JP2003181990A - Decorative sheet with irregular pattern and method for manufacturing the sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet with an irregular pattern which shows a hardly damageable microirregular pattern and a feel of bulkiness/heftiness. <P>SOLUTION: A transparent irregular layer 12 having a microirregular shape is at least laminated on the back of a transparent base material sheet 11 showing a three-dimensional workability, and the microirregular shape of the transparent irregular layer 12 is not exposed on the surface of the decorative sheet 10 with an irregular pattern. The transparent irregular layer 12 after the decorative sheet 10 is stretched to the elongation of 200% in the longitudinal direction and the crosswise direction under an atmosphere at 110°C by a tensile test base on the Japan Industrial Standard (JIS) C2318, indicates the microirregular shape with the irregularity width of 0.2 to 200 μm and the irregularity depth of 0.10 to 10 μm. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concavo-convex pattern decorative sheet used for decorating resin molded products such as building materials, interior / exterior parts for automobiles, parts for home electric appliances, parts for mobile phones and a method for producing the same. Is.

[0002]

2. Description of the Related Art Conventionally, a transparent release layer, a metal thin film layer, and a transparent release layer are formed on an uneven surface of a substrate sheet having a fine uneven surface.
There was a transfer material in which an adhesive layer and the like were sequentially formed. When the adhesive layer side of the transfer material having such a constitution is brought into close contact with the resin molded product and heated and pressed, the base sheet is peeled off from the release layer and removed. It is possible to give fine irregularities such as a hairline pattern, a spin pattern, a matte pattern, and a knurled pattern to the surface of the molded product by copying.

[0003]

However, there is a problem in that scratches are apt to stand out in such a pattern having fine irregularities formed on the surface of the release layer. That is, when an uneven shape is formed along a certain direction such as a hairline pattern and a scratch is generated in a direction different from this direction, the scratch becomes very noticeable. Further, even if the scratches are formed such that only the peaks of the convex portions of the fine concavo-convex shape are crushed, it seems that the scratches are larger than the actual crushing condition of the vertices.

Further, since the transfer material has a small thickness of each layer and the peeling layer located above the metal thin film layer is thin, there is a problem that only a decoration without a sense of solidity can be obtained.

Therefore, it is conceivable to further coat the transparent resin after the transfer processing to increase the surface strength of the molded product and form a transparent layer having a large thickness, but the uneven surface shape of the peeling layer is buried. As a result, the sharpness of the pattern expressed by the uneven surface shape is lost, and the pattern disappears.

Therefore, it is an object of the present invention to solve the above problems, and to provide an uneven pattern decorative sheet which is less likely to be scratched by a fine uneven pattern and has a heavy feeling, and a manufacturing method thereof.

[0007]

In order to achieve the above-mentioned object, the uneven-patterned decorative sheet of the present invention is constructed as follows.

That is, in the uneven pattern decorative sheet of the present invention, a transparent uneven layer having a fine uneven shape is laminated at least on the back side of a transparent substrate sheet having three-dimensional processability,
A finely rugged pattern of the transparent rugged layer is a rugged-pattern-decorated sheet which is not exposed on the surface of the rugged-pattern-decorated sheet.
In a tensile test based on Japanese Industrial Standards (JIS) C2318 under an atmosphere, the uneven pattern decorative sheet is stretched in the longitudinal direction and the transverse direction to an elongation of 200% each, and then the transparent uneven layer has an uneven width of 0.2 to 200 μm and a depth. 0.10-10μ
It was configured to have a fine uneven shape of m.

Further, in the above invention, the transparent uneven layer of the uneven pattern-decorating sheet before the tensile test based on Japanese Industrial Standard (JIS) C2318 in an atmosphere of 110 ° C. has a width of unevenness of 0.15 to 150 μm and a depth. 0.15-1
You may comprise so that it may have a fine uneven shape of 5 μm.

Further, in the above invention, an adhesive layer may be laminated on the rearmost surface side of the relief-patterned decorative sheet.

In the above invention, the glitter layer may be formed on the back side of the transparent uneven layer so as to contact the transparent uneven layer.

In addition, the method for producing a relief-patterned decorative sheet according to the present invention comprises:
A transparent concavo-convex layer is formed by adhering the transparent layer side of a transfer material provided with at least a transparent layer to the concavo-convex surface of a base sheet having a fine concavo-convex surface, and peeling and removing the base sheet from the transparent layer. Then, by forming at least an adhesive layer on the transparent uneven layer, the above-mentioned uneven pattern decorative sheet was obtained.

Further, the transparent layer side of the transfer material having at least the transparent layer provided on the uneven surface of the base sheet having the fine uneven surface is adhered onto the transparent base sheet having three-dimensional processability to form the base sheet. A transparent uneven layer is formed by peeling and removing the transparent layer, and then the uneven pattern decorative sheet is obtained by forming at least a glitter layer and an adhesive layer on the transparent uneven layer. Configured.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing an embodiment of a corrugated decorative sheet of the present invention. FIG. 2 is a cross-sectional view showing an embodiment of a transfer material used in the method for producing a concavo-convex pattern decorative sheet of the present invention. FIG. 3 is a sectional view showing the uneven width and the uneven depth of the transparent uneven layer of the uneven decorative sheet of the present invention. 4 to 5 are cross-sectional views showing the steps for producing an uneven pattern molded product using the uneven pattern decorative sheet of the present invention. FIG. 6 is a cross-sectional view showing an example of an uneven pattern molded product that can be obtained using the uneven pattern decorative sheet of the present invention. In the figure, 10 is a decorative sheet, 11 is a base sheet, 12 is a transparent uneven layer, 13 is a glitter layer, 14 is an adhesive layer, 20 is a transfer material, 21 is a base sheet, 22 is a transparent layer, and 23. Is an adhesive layer, 30 is an uneven pattern molded product, 31 is a mold, and 32 is a molding resin.

In the decorative pattern decorative sheet 10 of the present invention, the transparent uneven layer 12 having a fine uneven shape is laminated at least on the back side of the transparent base sheet 11 having a three-dimensional processability, and the fine uneven surface of the transparent uneven layer 12 is formed. The shape is not exposed on the surface of the uneven decorative sheet 10, and the uneven decorative sheet 10 is subjected to a tensile test based on Japanese Industrial Standard (JIS) C2318 in an atmosphere of 110 ° C. in the longitudinal direction and the lateral direction, respectively. After stretching to an elongation of 200%, the transparent concavo-convex layer 12 has a concavo-convex width of 0.2 to 200 μm and a depth of 0.10 to 10.
It has a fine concavo-convex shape of 10 μm (see FIG. 1).

The concavo-convex pattern decorative sheet 10 having such a structure
In order to obtain the above, it is preferable to use the transfer material 20. As the transfer material 20, a material in which at least a transparent layer 22 is formed on a base sheet 21 having an uneven surface is used (see FIG. 2).

As the material for the base sheet 21, polypropylene base resin, polyethylene base resin, polyamide base resin, polyester base resin, acrylic base resin, polyvinyl chloride base resin, etc., which are used as base base sheets for ordinary transfer materials, can be used. Can be used.

Fine irregularities are formed on the surface of the base sheet 21. By peeling the base sheet 21 in a later step, the fine irregularities of the base sheet 21 are copied onto the transparent layer 22 and fine irregularities such as a hairline pattern, a spin pattern, a matte pattern, and a knurled pattern can be expressed. it can.

As a method for forming fine irregularities on the surface of the base sheet 21, wire brush, sandpaper,
Base sheet 2 by rubbing with steel wool, etc.
There is a film excavation method that scratches the surface of 1. In addition, there is a matting agent kneading method in which a matting agent is kneaded into a material of a base sheet original material, and the matting agent is made into a sheet and is raised to the surface to make unevenness. Further, there is a matting agent coating method in which an ink mixed with a resin, a matting agent and a solvent is coated on the base sheet 21, and after the solvent is dried, the matting agent is raised on the surface of the resin to make unevenness. Further, there is a pressing method in which a base sheet 21 made of a thermoplastic resin is pressed by a concave-convex type by applying pressure while applying heat near or above the softening point and the unevenness is copied on the surface by the embossing principle.

When the releasability of the base sheet 21 from the transparent layer 22 is good, the transparent layer 22 may be directly provided on the base sheet 21. In order to improve the releasability of the base sheet 21 from the transparent layer 22, the transparent layer 22 is formed on the base sheet 21.
A release layer (not shown) may be formed on the entire surface before the step of providing. The release layer is removed from the transparent layer 22 together with the base sheet 21 when the base sheet 21 is peeled off after the transfer. The material of the release layer, melamine resin-based release agent, silicone resin-based release agent, fluororesin-based release agent, cellulose derivative-based release agent, urea resin-based release agent, polyolefin resin-based release agent, A paraffin-based release agent and a composite release agent of these may be used. Examples of the method for forming the release layer include a coating method such as a roll coating method and a spray coating method, and a printing method such as a gravure printing method and a screen printing method.

The transparent layer 22 is wholly or partially formed on the base sheet 21 or the release layer. The transparent layer 22 is
When the base sheet 21 is peeled off after transfer, the base sheet 2
The fine concavo-convex shape 1 is copied to form the transparent concavo-convex layer 12. Examples of the material of the transparent layer 22 include acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and vinyl chloride-vinyl acetate copolymer. Copolymers such as a system resin and an ethylene-vinyl acetate copolymer system resin may be used. When hardness is required, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. The transparent layer 22 may be colored or uncolored. As a method of forming the transparent layer 22, there are a coating method such as a gravure coating method, a roll coating method and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

A pattern layer (not shown) may be formed if necessary. As the material of the pattern layer, polyvinyl resin, polyamide resin, polyester resin, acrylic resin, polyurethane resin, polyvinyl acetal resin, polyester urethane resin, cellulose ester resin, alkyd resin, etc. are used as binders. It is preferable to use a colored ink containing a pigment or dye of an appropriate color as a colorant. As a method of forming the pattern layer, a normal printing method such as a gravure printing method, a screen printing method and an offset printing method may be used. In particular, offset printing and gravure printing are suitable for multicolor printing and gradation expression. Further, in the case of a single color, a coating method such as a gravure coating method, a roll coating method or a comma coating method can be adopted.

If desired, the adhesive layer 23 may be formed. As the adhesive layer 23, a heat-sensitive or pressure-sensitive resin suitable for the material of the base material sheet 11 which is the transfer target is appropriately used. For example, when the material of the base material sheet 11 is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin may be used. When the material of the base material sheet 11 is acrylic resin, acrylic resin can be used. As a method for forming the adhesive layer 23, there are a coating method such as a gravure coating method, a roll coating method and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

The transparent uneven layer 12 is formed on the base material sheet 11 using the transfer material 20 having such a layer structure. For that purpose, first, the transparent layer 22 side of the transfer material 20 is brought into close contact with one surface of the base material sheet 11.

As the base sheet 11, a transparent one having a three-dimensional processability is used. The material of the base sheet 11 includes polypropylene resin, polyethylene resin, polyamide resin, polyester resin, acrylic resin,
It is preferable to use a resin sheet such as polyvinyl chloride resin.

Next, using a transfer machine such as a roll transfer machine or an up-down transfer machine equipped with a heat-resistant rubber-like elastic material such as silicon rubber, a temperature of about 80 to 260 ° C. and a pressure of 490 to 490.
Heat and pressure are applied from the side of the base sheet 21 of the transfer material 20 via the heat-resistant rubber-like elastic body set to the condition of about 1960 Pa. By doing so, the transparent layer 22 side is adhered to the surface of the base material sheet 11. When the base sheet 21 is peeled off after cooling, peeling occurs between the base sheet 21 and the transparent layer 22 to complete the transfer. Further, when the release layer is provided on the base sheet 21, when the base sheet 21 is peeled off, peeling occurs between the release layer and the transparent layer 22 to complete the transfer.
In this way, the transparent uneven layer 12 can be formed on the base material sheet 11.

Next, the glitter layer 13 is formed on the transparent uneven layer 12 if necessary.

The glitter layer 13 is composed of a metal thin film layer or a printed layer, expresses a metallic luster, and has a transparent uneven layer 12
It is a layer that makes the unevenness of the surface visible more clearly. The glitter layer 13 is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. Depending on the metallic luster color you want to express, aluminum, nickel, gold, platinum,
Chrome, iron, copper, tin, indium, silver, titanium,
Metals such as lead and zinc, alloys or compounds thereof are used. As an example of forming a partial metal thin film layer, after forming a solvent-soluble resin layer in a portion that does not require a metal thin film layer, a metal thin film is formed on the entire surface, and solvent cleaning is performed. There is a method of removing an unnecessary metal thin film together with the solvent-soluble resin layer. The solvent often used in this case is
It is water or an aqueous solution. Further, as another example, there is a method of forming a metal thin film on the entire surface, then forming a resist layer on the portion where the metal thin film is to be left, and etching with acid or alkali to remove the resist layer. .

The glitter layer 13 can also be formed by using an ink having a pigment such as metal powder of aluminum or the like. As a method of forming the glitter layer 13 formed of a print layer, an ordinary printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. When the glitter layer 13 made of ink is formed, the fine uneven shape of the transparent uneven layer 12 is filled.

When the glittering layer 13 is provided, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesiveness with other layers. The materials of the front anchor layer and the rear anchor layer are two-component curable urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, acrylic resin, epoxy. Resins, vinyl copolymer resins, etc. may be used. As a method of forming the front anchor layer and the rear anchor layer, a gravure coating method, a roll coating method, a coating method such as a comma coating method, a gravure printing method,
There is a printing method such as a screen printing method.

Next, an adhesive layer 14 is formed on the glitter layer 13 if necessary. The adhesive layer 14 adheres each of the above layers to the surface of the molded product that is to be decorated with the embossed decorative sheet 10. As the adhesive layer 14, a heat-sensitive or pressure-sensitive resin suitable for the material of the surface of the object to be decorated is appropriately used. For example, when the surface material of the object to be decorated is acrylic resin, acrylic resin may be used. In addition, the surface material of the object to be decorated is polyphenylene oxide.
In the case of polystyrene-based resin, polycarbonate-based resin, styrene-copolymer-based resin, or polystyrene-based blend resin, acrylic resin, polystyrene-based resin, polyamide-based resin, or the like having an affinity for these resins may be used. Further, when the surface material of the object to be decorated is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber and coumarone indene resin can be used. As a method for forming the adhesive layer 14, there are a coating method such as a gravure coating method, a roll coating method and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

The embossed pattern-decorated sheet 10 thus obtained was stretched in the longitudinal direction and the transverse direction to an elongation of 200% in a tensile test based on Japanese Industrial Standard (JIS) C2318 in an atmosphere at 110 ° C. It is important that the transparent concavo-convex layer 12 has a fine concavo-convex shape with a concavo-convex width of 0.2 to 200 µm and a depth of 0.10 to 10 µm later.

The tensile test based on JISC2318 is performed as follows. First, length 200mm, width 1
Five 5 mm test pieces were taken from each of the lengthwise and widthwise directions over the entire width on average, and 5 pieces were placed at the center of the test piece.
Mark points at a distance of 0 mm. With a shopper type pendulum type tensile tester or something similar to this,
The distance between the grips is set to about 100 mm, the test piece is attached to the grips, and the tensile elongation is measured at a speed of about 200 mm / min. When the gauge length before the test is L ₀ and the gauge distance after the test is L, the elongation (%) is ((L−L ₀ ) /
It is represented by L ₀ ) × 100.

The atmosphere for conducting the tensile test is set to 110 ° C. The reason why the uneven pattern decorative sheet 10 is three-dimensional in the vacuum forming method which can be used as one of the three-dimensional processing methods of the uneven pattern decorative sheet 10 of the present invention. As a result of investigating a suitable temperature for processing, most of the decorative sheet 1 having an uneven pattern
Since 0 was suitable for processing in the vicinity of 110 to 180 ° C., the lowest value in the above temperature range was adopted. Processing at a temperature as low as possible has an advantage that thermal deterioration of each optical element such as an ink layer or a film that constitutes the decorative sheet 10 can be prevented.

In the tensile test, it is 11 that the elongation is 200% in each of the longitudinal and transverse directions.
As a result of examining a tensile test at 0 ° C., the uneven pattern decorative sheet 10 having mechanical properties such that the elongation is at least 200% or more can be processed into a deep three-dimensional shape sufficient for decorating a resin molded product. Is.

After the tensile test, the transparent uneven layer 12
Has an uneven width of 0.2 to 200 μm and a depth of 0.10 to 10 μ
It has a fine uneven shape of m. Asperity width is 0.2
If the thickness is less than μm, a transfer failure occurs in the transfer process for producing the embossed pattern decorative sheet 10, and the embossed width is 20.
If it exceeds 0 μm, the sharpness as a fine pattern is lost in design. Further, when the unevenness depth is less than 0.10 μm, the sharpness as a fine pattern is lost, and when the unevenness depth exceeds 10 μm, a transfer failure occurs in the transfer process for producing the uneven pattern decorative sheet 10. .

Further, before the tensile test, the transparent uneven layer 12
Has an uneven width of 0.15 to 150 μm and a depth of 0.15 to 15
It is preferable to have fine irregularities of μm.
When the transparent concavo-convex layer 12 is in the above range, it becomes easy to configure the transparent concavo-convex layer 12 to have a fine concavo-convex shape having a concavo-convex width of 0.2 to 200 µm and a depth of 0.10 to 10 µm after the tensile test. Because.

In the present invention, the width of the unevenness means
It is the average of the shortest distances between the peaks of the irregularities formed in the transparent irregular layer 12. The depth of the unevenness means the transparent unevenness layer 1
2 means the average distance from the deepest part to the top part of the unevenness formed in large numbers (see FIG. 3).

With respect to the uneven pattern decorative sheet 10 prepared by using the transfer material 20 so that the uneven width and the uneven depth of the transparent uneven layer 12 have various values, the tensile test and the processing into the uneven pattern molded product 30 are carried out. The results obtained are shown in Tables 1 and 2.

In the table, the transferability was evaluated as ◯ when the transparent layer 22 was transferred from the base sheet 21 in an area of 99% or more, and 90% or more of the transparent layer 22 was 99% of the transparent layer 22 although some areas were not transferred. When less than 100% was transferred, it was evaluated as Δ, and when there were many non-transferred portions and the transparent layer 22 was transferred less than 90%, it was evaluated as ×.

In the tensile test, each transfer material 20 was stretched to an elongation of 200% by a tensile test based on JISC2318 in an atmosphere at a temperature of 110 ° C., and the average value of the width and depth of the unevenness was calculated.

In addition, the evaluation of the fine concavo-convex pattern is ◯ when the fine concavo-convex pattern is clearly expressed even after the molding process, and Δ when the existence of the fine concavo-convex pattern can be confirmed but is not clear. Was partially lost, or the sharpness of the fine uneven pattern was lost, and was marked with x.

First, the concavo-convex width of the base sheet 21 of the transfer material 20 is fixed to 1.0 μm, the concavo-convex depth of the base sheet 21 is set to various values, and the concavo-convex pattern decorative sheet 10 and the concavo-convex molded article 30 are set. Was obtained (see Table 1).

[0045]

[Table 1]

The unevenness depth of the base sheet 21 is 0.15 μm.
When it was less than the above, the uneven depth of the transparent uneven layer 12 before the tensile test of the uneven decorative sheet 10 could be the same as the uneven depth formed on the base sheet 21. However, after the tensile test of the uneven pattern decorative sheet 10, the uneven depth of the transparent uneven layer 12 was less than 0.10 μm, and the fine uneven pattern was not clear even in the uneven pattern molded product 30.

The unevenness depth of the base sheet 21 is 0.15 μm.
When the thickness is 15.0 μm or less, the uneven depth of the transparent uneven layer 12 before the tensile test of the uneven decorative sheet 10 is:
It was possible to obtain the same value as the uneven depth formed on the base sheet 21. Further, after the tensile test of the uneven pattern decorative sheet 10, the uneven depth of the transparent uneven layer 12 becomes 0.10 μm or more and 10.0 μm or less, and the fine uneven pattern is clearly expressed in the uneven pattern molded product 30, which is sufficient. A product having both scratch strength and solid feeling was obtained.

The unevenness depth of the base sheet 21 is 15.0 μm.
If it exceeds, the number of places where the transparent layer 22 is not transferred increases in the transfer step, and a clear fine uneven pattern cannot be obtained.

Next, the unevenness depth of the base sheet 21 of the transfer material 20 is fixed to 1.0 μm, and the uneven width of the base sheet 21 is set to various values to obtain various uneven pattern decorative sheets 10 and uneven patterns. A molded product 30 was obtained (see Table 2).

[0050]

[Table 2]

When the uneven width of the base sheet 21 is less than 0.15 μm, there are many places where the transparent layer 22 is not transferred in the transfer step, and a clear fine uneven pattern cannot be obtained.

When the uneven width of the base sheet 21 is 0.15 μm or more and 150.0 μm or less, the uneven width of the transparent uneven layer 12 before the tensile test of the uneven pattern decorative sheet 10 is the uneven width formed on the base sheet 21. I was able to get the same value as. In addition, after the tensile test of the uneven pattern decorative sheet 10, the uneven width of the transparent uneven layer 12 is 0.20 μm or more 20
Since it was 0.0 μm or less, the fine concavo-convex pattern was clearly expressed even in the concavo-convex pattern molded product 30, and a product having both sufficient scratching strength and a solid feeling was obtained.

Concavo-convex width of the base sheet 21 is 150.0 μm
In the case of exceeding the above, the uneven width of the transparent uneven layer 12 before the tensile test of the uneven pattern decorative sheet 10 could obtain the same value as the uneven width formed on the base sheet 21. However, after the tensile test of the uneven pattern decorative sheet 10, the transparent uneven layer 1
The uneven width of 2 becomes a value that greatly exceeds 200.0 μm,
Also in the concavo-convex pattern molded product 30, the fine concavo-convex pattern was not clear.

An example of the method for obtaining the uneven pattern molded article 30 using the uneven pattern decorative sheet 10 of the present invention will be described.

First, the embossed decorative sheet 10 is set in the injection molding die 31 (see FIG. 4).

As a concrete example of the method of setting in the injection molding die 31, a long concave-convex decorative sheet 1 is attached to the roll shaft.
0 is once wound into a roll-shaped roll, and the roll-shaped roll is placed on the upper part of the movable mold for injection molding so as to be movable integrally with the movable mold.
The roll shaft of the film winding means, which is installed under the movable mold for injection molding so as to move integrally with the movable mold for injection molding, while unwinding 0, passes through the space between the retracted movable mold and the fixed mold. The decorative sheet 10 may be wound up. In addition, using the sheet-shaped uneven sheet decorative sheet 10,
It may be set on a movable surface by a robot or manually. When the uneven pattern decorative sheet 10 is set on the movable surface, after the uneven pattern decorative sheet 10 is arranged on the movable surface, the position of the uneven pattern decorative sheet 10 relative to the movable surface is determined by a positioning sensor or the like. It is advisable to press the concave-convex decorative sheet 10 against the surface of the movable mold for injection molding with a clamp member or the like.

Next, by using the vacuum suction holes formed in the movable mold, the concave-convex pattern decorative sheet 10 is vacuum-sucked along the cavity forming surface of the movable mold to form a concave portion of the movable mold, that is, a cavity. It is processed into a three-dimensional shape along the surface. As a specific example, with a heating plate or the like inserted between the movable mold and the fixed mold, the concave-convex decorative sheet 10 set on the surface of the movable mold is heated above its softening point to be softened to form a concave portion of the movable mold. The space between the concave and convex decorative sheet 10 is hermetically closed, exhausted from the vacuum suction holes, and vacuum sucked,
There is a method of bringing the uneven decorative sheet 10 into close contact with the inner surface of the movable recess.

In place of the above method, the decorative sheet 1 for embossing a pattern
Before setting 0 in the injection-molding die 31, the concave-convex decorative sheet 10 is preliminarily used in a cavity forming surface of the injection-molding die 31 using a three-dimensional processing molding die different from the injection-molding die 31. It may be three-dimensionally processed into a shape that conforms to, or may be punched into a desired shape. As a three-dimensional processing method, there are a vacuum forming method, a pressure forming method, a press forming method of pressing heated rubber, a press forming method and the like. As a method of punching, Thomson punching method, die 31
There is a pressing method, etc. It should be noted that punching may be performed simultaneously with the three-dimensional processing.

Next, the injection molding die 31 is closed and the molten molding resin 32 is injected from the gate of the fixed mold into the cavity to solidify the molding resin 32 to form a resin molded product in the cavity. At the same time as the formation, the adhesive layer 14 of the embossed decorative sheet 10 is integrally attached to the surface (see FIG. 5).

The molding resin 32 is not particularly limited. For example, acrylic resin, polystyrene resin,
Polyacrylonitrile styrene resin, polyacrylonitrile butadiene styrene resin, etc. can be used. Typical molding resins 32 used for interior parts and exterior parts of automobiles include polypropylene resin containing talc and modified polypropylene resin.

After that, the mold is opened and the decorative sheet 1 having a concave-convex pattern is formed.
0 is taken out together with the resin molded product, and an unnecessary portion of the uneven decorative sheet 10 adhered to the resin molded product is removed (see FIG. 6). In addition, when the corrugated pattern decorative sheet 10 is punched beforehand, the work of removing an unnecessary portion of the corrugated pattern decorative sheet 10 becomes unnecessary. In this way, the uneven pattern molded product 30 can be obtained.

In the uneven pattern molded article 30 decorated with the uneven pattern decorative sheet 10 of the present invention, since the fine uneven pattern of the transparent uneven layer 12 is covered with the base sheet 11, the fine uneven pattern is not easily scratched, It will have a profound feeling.

[0063]

EXAMPLES Example 1 A polyethylene terephthalate film having a thickness of 38 μm was subjected to abrasion processing with sandpaper, and an uneven width of 0.2 to 1.0 μm and a depth of 0.2 to 8.0.
A base sheet having a fine uneven shape with a hairline pattern of μm was prepared. Then, a transparent layer made of an acrylic resin and an adhesive layer made of a vinyl chloride-vinyl acetate copolymer resin were respectively formed on the uneven surface of the base sheet by a gravure printing method to obtain a transfer material.

An acrylic film having a thickness of 125 μm was used as a base sheet, and the transfer material obtained above was transferred onto the base sheet to form an uneven width of 0.2 to 1.0 μm and a depth of 0.2 to 8.0.
A transparent uneven layer having a fine uneven shape of μm was formed on the substrate sheet. Then, on the transparent uneven layer, a glitter layer made of an ink containing an aluminum paste in a resin binder of acrylic-vinyl copolymer resin / vinyl chloride-vinyl acetate copolymer resin = 1/1, and vinyl chloride −
An adhesive layer made of a vinyl acetate copolymer resin was formed by a gravure printing method to obtain a decorative sheet with a concavo-convex pattern.

The thus-obtained relief-patterned decorative sheet was subjected to a tensile test according to JIS C2318 in an atmosphere of 110 ° C. to obtain elongations of 200% in each of the longitudinal and transverse directions.
And the width and depth of the unevenness of the transparent uneven layer were measured, and the uneven width was 0.3 to 1.4 μm and the depth was 0.1.
It was 5 to 7.0 μm.

(Reference Example 1) The decorative sheet with a concavo-convex pattern obtained in Example 1 was vacuum-molded into a desired three-dimensional shape and then injection-molded with heat-resistant ABS to have a fine concavo-convex shape with a hairline pattern. An embossed pattern decorative molded article, which is an automobile part, was obtained. The surface of the thus obtained decorative molded article having a concavo-convex pattern had excellent designability having both scratch strength and solid feeling.

Example 2 A polyethylene terephthalate film having a thickness of 38 μm was subjected to abrasion processing with sandpaper to give an uneven width of 0.3 to 1.1 μm and a depth of 0.3 to 9.
A base sheet having a fine uneven shape with a hairline pattern of 0 μm was prepared. Then, on the uneven surface of the base sheet, a transparent layer made of a two-component curing urethane resin and vinyl chloride-
An adhesive layer made of a vinyl acetate copolymer resin was formed by a gravure printing method to obtain a transfer material.

A 100 μm thick polycarbonate and polybutylene terephthalate polymer alloy film was used as a base sheet, and the transfer material obtained above was transferred onto the base sheet to form an uneven width of 0.3 to 1.1 μm and a depth of 0. 3-9.
A transparent uneven layer having a fine uneven shape of 0 μm was formed.
Next, on the transparent uneven layer, a glitter layer made of an aluminum thin film was formed, and then an adhesive layer made of vinyl chloride-vinyl acetate copolymer resin was formed by a gravure printing method to obtain an uneven pattern decorative sheet. .

The thus-obtained relief-patterned decorative sheet was subjected to a tensile test according to JIS C2318 in an atmosphere at 110 ° C. to obtain elongations of 200% in each of the longitudinal and transverse directions.
When the width and depth of the unevenness of the transparent unevenness layer were measured, the width of the unevenness was 0.4 to 1.5 μm and the depth was 0.2.
Was about 7.4 μm.

Reference Example 2 The uneven decorative sheet obtained in Example 2 is vacuum-formed into a desired three-dimensional shape and then injection-molded with heat-resistant ABS to have a fine uneven shape of a hairline pattern. A concavo-convex decorative molded product, which is a mobile phone component, was obtained. The surface of the thus-obtained unevenly patterned decorative molded product had both scratching strength and solid feeling.

[0071]

Since the present invention is constructed as described above, it has the following effects.

In the uneven pattern decorative sheet of the present invention, a transparent uneven layer having a fine uneven shape is laminated at least on the back side of a transparent substrate sheet having a three-dimensional processability, and the fine uneven shape of the transparent uneven layer is an uneven pattern. A decorative sheet which is not exposed on the surface of the decorative sheet and which is stretched in the longitudinal direction and the lateral direction in a tensile test based on Japanese Industrial Standard (JIS) C2318 under an atmosphere of 110 ° C. After being stretched to 200%, the transparent uneven layer has a fine uneven shape having an uneven width of 0.2 to 200 μm and a depth of 0.10 to 10 μm. The shape can be retained, the fine uneven pattern is not easily scratched, and the solid feeling is excellent.

In addition, the method for producing a relief-patterned decorative sheet according to the present invention comprises: a transparent base material sheet having three-dimensional processability;
A transparent concavo-convex layer is formed by adhering the transparent layer side of a transfer material provided with at least a transparent layer to the concavo-convex surface of a base sheet having a fine concavo-convex surface, and peeling and removing the base sheet from the transparent layer. Then, since it is configured to obtain the above-mentioned uneven pattern decorative sheet by forming at least an adhesive layer on the transparent uneven layer, the fine uneven pattern is not easily scratched, and the uneven pattern decoration is excellent in solid feeling. The sheet can be easily obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a corrugated decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of a transfer material used in the method for producing a relief-patterned decorative sheet of the present invention.

FIG. 3 is a cross-sectional view showing the uneven width and the uneven depth of the transparent uneven layer of the uneven decorative sheet of the present invention.

FIG. 4 is a cross-sectional view showing a step of producing a concavo-convex molded article using the concavo-convex pattern decorative sheet of the present invention.

FIG. 5 is a cross-sectional view showing a step of producing an uneven pattern molded article using the uneven pattern decorative sheet of the present invention.

FIG. 6 is a cross-sectional view showing an example of an uneven pattern molded product that can be obtained using the uneven pattern decorative sheet of the present invention.

[Explanation of symbols]

10 Uneven pattern decorative sheet 11 Base sheet 12 Transparent uneven layer 13 Glittering layer 14 Adhesive layer 20 Transfer material 21 Base sheet 22 Transparent layer 23 Adhesive layer 30 Concavo-convex pattern molded product 31 mold 32 Molding resin

Continued front page    F term (reference) 3B005 EA07 EB01 EB03 EC02 FA17                       FD02Z FD10Z FE03 FE11                       GB01                 4F100 AB10 AK15G AK15J AK22G                       AK22J AK25 AK42 AL01G                       AR00C AR00D AT00A BA04                       BA07 BA10A BA10D CB00D                       DD07B EH461 EH462 EJ301                       EJ371 GB08 GB33 GB81                       HB21B HB31 JK08 JK14                       JL11D JN01B JN21C

Claims (6)

[Claims] 1. A transparent concavo-convex layer having a fine concavo-convex shape is laminated at least on the back side of a transparent substrate sheet having three-dimensional processability, and the fine concavo-convex shape of the transparent concavo-convex layer is exposed on the surface of a concavo-convex pattern decorative sheet. It is a decorative sheet that does not have an uneven pattern, and is a Japanese Industrial Standard (JIS) C23 in an atmosphere at 110 ° C.
In the tensile test based on No. 18, the uneven pattern decorative sheet was stretched in the longitudinal direction and the transverse direction to an elongation of 200%, and then the transparent uneven layer had an uneven width of 0.2 to 200 μm and a depth of 0.
An uneven pattern decorative sheet, which has a fine uneven shape of 10 to 10 μm. 2. The Japanese Industrial Standard (JI) in an atmosphere at 110 ° C.
S) The transparent concavo-convex layer of the concavo-convex pattern decorative sheet before the tensile test based on C2318 has a concavo-convex width of 0.15 to 15
The concavo-convex pattern decorative sheet according to claim 1, which has a fine concavo-convex shape with a depth of 0 µm and a depth of 0.15 to 15 µm. 3. The uneven pattern decorative sheet according to claim 1, wherein an adhesive layer is laminated on the rearmost surface side of the uneven pattern decorative sheet. 4. The concavo-convex pattern decorative sheet according to claim 1, wherein a glitter layer is laminated on the back surface side of the transparent concavo-convex layer so as to be in contact with the transparent concavo-convex layer. 5. A transparent base material sheet having a three-dimensional processability is bonded onto a transparent base material sheet having a fine concavo-convex surface on which the transparent layer side of a transfer material is provided. A concavo-convex pattern decorative sheet according to claims 1 to 3 is obtained by forming a transparent concavo-convex layer by peeling and removing it from the transparent layer, and then forming at least an adhesive layer on the transparent concavo-convex layer. A method for producing a concavo-convex pattern decorative sheet, comprising: 6. A transparent base material sheet having three-dimensional processability is bonded onto a transparent base material sheet having a fine concavo-convex surface on the transparent layer side of a transfer material having at least a transparent layer provided on the concavo-convex surface to form a base sheet. The concavo-convex pattern decorative sheet according to claim 4, wherein the transparent concavo-convex layer is formed by peeling and removing the transparent concavo-convex layer, and then at least a glitter layer and an adhesive layer are formed on the transparent concavo-convex layer. A method for producing an embossed decorative sheet, which comprises: