JP2011213067A - Method for manufacturing decorative sheet, and method for manufacturing decorative molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative sheet which is excellent in productivity and can enhance a grain effect of wood, and a method for manufacturing a decorative molded product.SOLUTION: The method for manufacturing a decorative sheet includes a joint layer forming step, a roll processing step and an irregularity forming step. In the joint layer forming step, a laminated sheet 15 is obtained by forming a joint layer 11 on the reverse side 19 of a decorative sheet 10 including a sheet-like wood. In the roll processing step, a laminated sheet roll is formed by winding the laminated sheet 15 in a roll shape. In the irregularity forming step, a decorative sheet 1 is obtained by forming irregularities 105 on a surface of the decorative sheet 10 while feeding the laminated sheet 15 from the laminated sheet roll. The decorative molded product is manufactured by arranging the decorative sheet 1 within a molding die and injection-molding a base resin on the joint layer 11 side of the decorative sheet 1.

Description

  The present invention relates to a method for producing a decorative sheet that is used by being integrated with a base resin by injection molding a base resin on the back side in a mold, and a method for producing a cosmetic molded article using the decorative sheet About.

For automobile interiors such as armrests, cosmetic molded products obtained by in-mold molding of a decorative sheet using a decorative sheet made of a wood veneer are used.
Conventionally, in the production of a decorative molded product, as shown in FIG. 9A, first, a veneer 92 having a thickness of about 200 to 500 μm is prepared as a decorative sheet.

  Next, as shown in FIG. 9B, the veneer 92 is impregnated with a thermosetting resin 93 such as a polyester-based styrene crosslinked alkyd resin to obtain a decorative sheet 90. Next, as shown in FIG. 10A, an adhesive layer 94 suitable for a base resin to be molded later is bonded to the back side of the decorative sheet 90. Next, as shown in FIG. 10B, a decorative sheet 90 is inserted into the mold, and then a base resin is injection-molded on the back surface side to obtain an intermediate molded product 97.

  Next, as shown in FIGS. 10C to 10F, after the first clear layer 95 made of polyester is formed on the surface of the decorative sheet 90 by painting on the intermediate molded product 97, the painted surface is polished. . Furthermore, after coating the second clear layer 96 on the first clear layer 95, the coated surface is polished to obtain a cosmetic molded product 98.

  In addition, in a design product using the main basket, a method of performing processing such as sand blasting has been developed in order to emphasize the grain feeling by utilizing the pattern of the conduit or the like (see Patent Documents 1 and 2). Conventionally, processing such as sandblasting is performed on a molded product after molding, and then a clear layer is formed on the surface of the molded product.

JP-A-6-335922 Japanese Patent Laid-Open No. 61-58799

However, if the blasting process is performed after molding, the blasting process is required for each of the molded products, so that productivity is lowered. Therefore, it is desired to develop a decorative sheet whose surface has irregularities formed in advance.
However, when molding such as injection molding is performed on the decorative sheet on which the unevenness is formed, there is a problem that the unevenness becomes small and the emphasized grain feel is lost.

  The present invention has been made in view of such problems, and is intended to provide a method for manufacturing a decorative sheet and a method for manufacturing a decorative molded product, which are excellent in productivity and can enhance the graininess of wood. is there.

1st invention is a manufacturing method of the decorative sheet used by injection-molding base resin on the back side in a mold,
On the back side of the decorative sheet containing sheet-like wood, a bonding layer forming step for obtaining a laminated sheet by forming a bonding layer for bonding with the base resin,
A roll processing step of winding the laminated sheet into a roll to produce a laminated sheet roll;
A method for producing a decorative sheet, comprising: forming an unevenness on a surface of the decorative sheet in the laminated sheet while feeding the laminated sheet from the laminated sheet roll to obtain the decorative sheet. (Claim 1).

  2nd invention has the injection molding process which arrange | positions the said decorative sheet obtained by the manufacturing method of 1st invention in a shaping | molding die, and injection-molds base resin to the said joining layer side in the said decorative sheet. The feature of the present invention resides in a method for producing a decorative molded article (claim 5).

In the first invention, the decorative sheet is used by injection-molding a base resin on the back side in a molding die, and performs the joining layer forming step, the roll processing step, and the unevenness forming step. To manufacture.
In the bonding layer forming step, a bonding layer for bonding to the base resin is formed on the back surface side of the decorative sheet including sheet-like wood. Thereby, the said laminated sheet excellent in bondability with the said base resin can be obtained.

  Moreover, in the said roll processing process, the said laminated sheet is wound in roll shape and a laminated sheet roll is produced. Subsequently, in the said uneven | corrugated formation process, an unevenness | corrugation is formed in the surface of the said decoration sheet in this laminated sheet, sending out the said laminated sheet from the said laminated sheet roll. Since irregularities are formed on the surface of the laminated sheet while feeding the laminated sheet from the laminated sheet roll, irregularities can be continuously formed on the surface of the decorative sheet. Therefore, the decorative sheet can be produced with high productivity.

  Moreover, the said decorative sheet in which the unevenness | corrugation was formed in the surface of the said decorative sheet can be obtained. Therefore, in the said decorative sheet, the wood grain feeling of the said decorative sheet is emphasized, and the said decorative sheet can exhibit the outstanding design property.

  Furthermore, in the said uneven | corrugated formation process, an unevenness | corrugation is formed with respect to the said lamination sheet in which the said joining layer was formed in the back surface side of the said decorative sheet. Therefore, it is possible to obtain the decorative sheet having the decorative sheet on which irregularities are formed and the bonding layer formed on the back surface side. Even if the base resin is injection-molded on the back surface side of the decorative sheet having such a configuration, it is possible to suppress the unevenness from being reduced during molding. Therefore, the decorative sheet can exhibit an excellent grain feeling even after injection molding.

  Thus, according to 1st invention, it is excellent in productivity and can provide the manufacturing method of the decorative sheet which can raise the wood grain feeling of wood.

In the second invention, a cosmetic molded article is manufactured by performing the injection molding process.
In the injection molding step, the decorative sheet is placed in a molding die, and a base resin is injection-molded on the bonding layer side of the decorative sheet. Since the base resin is injection-molded on the bonding layer side, the base resin can be bonded with good adhesion to the decorative sheet.

  Moreover, in the said injection molding process, using the said decorative sheet obtained by the manufacturing method of the said 1st invention which has the said decorative sheet in which the unevenness | corrugation was formed, and the said joining layer formed in the back surface side. Yes. Therefore, even if the base resin is injection-molded on the back side of the decorative sheet, the unevenness formed on the decorative sheet at the time of molding is difficult to be reduced. Therefore, the decorative molded product can exhibit an excellent design by taking advantage of the wood grain of the decorative sheet.

  Furthermore, the decorative molded product can be manufactured by performing injection molding on the decorative sheet on which irregularities are formed. Therefore, an operation for forming irregularities on the molded product after molding becomes unnecessary, and a cosmetic molded product can be manufactured with high productivity.

  As described above, according to the second aspect of the present invention, it is possible to provide a method for manufacturing a decorative molded article that is excellent in productivity and can enhance the wood grain feeling of wood.

Explanatory drawing (a) which shows the cross section of a decoration sheet in Example 1, explanatory drawing (b) which shows the cross section of a lamination sheet, explanatory drawing (c) which shows the cross section of a decorative sheet. Explanatory drawing which shows the cross-section of the cosmetic molded product in Example 1. FIG. FIG. 3 is an explanatory diagram illustrating a configuration of a laminating apparatus according to the first embodiment. Explanatory drawing which shows a mode that an unevenness | corrugation is formed in a lamination sheet by the blast process in Example 1. FIG. Explanatory drawing which shows the three-dimensional photograph of the decoration sheet | seat before performing a blast process in Example 1. FIG. FIG. 3 is an explanatory diagram showing a three-dimensional photograph of a decorative sheet after blasting in Example 1. The photograph substitute figure (a) which shows the surface state of the decorative sheet before performing a blasting process in Example 1, and explanatory drawing which shows the uneven | corrugated state of the decorative sheet before performing a blasting process. The photograph substitute figure (a) which shows the surface state of the decoration sheet after blasting in Example 1, and explanatory drawing which shows the uneven | corrugated state of the decoration sheet after blasting. Explanatory drawing which shows the manufacturing procedure of the conventional decorative sheet. Explanatory drawing which shows the manufacturing procedure of the conventional cosmetics molded product.

Next, a preferred embodiment of the present invention will be described.
The said decorative sheet can be manufactured by performing the said joining layer formation process, the said roll processing process, and the said uneven | corrugated formation process.

In the said joining layer formation process, the joining layer for joining with the said base resin is formed in the said back surface side of the decoration sheet containing a sheet-like wood, and a laminated sheet is obtained.
As the decorative sheet, for example, a veneer of a main tree obtained by cutting out a very thin piece of wood can be used. Further, the decorative sheet may have a layer made of another material laminated thereon other than a layer made of wood such as a protruding plate. The above-mentioned protruding plate is a porous sheet obtained by cutting out wood very thinly, and can exhibit excellent design properties of the main wood.
The thickness of the decorative sheet can be set to 200 to 1000 μm, for example.

As the decorative sheet, it is preferable to use a sheet obtained by pressurizing and filling a synthetic resin into the wood-like conduit portion of the wood.
In this case, it is possible to prevent bubbles from being generated from the protruding plate during molding.
For example, polyethylene glycol, polypropylene glycol, or the like can be used as the synthetic resin to pressurize the conduit portion of the protruding plate. Moreover, polyester-type resin, such as polybutylene terephthalate or polyethylene terephthalate, can also be employ | adopted.

Next, as the bonding layer, an impregnated paper impregnated with a resin excellent in adhesiveness to the base resin, a resin sheet, a nonwoven fabric, or the like can be used.
That is, in the bonding layer forming step, the bonding layer can be formed by sticking a nonwoven fabric, a resin-impregnated paper, or a resin sheet on the back side of the decorative sheet.

  When the bonding layer is formed by sticking a nonwoven fabric, it is possible to improve the adhesiveness to the base resin by an anchor effect by utilizing the characteristics of the porous nonwoven fabric. As a nonwoven fabric, a polyester nonwoven fabric, a rayon nonwoven fabric, a polyolefin-type nonwoven fabric, etc. are employable, for example. Moreover, when an impregnated paper or a resin sheet is employed, the material can be appropriately selected according to the type of base resin to be injection-molded on the decorative sheet.

As the impregnated paper, for example, an impregnated paper impregnated with acrylic resin, polyurethane resin, phenol resin, diallyl phthalate resin, epoxy resin or the like can be used.
The resin sheet includes ABS resin (acrylonitrile / butadiene / styrene copolymer), thermoplastic polyurethane resin, polyester resin, alloy material including polycarbonate resin, polypropylene resin, polyethylene terephthalate resin, polyvinyl chloride resin, polymethacrylic acid. What consists of methyl resin etc. is employable. The resin sheet can be bonded to the base resin by heat fusion.

  By adopting the resin sheet or the impregnated paper as the bonding layer, the hard bonding layer can be formed. Therefore, it is possible to further suppress the unevenness formed on the surface of the decorative sheet in the unevenness forming step during the above-described injection molding.

The thickness of the bonding layer can be set to, for example, 50 μm to 1000 μm.
By forming the bonding layer having a thickness of 50 μm or more, it is possible to further suppress the unevenness formed on the surface of the decorative sheet in the unevenness forming step when the decorative sheet is formed. More preferably, the thickness of the bonding layer is 100 μm or more. Moreover, there is no big merit even if the bonding layer exceeding 1000 μm is formed, and the thickness of the laminated sheet becomes too large, and it may be difficult to wind in a roll shape in the roll processing step. More preferably, the thickness of the bonding layer is 500 μm or less.

In the bonding layer forming step, it is preferable to use a moisture-curable polyurethane adhesive.
In this case, the bonding layer can be formed with flexibility, and the flexibility of the entire decorative sheet can be further improved. In this case, since the polyurethane resin exhibits excellent adhesiveness to cellulose of the sheet-like wood, the bonding layer can be adhered to the decorative sheet with good adhesion.

  Next, in the roll processing step, the laminated sheet is wound into a roll to produce a laminated sheet roll. And in the said uneven | corrugated formation process, while sending out the said laminated sheet from the said laminated sheet roll, an unevenness | corrugation is formed in the surface of the said decorative sheet in this laminated sheet, and the said decorative sheet is obtained.

The unevenness can be formed by shot blasting such as sand blasting, flame treatment or the like.
In the blast treatment, irregularities can be formed by spraying abrasive particles such as resin beads such as nylon beads, glass beads, walnuts, and alumina beads on the decorative sheet.
In the flame treatment, irregularities can be formed by burning the surface of the decorative sheet.

Preferably, in the unevenness forming step, the unevenness is formed by shot blasting.
In this case, the size of the unevenness to be formed can be easily adjusted by adjusting the particle size, shape, material (hardness), and pressure at the time of spraying of the abrasive particles.

As the shape of the abrasive particles, for example, a substantially spherical shape, a cylindrical shape, a polygonal shape or the like can be adopted.
As the abrasive particles, particles having a Mohs hardness of about 2 to 12, for example, can be employed. More preferably, the Mohs hardness is 10 or less, and even more preferably 7 or less.
The abrasive particles can be sprayed at a pressure of, for example, 1 to 5 kg / cm ² , preferably ² to 3 kg / cm ² .
The blasting process may be performed only once, but can be repeated a plurality of times.

  Next, the decorative molded product can be manufactured by performing an injection molding process on the decorative sheet. That is, in the injection molding step, the decorative sheet is placed in a mold, and a base resin is injection molded on the bonding layer side of the decorative sheet.

Prior to the injection molding step, vacuum molding or press molding can be performed on the decorative sheet.
In this case, a decorative molded article having a curved surface or a curved portion can be produced by making the surface of the decorative sheet a curved surface or forming a curved portion. That is, a decorative molded article having a desired surface shape can be produced. Moreover, generally, when vacuum forming or press molding is performed on a veneer having an uneven surface, the unevenness tends to be reduced. However, in the present invention, since the bonding layer is formed on the back side of the decorative sheet, the unevenness formed on the decorative sheet is suppressed from being reduced even if vacuum molding or press molding is performed. be able to.

Moreover, it is preferable to have the clear layer formation process of apply | coating a transparent synthetic resin to the said decoration sheet side in the said decorative sheet, and making it harden | cure after the said injection molding process (Claim 7).
By forming the transparent clear layer, it is possible to give a sense of depth to the texture of the decorative sheet and to further improve the design. Further, the surface of the decorative sheet can be protected by the clear layer.

  The clear layer is made of a transparent synthetic resin. The term “transparency” as used herein includes not only complete transparency but also colored transparency and translucency. With this transparency, the decorative effect of the decorative sheet can be sufficiently exhibited. The clear layer only needs to have such transparency that the design of the decorative sheet can be seen through when the decorative sheet is viewed from the clear layer side.

The clear layer preferably has a light transmittance of 90% or more.
In this case, when the user visually recognizes the decorative molded product from the clear layer side, the decoration of the decorative sheet can be sufficiently visually recognized through the clear layer. The light transmittance is the total light transmittance.

The clear layer preferably has a haze of 2% or less.
Also in this case, the user can fully visually recognize the decoration of the decorative sheet through the clear layer.

The clear layer preferably has a glass transition point of 90 to 130 ° C.
When the glass transition point is less than 90 ° C., the heat resistance becomes insufficient, and it may be difficult to apply the cosmetic molded product to a product used in a high temperature environment such as an automobile interior product. There is.

Next, the thickness of the clear layer is preferably 10 to 50 μm.
When the thickness exceeds 50 μm, the clear layer fills the wood grain groove of the wood in the decorative sheet, and the wood texture may not be sufficiently exhibited. Moreover, when it is less than 10 μm, when the decorative molded article is held for a long time in a high temperature and high humidity environment, there is a possibility that unevenness is likely to occur due to a dimensional change of the decorative sheet. Further, the thickness of the clear layer is preferably 40 μm or less in practice. More preferably, the thickness of the clear layer is 15 μm or more and 35 μm or less.
The clear layer formed on the surface of the decorative sheet can be formed by a single layer, but can be formed by, for example, a plurality of layers made of different synthetic resins.

  Examples of the synthetic resin for forming the clear layer include polyester resin, polyurethane resin, acrylic resin, polyvinyl chloride resin, polyolefin resin, amino resin, polycarbonate resin, epoxy resin, and phenol resin.

Further, before the clear layer forming step, a colorant can be applied to the surface of the decorative sheet, or a sealer whose main component is a synthetic resin such as a polyurethane resin and / or an acrylic resin can be applied.
By applying the colorant, the design properties can be further improved.
Further, by applying a sealer, it is possible to prevent bubbles that may be generated from the sheet-like wood from entering the clear layer or the like. In addition, when a sealer (urethane adhesive) containing a polyurethane resin as a main component is employed, the polyurethane resin exhibits excellent adhesion to cellulose in a sheet-like wood, so that it has good adhesion to the decorative sheet. A layer (sealing layer) made of a sealer can be formed.

Example 1
Next, the decorative sheet and the decorative molded product according to the example of the present invention will be described.
In this example, as shown in FIG.1 (c), the decorative sheet 1 which consists of a laminated sheet | seat of the decoration sheet 10 containing a sheet-like wood, and the joining layer 11 which consists of synthetic resins formed in the back surface 19 is shown. Make it.

The decorative sheet 10 is made of sheet-like wood (a veneer) having a thickness of 200 μm, and the conduit portion of the wood is pressure-filled with a synthetic resin. On the surface side 18 of the decorative sheet 10, irregularities 105 are formed.
The bonding layer 11 is made of an ABS resin sheet having a thickness of 200 μm. The ABS resin sheet is bonded to the decorative sheet 10 with a moisture-curable polyurethane adhesive 12 to form a bonding layer 11.

  Further, the decorative sheet of this example is formed by integrally molding the base sheet resin and the base sheet resin 20 as shown in FIG. 2 by injection molding the base resin on the back side (bonding layer side) in the mold. It is used to produce a decorative molded product 2 formed.

As shown in FIG. 2, the decorative molded product 2 of this example is formed by integrating a decorative sheet 1 and a base resin 20. Although not clearly shown in the figure, the decorative sheet 1 has a curved portion formed by vacuum forming or hot press forming. The base resin 20 is integrally bonded to the back surface (bonding layer) side 19 of the decorative sheet 1 by injection molding to form the decorative molded product 2.
In this example, the base resin is composed of a composite resin (PC / ABS resin) of a PC resin and an ABS resin.

In addition, on the surface side 18 of the decorative sheet 1, a clear layer 25 having a thickness of 20 μm is formed on the surface of the decorative sheet 10 on which irregularities are formed. The clear layer 25 includes a first clear layer made of a composite resin of polycarbonate (PC) and polybutylene terephthalate (PBT) and a second clear layer made of polymethyl methacrylate (PMMA). In the figure, these are shown as one clear layer 25.
Although not shown in FIG. 2, a colored layer (not shown) and a sealing layer (not shown) are formed between the clear layer 25 and the decorative sheet 10 from the decorative sheet 10 side. Yes.

Hereinafter, the manufacturing method of the decorative sheet and the decorative molded product of this example will be described.
A decorative sheet can be manufactured by performing a joining layer formation process, a roll processing process, and an unevenness | corrugation formation process, as shown to Fig.1 (a)-(c).
In the bonding layer forming step, as shown in FIGS. 1A, 1B and 3, the bonding layer 11 for bonding with the base resin is formed on the back surface 19 of the decorative sheet 10 containing sheet-like wood. The laminated sheet 15 is obtained by forming.

In the roll processing step, the laminated sheet 15 is wound into a roll shape to produce a laminated sheet roll 150 (see FIGS. 3 and 4).
In the unevenness forming step, the decorative sheet 1 is obtained by forming the unevenness 105 on the surface of the decorative sheet 10 in the laminated sheet 15 while feeding the laminated sheet 15 from the laminated sheet roll 150 as shown in FIG. 4 and FIG. .

Hereinafter, the manufacturing method of the decorative sheet 1 will be described in detail.
First, a decorative sheet 10 made of a sheet-like wood (a veneer) having a thickness of 200 μm and pre-filled with polyethylene glycol was prepared. A commercially available sheet can be used as the decorative sheet 10 (see FIG. 1A).

Next, an ABS resin sheet having a thickness of about 200 μm was prepared for forming the bonding layer 11, and a moisture-curing polyurethane hot melt adhesive having a viscosity of 5000 mPa · s and a Young's modulus of 1 MPa was prepared as the adhesive 12 (FIG. 1 ( b)). The viscosity of the polyurethane adhesive can be measured using a cone plate viscometer DV1 manufactured by Yamato Scientific Co., Ltd. Further, the Young's modulus can be measured using a strograph VG manufactured by Toyo Seiki Co., Ltd.
Next, the bonding layer 11 is formed on the back side of the decorative sheet 10 using the adhesive 12 as follows.

The bonding layer is formed using a laminating apparatus 3 as shown in FIG.
The laminating apparatus 3 includes a melter 31 that stores a moisture-curing polyurethane adhesive 12 in a molten state (a moisture-curing polyurethane hot-melt adhesive), a T-die 32 that ejects the adhesive 12, and a discharge from the T-die 32. An application roller 33 for applying the adhesive 12 on the decorative sheet 10, a pressure roller 34 for pressing the decorative sheet 10 and the ABS resin sheet (joining layer) 11, and a pressure table 35 are provided.

The laminating apparatus 3 was provided with a decorative roll 100 formed by winding the decorative sheet 10 in a roll shape and a resin roll 110 formed by winding the ABS resin sheet 11 in a roll shape.
From the decoration roll 100, the decoration sheet 10 is sent out to the application roller 33 via the feed roll 36. In the application roller 33, the adhesive 12 in the melter 31 is extruded from the T die 32, applied to the back surface 19 of the decorative sheet 10 with a predetermined thickness, and further sent to the pressure roller 34. On the other hand, the ABS resin sheet 11 is sent from the resin roll 110 to the pressure roller 34 along the pressure table 35. The decorative sheet 10 and the ABS resin sheet 11 delivered to the pressure roller 34 are pressure bonded between the pressure roller 34 and the pressure table 35. At this time, the decorative sheet 10 and the ABS resin sheet (bonding layer) 11 are bonded by the adhesive 12 applied to the decorative sheet 10. A laminated sheet 15 in which the decorative sheet 13 and the bonding layer 11 are integrated is wound up by a laminated sheet roll 150.
In this way, the bonding layer 11 is formed on the back side 19 of the decorative sheet 10 via the adhesive 12 to obtain the laminated sheet 15 (see FIG. 1B), and the laminated sheet is wound into a roll shape. A laminated sheet roll 150 was obtained (see FIG. 3).

  Next, as shown in FIG. 4, the decorative sheet 1 is obtained by forming irregularities on the surface side 18 of the decorative sheet in the laminated sheet 15 while feeding the laminated sheet 15 from the laminated sheet roll 150.

  Specifically, as shown in FIG. 4, the laminated sheet roll 150 and the take-up roll 190 are arranged to face each other, and the sandblasting device 4 is arranged between the laminated sheet roll 150 and the take-up roll 190. . The sandblasting device 4 is configured to blow out abrasive particles 40. In this example, glass beads having a particle diameter of 90 to 106 μm and a Mohs hardness of 6.5 were employed as the abrasive particles 40.

Then, the laminated sheet 15 is sent out from the laminated sheet roll 150 and taken up by the take-up roll 190. At this time, the abrasive particles 40 are blown out from the sand blasting device 4 disposed between the laminated sheet roll 150 and the take-up roll 190 under the condition of a pressure of 3 kg / cm ² to cause the abrasive particles 40 to collide with the surface side 18 of the laminated sheet 15. It was. At this time, the laminated sheet 15 can be reciprocated between the laminated sheet roll 150 and the take-up roll 190 so that the abrasive particles 40 repeatedly collide with a predetermined region of the laminated sheet 15.

In this way, irregularities were formed on the surface side 18 of the laminated sheet, that is, the surface of the decorative sheet 10, and the decorative sheet 1 was produced as shown in FIG.
5 shows a three-dimensional photograph of the laminated sheet before the blasting process, and FIG. 6 shows a three-dimensional photograph of the decorative sheet on which the unevenness after the blasting process is formed.

  Moreover, in this example, the change of the unevenness | corrugation on the surface of a decoration sheet before and behind blasting was investigated. For the measurement, a digital microscope VHX-900 manufactured by Keyence Corporation was used.

  FIG. 7A shows a three-dimensional photograph (100 times magnification) of the surface of the decorative sheet (veneer) before blasting. FIG. 7B shows the size of the irregularities on the line X shown in FIG. In FIG.7 (b), a horizontal axis shows the position on the line X of Fig.7 (a), and a vertical axis | shaft shows the magnitude | size of an unevenness | corrugation. As shown in FIG. 7B, there is almost no unevenness before the blasting process.

  FIG. 8A shows a three-dimensional photograph (100 × magnification) of the surface of the decorative sheet (veneer) after blasting. FIG. 8B shows the size of the irregularities on the line Y shown in FIG. In FIG. 8B, the horizontal axis indicates the position on the line Y in FIG. 8A, and the vertical axis indicates the size of the unevenness. As shown in FIG. 8B, the unevenness becomes large after the blasting process.

  Thus, in this example, the said bonding layer formation process, the said roll processing process, and the said uneven | corrugated formation process were performed, and the decorative sheet which formed the unevenness | corrugation 105 on the surface of the decoration sheet 10 was produced (FIG. 1 ( c)).

  In this example, as shown in FIGS. 1A and 1B, a bonding layer 11 for bonding with a base resin is formed on the back surface side 19 of the decorative sheet 10 containing sheet-like wood. Thereby, the lamination sheet 15 excellent in bondability with base-material resin can be obtained.

In the roll processing step, the laminated sheet 15 is wound into a roll shape to produce a laminated sheet roll 150 (see FIGS. 3 and 4). Next, in the unevenness forming step, the unevenness 105 is formed on the surface of the decorative sheet 10 in the laminated sheet 15 while feeding the laminated sheet 15 from the laminated sheet roll 150 (see FIGS. 4 and 1C).
Since the unevenness 105 is formed on the surface of the laminated sheet 15 while the laminated sheet 15 is fed out from the laminated sheet roll 150, the unevenness 105 can be continuously formed on the surface of the decorative sheet 10. Therefore, the decorative sheet 1 can be manufactured with high productivity.

  And in this example, the decorative sheet 1 in which the unevenness | corrugation 105 was formed in the surface of the decoration sheet 10 can be obtained. Therefore, in the decorative sheet 1, the wood grain feeling of the decorative sheet 10 is emphasized, and the decorative sheet 1 can exhibit excellent design properties.

  Further, in the unevenness forming step, unevenness is formed on the laminated sheet 15 in which the bonding layer 11 is formed on the back surface 19 of the decorative sheet 10 (see FIGS. 1B, 1C, and 4). ). Therefore, it is possible to obtain the decorative sheet 1 having the decorative sheet 10 with the unevenness and the bonding layer 15 formed on the back side 19 thereof. Even if the base resin is injection-molded on the back surface side of the decorative sheet 1 having such a configuration, it is possible to suppress the unevenness 105 of the decorative sheet 10 from being reduced during molding. Therefore, the decorative sheet 1 can exhibit an excellent wood grain feeling even after injection molding.

  Next, using the decorative sheet prepared as described above, a decorative molded product 2 is prepared as shown in FIG. In this example, the decorative sheet 2 is prepared by placing the decorative sheet in a mold and injection molding the base resin on the bonding layer side of the decorative sheet.

  Specifically, first, a decorative sheet was placed in a mold and vacuum forming was performed (not shown). The heating temperature during vacuum forming was 100 ° C. (sheet surface temperature). By this vacuum forming, a curved portion (not shown) was formed on the decorative sheet 1.

Next, the decorative sheet is placed in a mold for injection molding, and a base resin is injected into the mold using an injection molding machine. As shown in FIG. Material resin 2 was injection molded. As the base resin 2, a composite resin of PC resin and ABS resin (PC / ABS resin) was used.
In this way, as shown in FIG. 2, a decorative molded product 2 was produced in which the base resin 2 was integrated with the back surface 19 of the decorative sheet 1.

  Next, a colorant was applied to the surface side of the decorative sheet 1 (decorative sheet 10), and a sealing layer (not shown) was formed by applying a polyurethane resin sealer.

  Next, a paint mainly composed of a composite resin of polycarbonate (PC) and polybutylene terephthalate (PBT) is applied on the surface of the decorative sheet 1 (decorative sheet 10), more specifically, on the sealing layer, The first clear layer 25 was formed by curing. Next, a paint containing polymethyl methacrylate (PMMA) as a main component was applied and cured to form the second clear layer 25.

In FIG. 2, the first clear layer and the second clear layer are shown as one clear layer 25. In this example, the glass transition point of the clear layer 25 is 120 ° C.
The clear layer 25 has a total light transmittance of 91.2% and a haze of 1%.

The total light transmittance L _t is the light transmittance of a transparent plastic, and there are tests for visible light and ultraviolet light. When the haze value is small, the test is performed using an integrating sphere light transmittance measuring device, and the ratio of the incident light amount L ₁ to the total light amount L ₂ passing through the test piece for visible light and ultraviolet light is expressed as a percentage (L _t (%)). = L ₂ / L ₁ × 100).

The haze (haze; L _h ) is a degree of an unclear cloudy appearance inside or on the surface of the transparent plastic, and the numerical value is called a cloudiness value (haze, haze). The cloudiness value test method measures the light transmittance of the test piece by the same operation as the total light transmittance test, and L _h (%) = L _d / L _t × 100 (L _d is the scattered light transmittance, L _t can be calculated by the equation (total light transmittance).

  In this example, a digital haze computer HGM-2DP manufactured by Suga Test Instruments Co., Ltd. was used as an integrating sphere light transmittance measuring device. The glass transition point can be measured with a viscoelasticity measuring apparatus (FT Rheospector DVE-V4 manufactured by Rheology Co., Ltd.).

As described above, as shown in FIG. 2, a cosmetic molded article 2 was produced in which the base resin was bonded to the back surface 19 of the decorative sheet 1 and the clear sheet 25 was formed on the front surface 18.
In this example, as described above, not only the cosmetic sheet is manufactured using the decorative sheet having the unevenness formed on the surface by forming the unevenness, but the unevenness is formed on the surface without performing the unevenness forming step. A comparative decorative molded product was prepared using a decorative sheet that was not used.
And the graininess was visually evaluated about these cosmetic molded products.
As a result, the decorative molded product produced using the decorative sheet subjected to the above-described unevenness forming step had a strong grain feeling and exhibited excellent design properties.

  In manufacturing the decorative molded product 2 of this example, as shown in FIG. 2, the base resin 20 is injection-molded on the bonding layer 11 side of the decorative sheet 1. Since the base resin 20 is injection-molded on the bonding layer 11 side, the base resin 20 can be bonded to the decorative sheet 1 with good adhesion.

  Moreover, as shown in FIG.1 (c), the decorative sheet 1 which has the decoration sheet 10 in which the unevenness | corrugation 105 was formed, and the joining layer 11 formed in the back surface side 19 is used. Therefore, even if the base resin 20 is injection-molded on the back surface 19 of the decorative sheet 1 as shown in FIG. 2, the unevenness 105 formed on the decorative sheet 10 is not easily reduced. Therefore, the decorative molded product 2 can exhibit an excellent design by making use of the wood grain of the decorative sheet 1.

  Furthermore, the decorative molded product 2 can be manufactured by performing injection molding on the decorative sheet 1 on which irregularities are formed. Therefore, an operation for forming irregularities on the molded product after molding becomes unnecessary, and the cosmetic molded product 2 can be manufactured with high productivity.

  As described above, according to this example, it is possible to manufacture a decorative sheet and a decorative molded article that are excellent in productivity and can enhance the wood grain feeling of wood.

DESCRIPTION OF SYMBOLS 1 Decorative sheet 10 Decorative sheet 105 Concavity and convexity 11 Bonding layer 18 Front side 19 Back side 2 Cosmetic molded product 20 Base resin

Claims (7)

A method for producing a decorative sheet used by injection molding a base resin on the back side in a mold,
On the back side of the decorative sheet containing sheet-like wood, a bonding layer forming step for obtaining a laminated sheet by forming a bonding layer for bonding with the base resin,
A roll processing step of winding the laminated sheet into a roll to produce a laminated sheet roll;
A method for producing a decorative sheet, comprising: forming an unevenness on the surface of the decorative sheet in the laminated sheet while feeding the laminated sheet from the laminated sheet roll to obtain the decorative sheet.   2. The method for manufacturing a decorative sheet according to claim 1, wherein, in the unevenness forming step, the unevenness is formed by shot blasting.   In the manufacturing method of Claim 1 or 2, in the said joining layer formation process, forming the said joining layer by sticking a nonwoven fabric, resin impregnated paper, or a resin sheet on the back surface side of the said decoration sheet. A method for producing a decorative sheet.   4. The method for manufacturing a decorative sheet according to claim 3, wherein, in the bonding layer forming step, a moisture-curable polyurethane adhesive is used for attachment.   It has the injection molding process which arrange | positions the said decorative sheet obtained by the manufacturing method as described in any one of Claims 1-4 in a shaping | molding die, and carries out injection molding of base resin to the said joining layer side in the said decorative sheet. A method for producing a cosmetic molded product.   6. The manufacturing method according to claim 5, wherein vacuum molding or press molding is performed on the decorative sheet before the injection molding step.   7. The manufacturing method according to claim 5, further comprising a clear layer forming step of forming a clear layer by applying a transparent synthetic resin to the decorative sheet side of the decorative sheet and curing after the injection molding step. A method for producing a cosmetic molded product characterized by the above.