a decorative component was prepared under the same conditions as the standard specimen, except that the colored resin layer was adjusted to contain 10% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0071] <Test Specimen 2> Test specimen 2 of a decorative sheet (recycled resin material as a percentage of the total: 20% by mass) and a decorative component was prepared under the same conditions as the standard specimen, except that the colored resin layer was adjusted to contain 40% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0072] <Test Specimen 3> Test specimen 3 of a decorative sheet (recycled resin material as a percentage of the total: 30% by mass) and a decorative component was prepared under the same conditions as the reference specimen, except that the colored resin layer was adjusted to contain 60% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0073] <Test Specimen 4> Test specimen 4 of a decorative sheet (recycled resin material as a percentage of the total: 40% by mass) and a decorative component was prepared under the same conditions as the reference specimen, except that the colored resin layer was adjusted to contain 80% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0074] <Test Specimen 5> Test specimen 5 of a decorative sheet (recycled resin material as a percentage of the total: 45% by mass) and a decorative component was prepared under the same conditions as the reference specimen, except that the colored resin layer was adjusted to contain 90% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0075] <Test Specimen 6> Test specimen 6 of a decorative sheet (recycled resin material as a percentage of the total: 35% by mass) and a decorative component was prepared under the same conditions as test specimen 3, except that the transparent resin layer was adjusted to contain 10% by mass of recycled polypropylene resin used in packaging materials.

[0076] <Test Specimen 7> Test specimen 7 of a decorative sheet (recycled resin material as a percentage of the total: 50% by mass) and a decorative component was prepared under the same conditions as Test Specimen 3, except that the transparent resin layer was adjusted to contain 40% by mass of recycled polypropylene resin used in packaging materials.

[0077] <Test Specimen 8> Test specimen 8 of a decorative sheet (recycled resin material as the whole: 70% by mass) and a decorative component was prepared under the same conditions as Test Specimen 3, except that the transparent resin layer was adjusted to contain 80% by mass of recycled resin raw material from polypropylene resin used in packaging materials.

[0078] [Evaluation Method] <Recyclability> The recyclingability (mass %) of recycled resin raw materials in the entire decorative sheet was evaluated for the standard sample and test samples 1 to 8. The results are shown in Table 1 below. The recyclingability was marked "○" when the mass % of recycled resin raw materials in the entire decorative sheet was 20% or more and 100% or less, "△" when it was 5% or more and less than 20%, and "×" when it was 0% or more and less than 5%.

[0079] <Scratch Hardness (Pencil Method) Test> A scratch hardness (pencil method) test was performed on the reference specimen and test specimens 1-8 of the decorative material in accordance with the Japanese Industrial Standard (JIS) "K 5600-5-4". Briefly, a pencil scratch test machine (Yoshimitsu Seiki Co., Ltd. "C221A (model number)") was used to press a pencil against the reference specimen and test specimens 1-8 of the decorative material, and the hardness of the pencil was gradually increased until a scratch occurred. The hardness of the pencil just before a scratch (gouge) occurred was determined. The results are shown in Table 1. A "○" indicates that the hardness was equal to or greater than that of the reference specimen, and a "×" indicates that the hardness was less than that of the reference specimen.

[0080] [Evaluation Results] The evaluation results are shown in Table 1 below.

[0081]

[0082] As can be seen from Table 1, in test specimen 5, where the recycled resin raw material content of the colored resin layer exceeded 80% by mass, a decrease in scratch hardness occurred, resulting in an overall evaluation of "× (unacceptable)". On the other hand, in test specimen 1, where the recycled resin raw material content of the colored resin layer was 10% by mass, the overall recycling rate was low, resulting in an overall evaluation of "△ (suitable for practical use)".

[0083] In contrast, test specimens 2-4, in which the recycled resin raw material content of the colored resin layer was between 10% and 80% by mass, and test specimens 6-8, in which the recycled resin raw material content of the transparent resin layer was also between 10% and 80% by mass, showed "○ (good)" results for both the degree of recycling and scratch hardness, resulting in an overall evaluation of "○ (good)".

[0084] Based on the above, the effects of the present invention have been confirmed.

[0085] Furthermore, for example, the present invention can take the following configurations: (1) A decorative sheet in which a colored resin layer made of light-shielding polyolefin resin, a pattern layer on which a pattern is formed, and a transparent resin layer made of light-transmitting polyolefin resin are laminated in this order, wherein the colored resin layer is a mixture of virgin resin raw material and recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material mixed with the virgin resin raw material is 10% by mass or more and 80% by mass or less. (2) The decorative sheet according to (1) above, wherein the polyolefin resin of the colored resin layer is polyethylene resin or polypropylene resin. (3) The decorative sheet according to (1) or (2) above, wherein the transparent resin layer is a mixture of virgin resin raw material and recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material mixed with the virgin resin raw material is 10% by mass or more and 80% by mass or less. (4) The decorative sheet according to any one of (1) to (3) above, characterized in that the polyolefin resin in the transparent resin layer is polyethylene resin or polypropylene resin. (5) The decorative sheet according to any one of (1) to (4) above, characterized in that the recycled resin raw material in the colored resin layer and the transparent resin layer accounts for 10% by mass or more and 80% by mass or less of the total. (6) A decorative member comprising a base material and a decorative sheet according to any one of (1) to (5) above attached to the base material. (7) A method for manufacturing a decorative sheet according to any one of (1) to (5) above, comprising: a colored resin layer forming step of mixing the virgin resin raw material of the polyolefin resin and the recycled resin raw material and a coloring agent to form the colored resin layer such that the content of the recycled resin raw material of the polyolefin resin in the colored resin layer is 10% by mass or more and 80% by mass or less; a pattern layer forming step of providing the pattern layer on the colored resin layer; and a transparent resin layer forming step of providing the transparent resin layer with the pattern layer interposed between it and the colored resin layer.(8) The method for manufacturing a decorative sheet according to (7) above, characterized in that the transparent resin layer forming step is a step of forming and providing the transparent resin layer by mixing the virgin resin raw material of the polyolefin resin and the recycled resin raw material so that the content of the recycled resin raw material of the polyolefin resin in the transparent resin layer is 10% by mass or more and 80% by mass or less. (9) The method for manufacturing a decorative sheet according to (7) or (8) above, characterized in that the colored resin layer forming step and the transparent resin layer forming step are steps of mixing the recycled resin raw material of the polyolefin resin and the virgin resin raw material, respectively, so that the proportion of the recycled resin raw material in the colored resin layer and the transparent resin layer in the entire decorative sheet is 10% by mass or more and 80% by mass or less.

[0086] This invention can significantly suppress the deterioration of physical properties even when recycled materials are applied to resin materials, and therefore can be used very effectively in various industries.

[0087] 10 Decorative sheet 10a Embossing 11 Colored resin layer 12 Pattern layer 13 Transparent adhesive layer 14 Transparent resin layer 15 Surface protection layer 16 Underlayment layer 100 Decorative component 101 Base material 102 Adhesive layer

Claims

1. A decorative sheet comprising a colored resin layer made of light-shielding polyolefin resin, a patterned layer on which a pattern is formed, and a transparent resin layer made of light-transmitting polyolefin resin, laminated in this order, wherein the colored resin layer is a mixture of virgin resin raw material and recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material mixed with the virgin resin raw material is 10% by mass or more and 80% by mass or less.

2. The decorative sheet according to claim 1, characterized in that the polyolefin resin in the colored resin layer is polyethylene resin or polypropylene resin.

3. The decorative sheet according to claim 1, characterized in that the transparent resin layer is a mixture of virgin resin raw material and recycled resin raw material, and the ratio of the recycled resin raw material to the resin raw material mixed with the virgin resin raw material is 10% by mass or more and 80% by mass or less.

4. The decorative sheet according to claim 1, characterized in that the polyolefin resin in the transparent resin layer is polyethylene resin or polypropylene resin.

5. The decorative sheet according to claim 3, characterized in that the recycled resin raw material in the colored resin layer and the transparent resin layer accounts for 10% by mass or more and 80% by mass or less of the total.

6. A decorative member comprising a base material and a decorative sheet according to any one of claims 1 to 5 attached to the base material.

7. A method for manufacturing a decorative sheet according to claim 1, comprising: a colored resin layer forming step of mixing the virgin resin raw material of the polyolefin resin and the recycled resin raw material, and mixing a coloring agent, so that the content of the recycled resin raw material of the polyolefin resin in the colored resin layer is 10% by mass or more and 80% by mass or less, and forming the colored resin layer; a pattern layer forming step of providing the pattern layer on the colored resin layer; and a transparent resin layer forming step of providing the transparent resin layer with the pattern layer interposed between it and the colored resin layer.

8. The method for manufacturing a decorative sheet according to claim 7, characterized in that the transparent resin layer forming step is a step of forming and providing the transparent resin layer by mixing the virgin resin raw material of the polyolefin resin and the recycled resin raw material such that the content of recycled resin raw material of the polyolefin resin in the transparent resin layer is 10% by mass or more and 80% by mass or less.

9. The method for manufacturing a decorative sheet according to claim 8, characterized in that the colored resin layer forming step and the transparent resin layer forming step are steps of mixing the recycled resin raw material and the virgin resin raw material of the polyolefin resin, respectively, such that the proportion of the recycled resin raw material in the colored resin layer and the transparent resin layer to the entire decorative sheet is 10% by mass or more and 80% by mass or less.

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