JP2009297895A - Decorative sheet having uneven pattern on surface and method for manufacturing it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet with an uneven pattern on the surface expressing an excellent uneven feeling including a picture pattern expression and a gloss expression only with an unevenness of the surface even when a plain-colored solid state is used, and a method for manufacturing it. <P>SOLUTION: The decorative sheet with the uneven pattern on the surface is characterized in that in the uneven pattern, the unevenness has stepwise depths and the unevenness has a stepwise intervals, and the stepwise depths has the maximum difference of the arithmetic mean height ([Ra] JIS B 0601:2001) of ≥20 μm, and the stepwise intervals has the maximum difference of ≥100 μm around the mean length of the elements ([Psm] JIS B 0601:2001) of 500 μm. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention mainly relates to a decorative sheet used to improve the design by bonding to the surface of furniture, home appliances, automobile interiors, building material interiors, exteriors, etc., and in particular, due to the depth and density of the uneven pattern on the surface, The present invention relates to a decorative sheet expressing a difference in surface shade and a difference in gloss and a method for producing the same.

  In order to make the decorative sheet of the above-mentioned use closer to a decorative sheet or decorative plate closer to natural wood, a pattern resin layer is provided by a gravure printing method using a plurality of kinds of image data, and a transparent resin layer is provided. In addition, a decorative sheet is known in which a concavo-convex pattern having a degree of synchronization with the pattern of the pattern layer is provided on the surface.

  In addition, it is also known that various additives are added to the ink of the picture pattern layer and the transparent resin layer to give a difference in gloss expression and mat expression, and change the gloss state of the surface to show a feeling of unevenness. It has been.

  However, there are cases where the solid color is solid due to the harmony with other designs, etc. at the location to be used, etc. In such a case, there is no unevenness due to the pattern, and only a change in glossy state or a certain degree of unevenness on the surface is sufficient Unevenness could not be expressed.

It is possible to create an embossed plate by converting the image data into digital data and simply replacing the shading of the image data with unevenness, thereby creating a decorative sheet, but also a decorative sheet consisting of an uneven pattern synchronized with the pattern, It was inferior when viewed from the unevenness of a decorative sheet or the like having a difference in glossiness in synchronization with the pattern.
Japanese Patent No. 3188313 Japanese Patent No. 3629964

  The present invention has been made in order to solve such problems, and the object of the present invention is to provide excellent image expression and glossy expression only with surface irregularities, even in a single-color solid state. An object of the present invention is to provide a decorative sheet having a concavo-convex pattern on the surface, which expresses a feeling of unevenness, and a manufacturing method thereof.

  The present invention solves this problem, that is, the invention according to claim 1 is a decorative sheet having a concavo-convex pattern on the surface, and the concavo-convex pattern has a stepped depth in the concavo-convex pattern. And the unevenness has stepwise intervals, and the stepwise depth has a maximum difference of 20 μm or more in arithmetic average height (“Ra” JIS B 0601: 2001), The gap is a decorative sheet having a concavo-convex pattern on the surface, characterized in that the average length (“Psm” JIS B0601: 2001) of the elements is around 500 μm and the maximum difference is 100 μm or more.

  Further, the invention according to claim 2 is characterized in that the uneven pattern is a wood grain pattern, and the region where the stepwise depth is deep and the interval is dense expresses the conduit part of the wood of the ring material. A region having a shallow depth and a small interval represents a surface portion of a grain, and has a maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) of 50 to 100 μm. A decorative sheet having a concavo-convex pattern on the surface according to claim 1.

  Further, in the invention according to claim 3, the uneven pattern is a wood grain pattern, and the region where the stepwise depth is deep and the interval is dense expresses the conduit portion of the wood of the diffuser material, A region having a shallow depth and a small interval represents a surface portion of a grain, and a maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) is 20 to 40 μm. A decorative sheet having a concavo-convex pattern on the surface according to claim 1.

  According to the fourth aspect of the present invention, an image is captured as digital image data using a digital scanner device, and the image data is divided into multi-stage regions based on the density distribution. The unevenness is closely spaced, the shallower embossed unevenness is set at a shallow density and the embossed unevenness is sparse, and the stepwise depth is calculated by calculating the arithmetic average height ( The maximum difference of “Ra” JIS B 0601: 2001) is 20 μm or more, and the stepwise interval is about 100 μm or more when the average length of the elements (“Psm” JIS B0601: 2001) is around 500 μm. Create an embossed plate based on this setting and mold the uneven pattern on the decorative sheet surface using this embossed plate The symptom is a decorative sheet manufacturing method of having an uneven pattern on the surface.

  Further, the invention according to claim 5 is characterized in that the uneven pattern is a wood grain pattern, and the region where the stepwise depth is deep and the interval is dense expresses the conduit portion of the wood of the ring material. A region having a shallow depth and a small interval represents a surface portion of a grain, and has a maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) of 50 to 100 μm. The manufacturing method of the decorative sheet which has an uneven | corrugated pattern on the surface of Claim 4.

  The invention according to claim 6 is characterized in that the uneven pattern is a wood grain pattern, and the region where the stepwise depth is deep and the interval is dense expresses the conduit part of the grain of the diffuser material. A region having a shallow depth and a small interval represents a surface portion of a grain, and a maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) is 20 to 40 μm. The manufacturing method of the decorative sheet which has an uneven | corrugated pattern on the surface of Claim 4.

  According to the first and fourth aspects of the present invention, the density of the image data is divided into stepped regions, and the depth and interval of the unevenness provided on the surface of the decorative sheet are stepped in accordance with this. In addition, the maximum value of the arithmetic average height (hereinafter referred to as “Ra”) of the unevenness at that time is a certain value or more, and the maximum difference of the average length of the uneven elements (hereinafter referred to as “Psm”) By making it more than a certain value, it is possible to obtain an effect that a decorative sheet having a sense of unevenness and excellent design can be obtained.

  Further, according to the inventions of claims 2 and 5, it is possible to express the concavo-convex sensation of the pattern due to the conduit of the ring material such as zelkova, oak, paulownia, plug, teak, chestnut, ash, etc. near or more realistic. The effect that the decorative sheet which can be obtained can be obtained is produced.

  In addition, according to the third and sixth aspects of the invention, there is provided a decorative sheet that can express the unevenness of the pattern due to the conduit of a diffuser material such as beech, magnolia, cherry blossom, and katsura, close to real or more. There is an effect that it can be obtained.

  Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 shows a cross section of an embossed plate production process in one embodiment of the decorative sheet manufacturing method of the present invention. Here, the process of forming the recesses in the embossing plate by multi-stage corrosion is shown. However, in the present invention, the final shape of the embossing plate is stepwise in the depth of the recesses and the interval between the recesses as in the lowermost stage of FIG. If it can be, it may be manufactured at one time, or a method other than corrosion may be used. However, as shown in FIG. 1, it is preferable to provide a recess in multiple stages.

Among those showing the multi-stage corrosion process, the cross section of the block used at each stage is shown by a bold line. The cut-off portion is a void portion of the block image where corrosion is performed. And the result of being corroded at that stage by the composition is shown by a solid line.
FIG. 1 is an example of a wood grain pattern by a certain ring hole conduit. Embossed plates are created in a time series that progresses in five stages from the top to the bottom of the figure. In the left-right direction, the left side is the wood surface portion, the center is the conduit portion, and the right side is the surrounding tissue portion. In each stage divided into five stages, it is possible to finally divide the depth of the unevenness and the interval by providing the stages.

  In the present invention, the maximum difference of the “Ra” is designed to be 20 μm or more. When the thickness is less than 20 μm, the unevenness expression is not sufficient, and no significant difference is observed in the change in the glossy state expressed by the unevenness of the unevenness. Since the maximum difference cannot be equal to or greater than the thickness of the transparent resin layer on the surface of the decorative sheet on which the maximum difference is provided, the maximum difference is about 150 μm at the maximum, but a range of 50 to 100 μm is preferable in practice.

  In the present invention, the “Psm” is designed to have a maximum difference of 100 μm or more around 500 μm. If it is less than 100 μm, the difference in the appearance of the glossy state due to the unevenness of the unevenness cannot be obtained. Although it will not specifically limit if it is 100 micrometers or more, in consideration of the design nature of the repeating pattern of a normal picture pattern, since it will become the next pattern if an interval is 2000 micrometers, the range of 100-300 micrometers is suitable substantially. is there.

  In the present invention, when expressing a wood grain pattern, the maximum difference of the “Ra” is different from 50 to 100 μm in the case of the wood grain pattern by the ring hole conduit, and 20 to 40 μm in the case of the diffusion hole conduit. The maximum difference is similar. This is because it reproduces more realistically (or more realistically) in expressing the surface state and organization of the tree species. Other textures of the wood surface such as lines and tannins can be appropriately expressed by dividing the region from the whole grain pattern within the above range and providing the depth and spacing of the unevenness in stages. Become.

  As a method of providing unevenness on the surface of the decorative sheet having unevenness on the surface according to the present invention, the resin is embossed using the embossing plate according to the above design in a state where the resin is provided in a molten state on the decorative sheet substrate. Although the method of hardening | curing is suitable, it is not specifically limited to this, The method of bonding the shape | molded sheet | seat may be used. Thus, the uneven surface may be left as it is, or a surface protective layer may be provided by surface coating. At this time, it is preferable to make the surface coat as thin as the embossed unevenness is not impaired, and it is preferable to keep the average reflectance of the sheet surface in the range of 2 to 20. Within this range, the difference in surface gloss state (gross / matte expression) becomes clearer and the design improvement effect of the present invention is further improved, and the decorative sheet is improved by the physical properties of the resin used for the surface protective layer. The surface resistance can be made excellent.

  In the decorative sheet according to the present invention, it is assumed that only a colored base material without a design pattern or a solid print layer of only one color is used, but a design pattern layer is separately provided by printing. It may be a thing. In this case, printing may be provided on the base material of the decorative sheet, or when the transparent resin layer having the surface irregularities is bonded as a shaped sheet, the back surface may be printed. Of course, if the pattern and the unevenness provided on the surface are synchronized, it is more desirable to improve the design of the decorative sheet due to the unevenness and glossiness of the decorative sheet.

<Creation of composition image data>
First, a timber board is taken into a computer storage device as digital image data by a digital scanner device to create a document image, and 10%, 30%, 50 from an area from 0% to 100% of the image density of the digital document image. %, 70%, and 90% density areas were extracted, and the density at each stage was replaced with black and white negative block image data.

  The 10% concentration in the first stage is the deepest part of the conduit part, the 30% concentration in the second stage is the dense part of the middle part of the conduit part and the tissue, and the 50% concentration in the third stage is the middle part of the conduit part and the tissue. The middle concentration portion of the tube and the 70% concentration of the fourth stage were defined as the shallowest portion of the conduit portion and the light portion of the tissue, and the 90% concentration of the fifth step was defined as the lightest concentration of the surface structure of the conduit and the surface of the timber.

  As shown in FIG. 1, the created five-stage block image was created so as to reproduce the depth and density of the embossed unevenness in conjunction with the printed image and the unevenness of the embossed plate to be formed. At this time, “Psm” is set to 500 to 900 μm for the wood surface portion of a), and “Psm” is set to 200 to 400 μm for the wood conduit and tissue portion of b). The block image data of each stage was created so that the maximum difference of “Psm” before and after 500 μm was 150 μm or more.

<Creation of embossed version>
Using a multi-stage corrosion method on the cylinder roll with copper plating on the surface of the iron core, use the above-mentioned 5-stage block image data until the “Ra” of the 1-stage emboss becomes 15 μm, then The second-stage image is processed in the same way as described above. Repeatedly, the third, fourth, and fifth stages are repeated, and when the total of “Ra” reaches a maximum of 75 μm, the embossed version is created. did.

<Creating a decorative sheet>
Using a polypropylene resin sheet with a thickness of 70 μm that is colored brown by adding a colorant as a base material, a melt of transparent polypropylene resin is laminated with a thickness of 80 μm on it, and at the same time embossed with the embossed plate It was.
Finally, as with the irregularities on the surface, a urethane-based resin was coated so that the thickness after drying was 1 g / m 2 to form a surface protective layer to obtain a decorative sheet.
Although the finished decorative sheet is monochromatic, the surface condition of the wood grain can be expressed more easily and realistically due to the difference in glossiness due to the embossing of the surface.

<Comparative Example 1>
Except that the maximum difference of “Psm” was set so as not to reach 100 μm, a block image data was created in the same manner as in Example 1 to obtain a decorative sheet. The obtained decorative sheet had no change in glossiness, and could not express the surface condition of wood.

<Comparative Example 2>
Except that the “Ra” was set to 3 μm per step and the total amount was set to a maximum of 15 μm, a block image data was prepared in the same manner as in Example 1 to obtain a decorative sheet. The resulting decorative sheet lacked a feeling of unevenness.

  The decorative sheet of the present invention and the method for producing the same are excellent in unevenness even by forming a concavo-convex pattern on the surface, even if the decorative sheet is a single-colored solid sheet in consideration of harmony with other designs at the location used. It can be used as a decorative sheet that can express glossiness.

It is explanatory drawing which shows the cross section of the creation process of the embossing plate in one Example of the manufacturing method of the decorative sheet of this invention.

Claims (6)

  A decorative sheet having a concavo-convex pattern on a surface, wherein the concavo-convex pattern has a stepped depth, and the concavo-convex portions have a stepped interval, the stepped depth. Has a maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) of 20 μm or more, and the stepwise interval has an average length of elements (“Psm” JIS B0601: 2001) of 500 μm. A decorative sheet having a concavo-convex pattern on the surface, wherein the maximum difference between before and after is 100 μm or more.   The concavo-convex pattern is a wood grain pattern, and the region where the stepped depth is deep and closely spaced expresses the conduit portion of the wood of the perforated material, and the stepwise depth is shallow and the space is sparse 2 represents the surface part of the grain, and the maximum difference in the arithmetic average height (“Ra” JIS B 0601: 2001) is 50 to 100 μm. A decorative sheet having   The concavo-convex pattern is a wood grain pattern, and the region where the stepwise depth is deep and closely spaced expresses the conduit portion of the wood of the diffuser, and the stepwise depth is shallow and the space is sparse 2 represents the surface part of the grain, and the maximum difference in arithmetic average height (“Ra” JIS B 0601: 2001) is 20 to 40 μm. A decorative sheet having   The image is captured as digital image data using a digital scanner device, and the image data is divided into multi-level regions based on the density distribution. The dark embossed irregularities are deep and the embossed irregularities are closely spaced, and the density is low. However, the embossed unevenness is set stepwise so that the embossed unevenness is shallow and the embossed unevenness is sparse, and the stepped depth is the arithmetic average height (“Ra” JIS B 0601: 2001). The maximum difference is 20 μm or more, and the stepwise interval is set so that the average difference (“Psm” JIS B0601: 2001) of the elements is around 500 μm and the maximum difference is 100 μm or more. Create an embossed plate, and then use this embossed plate to shape the surface of the decorative sheet. Method of manufacturing that decorative sheet.   The concavo-convex pattern is a wood grain pattern, and the region where the stepped depth is deep and closely spaced expresses the conduit portion of the wood of the perforated material, and the stepwise depth is shallow and the space is sparse 5 represents a surface part of wood grain, and the maximum difference of the arithmetic average height (“Ra” JIS B 0601: 2001) is 50 to 100 μm. The manufacturing method of the decorative sheet which has this.   The concavo-convex pattern is a wood grain pattern, and the region where the stepwise depth is deep and closely spaced expresses the conduit portion of the wood of the diffuser, and the stepwise depth is shallow and the space is sparse 5 represents the surface part of the grain, and the maximum difference of the arithmetic average height (“Ra” JIS B 0601: 2001) is 20 to 40 μm. The manufacturing method of the decorative sheet which has this.

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