JP2019059141A - Production method of molding sheet with fine concavo-convex pattern and molding sheet produced by the production method - Google Patents

Abstract

To provide a production method of a molding sheet with high moldability by which a fine concavo-convex pattern can be formed, and a molding sheet produced by the production method.SOLUTION: The molding sheet is a laminate and produced from a molding original sheet by using a primary molding sheet. A molding original sheet 11 has a base layer 13 and a molding layer 12 that is an outermost surface on one side. A primary molding original sheet has a base layer made of a transparent resin film and a molding layer that is an outermost surface on one side and made of an ultraviolet ray curable resin composition. The molding original sheet 11 has a surface roughness in a specific range. The primary molding sheet is produced by pressing the molding original sheet to a surface of a drum-like molding plate having a surface aspect on the surface thereof that can impart a molding pattern, so as to transfer the surface aspect of the drum-like molding plate to the molding layer, and then irradiating the base layer 13 side of the molding original sheet with UV rays to cure the molding layer 12. The molding sheet is produced by heating the molding original sheet 11, hot-pressing with the primary molding sheet by use of a press machine, so as to transfer the surface aspect of the molding layer of the primary molding sheet to the molding layer of the molding original sheet.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method for producing a shaped sheet capable of forming a fine patterned uneven pattern, and a shaped sheet produced by the method.

  The forming sheet is a laminate including a base material layer and a forming layer having a surface form capable of forming a fine patterned concavo-convex pattern exposed on one side, and the fine patterned asperities visible on the surface, It is possible to shape a sheet having a diffraction gloss due to the diffraction phenomenon of a fine patterned uneven pattern, a matte texture and the like.

  For the purpose of improving the design on the surface of sheets such as synthetic leathers and packagings, and also on the surfaces of furniture, house interiors and car interior materials, pattern patterns by unevenness are shaped or diffracted. The phenomenon may be applied to give a gloss (eg, rainbow-like gloss). At that time, there is a method of forming fine unevenness on the sheet surface to cause a light diffraction phenomenon to express unique gloss.

  In order to express a unique pattern, it is necessary to shape various complicated patterns of depth and depth, and the manufacturing process has become complicated as the pattern becomes complicated.

  For example, a release sheet having a micro-relief shape in the form of a hologram is proposed on the surface, and in resin leather manufactured using such a release sheet, the micro-relief shape in the form of a hologram is formed in the skin layer. Multicolor gloss (rainbow gloss) according to the angle to be observed is exhibited (see Patent Documents 1 and 2).

  However, due to the transfer pressure when forming the fine concavo-convex shape, problems such as the fine concavo-convex shape being crushed or missing during mold release tend to occur, and there was a limit to the shallowness and fineness of the fine concavo-convex shape .

Patent 3098799 JP, 2010-253779, A

  A method of producing a shaped sheet of high formability capable of forming a fine patterned uneven pattern for obtaining a handle with high designability at a low cost without using special equipment, and a method of producing using the method To provide a shaped sheet.

  MEANS TO SOLVE THE PROBLEM The present inventors earnestly research in order to solve the said subject, and the manufacturing method of the shaping | molding sheet in this invention is a fine for obtaining a handle with high design property at low cost, without using a special installation. It has been found that it is possible to provide a shaped sheet having high formability, which can form a pattern asperity pattern with high accuracy.

That is, the present invention is characterized by the following points.
1. It is a manufacturing method of a forming sheet for forming a fine pattern concavo-convex pattern, and
The forming sheet is a laminate having a forming sheet base layer and a forming sheet forming layer which is the outermost layer on one side, and is produced using a primary forming sheet from a forming sheet raw fabric It is
The forming sheet forming layer has a surface mode capable of forming the fine patterned uneven pattern,
The formed sheet material is a laminate having a formed sheet material base layer and a formed sheet material opposite layer which is the outermost layer on one side,
As for the surface roughness of the forming sheet raw material forming layer, S _a is 0.03 μm or more and less than 5 μm,
The surface roughness of the surface on the side of the formed sheet raw material countering layer of the formed sheet raw fabric base layer is such that S _a is 0.3 μm or more and less than 15 μm,
The primary forming sheet is a laminate having a primary forming sheet base layer and a primary forming sheet forming layer which is the outermost layer on one side, and is produced from a primary forming sheet raw fabric. ,
The primary forming sheet forming layer has a surface aspect substantially the same shape as the fine pattern uneven pattern on the surface, and the primary forming sheet raw fabric is a primary forming sheet raw fabric base layer made of a transparent resin film And a primary forming sheet original counteracting layer which is the outermost layer on one side,
A method for producing a shaped sheet, wherein the primary shaped sheet raw material-imparting layer is a layer comprising an ultraviolet curable resin composition, and the method comprises the following steps 1 and 2.
Step 1) The primary forming sheet raw material forming layer capable of flowing the primary forming sheet raw fabric on the surface of a drum-shaped forming plate having a surface aspect capable of forming the fine pattern uneven pattern Wrap it so that
Transferring the surface aspect of the drum-shaped mold plate to the primary mold sheet original counter mold layer by pressure;
Subsequently, the process of irradiating the ultraviolet-ray from the said primary forming sheet raw fabric base-material layer side, hardening | curing the said primary forming sheet original-repelling layer, and producing the said primary forming sheet.
Process 2) overlapping the heated forming sheet raw fabric and the primary forming sheet so that the forming sheet original reflecting layer and the first forming sheet forming layer face each other,
Then, the step of transferring the surface aspect of the primary forming sheet forming layer to the forming sheet original reflecting layer by sandwiching and hot-pressing it with a press device to produce the forming sheet.
2. In the said process 2, the manufacturing method of the forming sheet of said 1 in which the said primary forming sheet and the said forming sheet original fabric are continuous sheets, Comprising: It is continuously drawn out and heat-pressed.
3. In the step 2, the pressed part on the side of the pressing device in contact with the primary forming sheet is a roll having a smooth and hard surface configuration,
The primary forming sheet is a sheet, and is wound around and fixed to the surface of the roll,
The formed sheet material is a continuous sheet which is continuously fed out.
The manufacturing method of a forming sheet as described in said 1.
4. As for the surface roughness of the surface on the side of the formed sheet raw material reflective layer of the formed sheet raw fabric base layer, the S _a is 0.3 μm or more and less than 5 μm,
As for the surface roughness of the surface of the forming sheet raw material forming layer, S _a is 0.03 μm or more and less than 0.5 μm,
The surface roughness of the surface of the primary forming sheet raw material forming layer is such that S _a is not less than 0.03 μm and less than 0.5 μm.
The manufacturing method of a shaping | molding sheet in any one of said 1-3.
5. The surface roughness of the surface on the side of the formed sheet raw material countering layer of the formed sheet raw fabric base layer is such that S _a is 0.3 μm or more and less than 15 μm,
The surface roughness of the surface of the shaped sheet original forming layer is such that S _a is at least 0.03 μm and less than 5 μm,
The surface roughness of the surface of the primary forming sheet raw material forming layer is such that S _a is not less than 0.03 μm and less than 5 μm.
The manufacturing method of a shaping | molding sheet in any one of said 1-3.
6. The formed sheet raw fabric base layer includes a paper layer and a clay layer,
The base sheet for forming a base sheet contains a polypropylene resin or a polymethylpentene resin.
5. Manufacturing method of shaped sheet in any one of said 1-5.
7. The method for producing a shaped sheet according to any one of the above 1 to 6, wherein the fine patterned uneven pattern has a depth of 0.08 μm or more and 10 μm or less.
8. The method for producing a shaped sheet according to any one of the above 1 to 6, wherein the fine patterned uneven pattern has a diffractive gloss and a depth of 0.08 μm or more and 5 μm or less.
9. The method for producing a shaped sheet according to any one of the above 1 to 6, wherein the fine patterned uneven pattern has a matte texture and a depth of 5 μm or more and 10 μm or less.
10. The shaping | molding sheet produced by the manufacturing method of the shaping | molding sheet in any one of said 1-9.

  According to the method for producing a shaped sheet of the present invention, it is possible to form a fine pattern asperity pattern for obtaining a design having a high designability with high accuracy at low cost without using special equipment. It is possible to make a shaped sheet.

  In the present invention, by using a primary forming sheet having a base layer and a resin layer smoother than before, and a primary forming sheet having a base layer smoother than before, the layer is shallower and finer than before. A shaped sheet having the following pattern can be produced with high accuracy.

  Moreover, it is also possible to reduce the pressure at the time of forming the fine patterned uneven pattern on the formed sheet by about 1/10 to 1/3 of the conventional pressure by the above, and the smoothness of the above-mentioned raw fabric The synergetic effect can further produce a shaped sheet having a shallow and fine pattern with high accuracy.

  Furthermore, the addition of the heating means at the time of forming makes it possible to form and process a fine pattern uneven pattern with high precision more stably than before, and the addition of a cooling means at the time of peeling makes the fine pattern unevenness even more stable than before. It is possible to prevent the missing of the pattern, to form and fix the fine patterned uneven pattern with high accuracy, and by the synergetic effect, it is possible to produce a shaped sheet having a shallow and further fine pattern.

  Moreover, the design sheet obtained using the forming sheet by the manufacturing method of this invention can be used for preparation applications of the member for decoration which gives a wrinkles pattern, a diffraction gloss, and a matte texture.

  Specific applications of the design sheet include, for example, synthetic leather products, shoes, bags, sofas, chairs, surface materials such as seats for vehicles, boxes, packaging containers, building interior materials such as wallpaper and flooring, refrigerators and the like The surface decoration material of household appliances, such as a television receiver, etc. can be mentioned.

  Furthermore, the shaped sheet by the manufacturing method of the present invention and the design sheet produced by the shaped sheet can be applied to products of various fields that require high designability and tactile sense.

  For example, it can be used for producing laminated tube containers of contents such as toothpaste, food, cosmetics, medicines, and the like. Laminated tube containers can be identified by tactile sensation by the visually impaired consumer by forming various asperities on the entire surface of the container body, and also by being non-slip, it is particularly elderly. It also has the effect of making it easier for handicapped consumers to hold the tube container.

It is an expanded sectional view of the fine pattern concavo-convex pattern for diffraction glossiness. It is an expanded sectional view of a fine pattern concavo-convex pattern for matte texture. It is the top view seen from the forming layer side of the fine pattern concavo-convex pattern for matte texture. It is a slope figure explaining a primary forming sheet raw fabric. It is a slope view explaining a primary forming sheet. It is a slope figure explaining a forming sheet original fabric. It is a slope view explaining a forming sheet. It is a slope view explaining a design sheet. It is the top view which looked at the fine pattern uneven | corrugated pattern from the forming layer side. FIG. 1 is a simplified diagram of a system for making a primary shaped sheet. FIG. 7 is a simplified diagram of an alternative system for making a primary shaped sheet. FIG. 1 is a simplified diagram of a system for making a shaped sheet.

  Hereinafter, the present invention will be described using the drawings. However, the present invention is not limited to the embodiments specifically illustrated or variously described structures. In the drawings shown below, in order to make it easy to understand, the sizes and ratios of members may be changed or exaggerated. In addition, in order to make it easy to read, unnecessary parts and repetitive reference numerals may be omitted.

  In FIGS. 1 to 8, the shape forming portion forms a linear convex portion extending in the y-axis direction (hereinafter, also referred to as “extending direction” or “longitudinal direction”). And a plurality of linear convex parts are arranged in the x-axis direction.

  Thereafter, in the present invention, a forming sheet having a surface form capable of forming a fine pattern asperity pattern formed on the forming layer of the forming sheet raw fabric is transferred to the forming sheet, and the surface aspect is transferred to the forming sheet raw fabric. A sheet which is a plate for printing is referred to as a primary forming sheet, and a sheet on which the fine patterned uneven pattern is formed by transfer from the forming sheet is referred to as a design sheet.

  Moreover, each of a forming sheet, a primary forming sheet, and a design sheet is manufactured from a forming sheet raw fabric, a primary forming sheet raw fabric, and a design sheet raw fabric.

  In the present invention, the fine patterned uneven pattern is first transferred from the surface of the drum-like shaped plate to the primary forming sheet original reaction layer, and then transferred to the forming sheet original reaction layer, Finally, it is transferred to the surface of the design sheet.

  Here, the fine patterned uneven pattern refers to the pattern on the design sheet in a narrow sense, but the aspect of the inverted uneven structure before transfer is also described similarly without distinction. In addition, although it is assumed that sharp corners become rounded due to transfer, the shape before and after transfer is considered to have substantially the same shape, and is similarly described as a fine patterned relief pattern.

  Specifically, for example, the manufacturing method of the present invention heats and heats a formed sheet material including a base material layer having a specific surface roughness and a forming layer having a specific surface roughness. Manufacturing forming a fine patterned uneven pattern in the forming layer by overlapping the forming layers with the forming sheet raw fabric, overlapping the forming layers, sandwiching and pressing with a press, and then cooling. It is a method. As a press part of a press, what combined the roll and the flat plate is used.

  In the description of each layer of each member, unless otherwise specified, for example, the term "raw" refers to the raw fabric of the member, and the terms base layer, shaping layer, shaping portion, base refer to the basis of the member. It is described as referring to a material layer, a forming layer, a forming part, and a base.

In the present invention, the emboss roll is, in a narrow sense, a roll having a surface aspect of the embossed structure on the surface, but a roll on which a drum-shaped embossed plate is attached or a side on which a forming sheet is in contact. Also described as a generic term that also includes roles.

  In the present invention, the backup roll is a pair of rolls used simultaneously with the emboss roll, and the surface of the backup roll is selected to be soft or hard depending on the purpose and usage.

  The backup roll having a soft surface is a roll provided with a surface configuration that can be transferred by pressure application to a roll having a emboss roll or a drum-shaped embossed forming plate attached or a surface-embossed uneven shape of a forming sheet forming layer, The transfer may be temporary or permanent, and when the backup roll is used, the surface embossed asperity shape can be reflected not only on the forming layer of various sheets but also on the base material layer.

  Specific examples of the backup roll having a soft surface include, for example, a paper roll such as a woolen paper roll, a high elasticity roll, a rubber roll and the like.

  The backup roll having a hard surface is a roll having a surface structure in which the surface embossed asperity shape of the roll on which the emboss roll or the drum-shaped embossed forming plate is attached and the formed sheet forming layer is not transferred by pressure bonding When the backup roll is used, transfer is mainly reflected on the forming layer of the transfer target sheet.

  In the present invention, as the backup roll, either a backup roll having a soft surface or a backup roll having a hard surface can be used, and when it is desired to form a particularly fine pattern, a backup having a hard surface Roll is preferred.

  The same applies to the case of using one roll and one flat plate, or the case of using two flat plates, and one having smooth and hard surfaces on both sides can also be selected, and the surface on the side to be a mold base is smooth Although it is hard, the side to be transferred can be selected from a wide variety according to the purpose.

  Although a resin composition refers to the thing which mix | blended the other component with resin in a narrow sense, in this invention, resin is also described as what is included in a resin composition.

<Fine pattern unevenness pattern>
In the present invention, the unit size of the handle means the pitch in the repeat direction in the case of a regular repeat pattern, and in the case of a random independent pattern, the long side of the long side of the rectangle when the unit pattern is enclosed in a rectangle. And may be very large, such as the width or length of the shaped sheet.

  In the present invention, the fine patterned uneven pattern may be a regular repeated pattern or a random pattern having different types of unit patterns and unit sizes of patterns.

  FIGS. 1 and 2 show enlarged cross-sectional views of the fine patterned uneven portion. P indicates the pitch of the fine patterned uneven pattern, D indicates the depth of the fine patterned uneven pattern, and the shaping portion is in the y-axis direction (hereinafter, also referred to as “extending direction” or “longitudinal direction”). Forming a linear convex portion extending to the And a plurality of linear convex parts are arranged in the x-axis direction.

  In the present invention, the depth D of the fine patterned relief pattern is preferably 0.08 μm or more and 10 μm or less.

When it is desired to obtain the diffraction gloss on the surface of the design sheet, the fine patterned uneven pattern is a line shape in which the linear convexes of the fine patterned uneven pattern are laterally inverted as shown in FIG. 1 as an example. The base has an isosceles triangular cross section having an apex on the side opposite to the base, and the shape extends in one direction while maintaining the isosceles triangular cross section, and the wide cross section has a substantially triangular shape. Is preferred.

  When it is desired to obtain diffraction gloss on the surface of the design sheet, the depth D of the fine patterned relief pattern is preferably 0.08 μm or more and 5 μm or less, and the pitch P is preferably 1 μm or more and 10 μm or less.

  In addition, when the pitch P is 1 μm or more and 3 μm or less, the apex angle θ at the apex of the isosceles triangle of the linear convex portion is 80 ° or more and 160 ° or less when the pitch P is 1 μm or more and 2 μm or less In the case where the pitch P is more than 2 μm and not more than 3 μm, 120 ° or more and 160 ° or less is preferable.

  When it is desired to obtain a matte texture on the surface of the design sheet, as shown in FIG. 2 as an example, the fine patterned concavo-convex pattern has a convex portion in the form of a substantially square pole having a substantially rhombus bottom surface, It is preferable that it has a wave shape or a substantially trapezoidal wave shape.

  When it is desired to obtain a matte texture on the surface of the design sheet, the depth D of the fine patterned relief pattern is preferably 5 μm or more and 10 μm or less, and the pitch P is preferably 0.1 mm or more and 5 mm or less. Moreover, in the case where the plan view when viewed from above is a fine patterned concavo-convex pattern giving a matte texture as shown in FIG. 3, the tactile sense that the width W of the convex portion is 0.1 mm or more and 1 mm or less Because it is excellent.

  The cross-sectional shape of the fine patterned concavo-convex pattern can be various shapes, and examples thereof include a substantially triangular wave shape, a substantially rectangular wave shape, a substantially trapezoidal wave shape, a substantially sinusoidal wave shape or a substantially sawtooth wave shape.

  By having the above-mentioned fine pattern concavo-convex pattern on the surface of the design sheet, the design sheet has the matte texture appearance, the distinguishability by the diffraction gloss and the touch feeling, and the consumer, particularly the elderly can use the design sheet container. It offers the advantage of being easy to hold without sliding.

  Moreover, as a shape pattern of the convex-concave part of the fine pattern uneven | corrugated pattern on the surface of a design sheet, a point dispersion form, stripe form, etc. can also be used. Furthermore, as shown in FIG. 8, triangular linear protrusions and flat linear recesses may be formed. The pattern of the design sheet shown in FIG. 8 is produced by using the shaped sheet shown in FIG.

  Further, as a shape pattern of the concavo-convex portion of the fine patterned concavo-convex pattern on the surface of the design sheet, a form for producing a sheet of a pattern in which islands of quadrangular pyramid are arrayed, or a non-geometrical pattern of wrinkles or crocodile leather It may be in the form of

  In the present invention, the form of the fine patterned uneven pattern on the surface of the design sheet is a convex portion, from the viewpoint of manufacturing that the fine patterned uneven pattern is transferred to the surface resin layer of the design sheet using the forming sheet. The recess, the top, and the valley may not be as clear as shown in FIGS. 1 and 2, but may be rounded in the corner or have a substantially trapezoidal cross section. However, the matte texture and the diffractive gloss can be sufficiently observed in a bright and wide field of view, if not the clear aspect.

  FIGS. 9 (a) and 9 (b) are plan views of the surface resin layer as viewed from above, in which a linear convex portion with a fine patterned uneven pattern and a linear concave portion extend. Fig. 9 (a) is an example in which the linear convex portion and the linear concave portion extend in parallel to the longitudinal direction (y-axis direction in the same figure) of the strip-like shaped sheet, and Fig. 9 (b) is a line This is an example in which the convex portion and the linear concave portion extend at an angle α with respect to the longitudinal direction (y-axis direction in the figure) of the strip-shaped shaped sheet.

  Although it varies depending on the pattern, in the case of the pattern of FIGS. 9A and 9B, the range of α is preferably 0 ° or more and 1 ° or less. FIG. 9A shows the case where α is 0 °. By setting α to the above-mentioned range, it is possible to improve the releasability at the time of producing the shaped sheet and the releasability at the time of producing the design sheet using the shaped sheet. Defects such as chipping are less likely to occur.

  The fine patterned relief pattern is preferably located on a smooth and substantially flat surface of the surface resin layer. This is because when the fine patterned uneven pattern is transferred from the forming sheet, the fine patterned uneven pattern positioned on a smooth substantially flat surface is excellent in transferability (forming property).

  Specific examples of the smooth substantially flat surface include a portion having no other pattern, the bottom of the concave portion of the surface resin layer, the top of the convex portion of the surface resin layer, and the like.

  Under the same conditions, the fine pattern concavo-convex pattern located around the convex top surface, around the concave bottom, and on the slope, and the fine pattern concavo-convex pattern located on the above-mentioned smooth and substantially flat surface are simultaneously transferred (formed) under the same conditions. It is difficult to be done.

  Therefore, it is also preferable to shape the fine pattern asperity pattern only on the smooth and substantially flat surface of the surface resin layer surface of the design sheet and finish with high accuracy.

<Primary form sheet original fabric>
In FIG. 4, the perspective view showing one example of the primary forming sheet raw fabric in this invention was shown. As can be seen from FIG. 4, the primary forming sheet raw fabric is a laminate having a forming layer and a base layer.

  Furthermore, the base material layer can also have a smoothing layer such as a smoothing resin layer in order to smooth the surface on the forming layer side of the base material layer.

  Furthermore, in order to improve the adhesion between the base material layer and the forming layer, the base material layer may be subjected to an easy adhesion treatment such as corona discharge treatment, ozone treatment, etc. An anchor coat layer comprising an anchor coat agent or the like can also be provided on the forming layer side.

  The primary formed sheet material may be in the form of a sheet or in the form of a continuous sheet wound on a roll.

[Base layer]
In the present invention, the base layer of the primary formed sheet raw fabric preferably transmits ultraviolet light, and more preferably has heat resistance, smoothness, bending resistance, rigidity, etc. Specifically, a resin film Alternatively, a sheet, a resin coating film or the like is preferably used.

  Specific examples of the resin include polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate, polyamide resins such as various nylons, polyethylene resins, polypropylene resins, cyclic polyolefin resins, polystyrene resins, acrylonitrile- Styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), polyolefin resin such as polybutene resin, polyvinyl chloride resin, polycarbonate resin, polyimide resin, polyamideimide resin, poly Aryl phthalate resin, silicone resin, polysulfone resin, polyphenylene sulfide resin, polyethersulfone resin, polyurethane resin, cellulose resin, poly (meth) acrylic resin, Li vinylidene chloride, acetal resins, fluorine-based resins, resins other, and the like.

  In the present invention, in particular, it is preferable to use a film or sheet of polyester resin, polypropylene resin, or polyamide resin, and from the viewpoint of heat resistance and smoothness, polyester such as polyethylene terephthalate and polyethylene naphthalate. It is more preferable to use a film or sheet of a base resin, and it is particularly preferable to use a PET film or sheet.

  Also, if necessary, films or sheets of two or more resins may be used in combination.

  In order to make the surface of the forming layer smooth, it is effective to make the surface of the base layer smooth.

Primary shaping sheet raw S _a surface roughness of the shaping layer side of the anti-substrate layer, or 0 .mu.m, preferably less than 15 [mu] m. Here, that Sa is 0 means that it is Sa below the measurement limit of the device.

  Furthermore, in the case where the surface of the original transfer layer is made to have mirror gloss specifications, or in the case of forming a fine patterned uneven pattern exhibiting diffractive gloss in a later step, 0 μm or more and less than 0.5 μm are preferable, and the original transfer layer In the case where the surface is made to have a matte matte specification or in the case of forming a fine patterned concavo-convex pattern exhibiting a matte texture in a later step, 0 μm or more and less than 15 μm is preferable.

The surface roughness of the S _z of shaping layer side of the primary shaping sheet raw substrate layer, 3 [mu] m or more, preferably 250μm or less, 5 [mu] m or more, more preferably at most 150 [mu] m.

  Furthermore, in the case where the surface of the original reaction layer is made to have mirror gloss specifications, or in the case of forming a fine patterned uneven pattern exhibiting diffractive gloss in a later step, 3 μm or more and less than 20 μm are preferable, and 5 μm or more and less than 20 μm are more preferable. Preferably, when the surface of the original transfer layer is made to have a matte matte specification or when forming a fine patterned uneven pattern exhibiting a matte texture in a later step, 20 μm or more and 250 μm or less is preferable, and 20 μm or more and 150 μm or less Is more preferred.

Here, S _a and S _z are arithmetic mean roughnesses defined in JIS B0601 2001, and can be measured using a shape analysis laser microscope (VK-8710 manufactured by Keyence Corporation) or the like.

If S _a or S _z is larger than the above range, unevenness is likely to occur in the formation of the fine patterned concavo-convex pattern on the formed sheet original reaction layer, and in particular, there is a risk of inhibiting the development of the diffraction gloss. If S _a or S _z is smaller than the above range, the cost for producing is high while the effect is limited. From the viewpoint of compatibility between cost and performance, S _a and S _z is preferably in the range of above.

In the present invention, by selectively using a smooth resin film or sheet of the above-mentioned range of S _a or S _z , it is possible to form a wide and shallow fine patterned uneven pattern with high accuracy.

  The thickness of the substrate layer is not particularly limited as long as it can support the forming layer, but is preferably 8 μm or more and 300 μm or less, and more preferably 10 μm or more and 200 μm or less.

  If the thickness is larger than the above range, the improvement of the supportability is limited when laminating and processing the forming layer, but the rigidity may be too strong, and the cost is also increased. If the thickness is smaller than the above range, the supportability in laminating and processing the forming layer may be insufficient.

(Smoothing layer)
The smoothing layer further smoothes the surface of the base layer to improve the shape transferability of the forming layer, and is provided on the surface of the base layer on the side of the forming layer, as necessary. However, the forming shape durability of the forming layer tends to be slightly reduced.

  The smoothing layer may be formed by coating or extrusion coating a resin layer made of a polyolefin-based resin or the like, or the surface roughness may be adjusted by a super mirror chill roll or the like.

  The thickness of the smoothing layer is not particularly limited, but is preferably 10 μm to 60 μm.

(Anchor coat layer)
The anchor coat layer is a layer provided as necessary for the purpose of improving the adhesion between the surface of the base material layer and the forming layer. In the present invention, it can be used as a generic term for coating treatment such as primer coat and anchor coat, and can be used in combination with easy adhesion treatment such as corona discharge treatment and ozone treatment. It can also be provided to improve the adhesion between the base resin film or sheet and the smoothing layer.

  The anchor coat layer can be formed, for example, by applying a water-soluble or water-dispersible emulsion or dispersion anchor coat agent.

  Examples of the anchor coating agent include polypropylene-based, modified polyolefin-based, ethylene-vinyl acetate copolymer-based, polyethyleneimine-based, polybutadiene-based, polyurethane-based, polyurethane-based, emulsion or dispersion of polyester resins, polyvinyl chloride emulsion, urethane acrylic Resin emulsion, silicone acrylic resin emulsion, vinyl acetate acrylic resin emulsion, acrylic resin emulsion, and styrene-butadiene copolymer latex, acrylonitrile-butadiene copolymer latex, methyl methacrylate-butadiene copolymer latex, chloroprene latex, polybutadiene latex Rubber latex, polyacrylate latex, polyvinylidene chloride latex, or These are carboxyl modified products of these latexes, and as water soluble anchor coating agents, polyvinyl alcohol, water soluble ethylene-vinyl acetate copolymer, polyethylene oxide, water soluble acrylic resin, water soluble epoxy resin, water soluble cellulose derivative, Aqueous solutions of water-soluble polyesters, water-soluble isocyanates, water-soluble lignin derivatives and the like can be used.

  Among these, an emulsion or dispersion of a polypropylene-based or modified polyolefin-based resin is preferable in that it can further increase the lamination strength of the polypropylene-based resin layer to paper and is excellent in heat resistance.

The anchor coating agent can be applied by, for example, a gravure coating method, a reverse roll coating method, a knife coating method, a kiss coating method, or the like. / m ² ~5g / m ² is preferred.

[Shape layer]
In the present invention, the forming layer of the primary forming sheet raw fabric is a layer formed of an ultraviolet ray curable resin or an ultraviolet ray curable resin composition laminated on one surface of the base material layer, It has a surface aspect of a structure which can form a surface aspect capable of transferring a target micropattern unevenness pattern by transfer, that is, a surface aspect of a micropattern unevenness structure having substantially the same shape as the target micropattern unevenness pattern It is what you get.

In the present invention, the ultraviolet curable resin composition may be solventless or solvent type, and further, if necessary, a dispersant, a viscosity modifier, a colorant, an antistatic agent, an inorganic substance. Or organic particles may be contained. By using the ultraviolet curable resin composition, it is easy to achieve high formation accuracy of the fine patterned relief pattern.

  The specific UV curable resin contained in the UV curable resin composition is not particularly limited as long as it can function as a mold sheet original reaction mold layer, but (meth) acrylic resin, It is preferable to contain an acrylic ester copolymer and the like. These resins may be used alone or in combination of two or more.

  Furthermore, in order to adjust the curability, toughness and rigidity, it is also possible to use a urethane resin, an epoxy resin, an ester resin, etc. in combination, as long as the ultraviolet curability is not impaired.

  Although the thickness of the forming layer depends on the desired fine patterned relief pattern, it is preferably 20 μm or more and 200 μm or less, and more preferably 30 μm or more and 150 μm or less.

Surface roughness S _a primary shaping sheet raw shaping layer is more than 0.03 .mu.m, preferably less than 5 [mu] m, a primary shaping sheet raw shaping layer surface mirror gloss specifications using mirrors chill roll or the like When forming a fine pattern asperity pattern exhibiting diffractive gloss in a later step or in a later step, it is preferable that the thickness is 0.03 μm or more and less than 0.5 μm. When using it as a matte mat specification and forming a fine patterned uneven pattern which exhibits matte texture in a later step, it is preferably 0.03 μm or more and less than 5 μm.

[Production of primary formed sheet stock]
The forming layer of the primary forming sheet raw fabric is formed, for example, by applying an ultraviolet curable resin composition to a base film, but the forming method is not particularly limited. For example, a die coating method or The gravure coating method is mentioned, and in the state which made the base film wound around a roll in the other, it is immersed in the ultraviolet curable resin composition which has fluidity, and it is ultraviolet curable resin composition only on the single side of a substrate film. The method of laminating | stacking and forming with a fixed thickness is also mentioned.

  As a method of imparting fluidity to the ultraviolet curable resin composition, even if it is rendered fluid by adding a solvent, even if it is rendered fluid by using a resin material having fluidity, it is rendered fluid by heating. You may have it.

  The primary formed sheet stock produced by the above method may dry the formed layer as needed. Alternatively, while producing the primary formed sheet, the primary formed sheet may be prepared by continuously forming immediately after.

<Primary form sheet>
The primary forming sheet is produced from the primary forming sheet raw fabric, is composed of a forming layer and a base material layer, and a fine patterned uneven pattern is formed on the forming layer. FIG. 5 is a perspective view showing an example of the primary forming sheet.

[Shape layer]
As can be seen from FIG. 5, in the forming layer of the primary forming sheet, the base and the forming portion are integrally configured.

  The shaping layer of the primary shaping sheet is a surface aspect capable of forming a structural portion of the surface aspect which can be formed by transferring the desired fine pattern unevenness on the shaping sheet forming layer, that is, the purpose Surface pattern of the micropattern on the design sheet and the micropattern on the design sheet.

The thickness of the forming layer base is not particularly limited, but is preferably 10 μm or more and 150 μm or less, and more preferably 15 μm or more and 100 μm or less. If the thickness is smaller than the above range, the formed sheet is likely to be torn, and if the thickness is larger than the above range, the flexibility tends to be lacking and the usability tends to be deteriorated.

  The thickness of the forming layer and the thickness of the base are not particularly limited, and are preferably determined appropriately in relation to the structure of the fine patterned relief pattern.

  A mirror chill roll or the like can be used to make the surface of the original application layer a mirror gloss specification or a diffraction gloss specification, and a matte chill specification or a matte texture specification can be used to make the surface of the formation layer matte. A roll etc. can be used.

[Base layer]
Although the base material layer of the primary forming sheet is the same as the primary forming sheet raw fabric, in some cases, even if it has a concavo-convex structure in which the fine patterned concavo-convex pattern formed in the forming layer is reflected Good.

[Preparation of primary shaped sheet]
In the primary forming sheet, for example, the forming layer of the primary forming sheet raw fabric is rendered fluid by heating or containing a solvent so that the forming layer is in contact with the surface of the drum-like forming plate. A state in which the surface asperity shape of the drum-like shaped plate is transferred to the forming layer by pressing the primary formed sheet raw fabric by pressure bonding, and further, the primary formed sheet raw fabric is wound around the drum shaped formed plate Then, the ultraviolet ray is irradiated from the substrate layer side to cure the ultraviolet ray curable resin composition, and then it is cooled to fix the surface asperity shape of the forming layer and then released from the drum-shaped forming plate. Can be obtained.

  The primary formed sheet may be in the form of a continuous sheet wound on a roll, or may be in the form of a sheet. Even if a sheet-like primary-formed sheet is produced from a sheet-like primary-formed sheet raw fabric, it can be obtained by cutting a continuous sheet-like primary formed sheet wound on a roll. It may be

  In addition, it is possible to apply well-known various methods to the means of said heating and cooling.

  As a specific heating means, for example, a method of applying hot air before the primary forming sheet raw fabric is wound on the drum-like forming plate, a feed roll in front of the drum-like forming plate and the drum-like forming plate from the inside The method of heating by steam, dielectric heating, etc., etc. are mentioned.

  The various heating means may be used alone or in combination of two or more. In addition, the primary forming sheet raw fabric may be sandwiched between the feed roll and the drum-like shaped plate and heated.

  As a specific cooling means, for example, a method of cooling the drum-shaped molding plate from the inside with a refrigerant etc., a method of applying cold air after irradiation with ultraviolet light, a method of cooling the take-out roll after the drum-shaped molding plate, etc. Be

  The various cooling means may be used alone or in combination of two or more. The primary formed sheet material may be sandwiched between the cooled take-out roll and the drum-shaped shaped plate.

  The heating temperature is different depending on the composition of the ultraviolet curable resin composition, and when the ultraviolet curable resin composition is solid at room temperature, the ultraviolet curable resin composition sufficiently forms the surface shape of the drum-shaped molding plate It is necessary that the temperature be such that it can be flowed so as not to drop from the base material layer, and the ultraviolet curable resin composition has fluidity at room temperature due to the inclusion of a solvent, etc. Can be made unnecessary. It is preferable to prepare so that a shaping | molding layer may be 30-130 degreeC.

The cooling temperature is preferably low enough to be appropriately hard enough to be released without losing the shape of the forming layer according to the physical properties of the cured product of the ultraviolet curable resin composition. It is preferable to prepare so that it may become 50 degreeC.

<Formed sheet raw fabric>
In FIG. 6, the perspective view showing one example of the forming sheet original fabric in this invention was shown. As can be seen from FIG. 6, the formed sheet stock has a formed layer and a base layer.

  Furthermore, in order to smooth the surface on the forming layer side of the base material layer, the base material layer can also include a smoothing layer.

  Furthermore, for the purpose of improving the adhesion between the base material layer and the forming layer, the surface of the base material layer may be subjected to an easy adhesion treatment such as corona discharge treatment or ozone treatment, and the primer or anchor coat An anchor coat layer comprising an agent or the like can also be included on the surface of the base layer.

  The formed sheet material may be in the form of a sheet or in the form of a continuous sheet wound on a roll.

[Base layer]
In the present invention, the base material layer of the formed sheet raw fabric is provided with forming property, bending resistance, rigidity and the like, and is conventionally known in general for release sheet for resin leather production and process paper. A base material of material can be used.

  For example, various types of paper base materials, resin films or sheets, metal foils, woven fabrics, non-woven fabrics, clays, laminates of any of these or the like may be used alone or in combination of two or more. Moreover, resin can also be apply | coated and used.

  In the present invention, it is preferable to use a paper base from the viewpoint of being hard to cause thermal deterioration and having high adhesion with the formed sheet original reaction layer, and in the case where heat resistance and surface smoothness are particularly required. It is preferable to use a polyester base such as polyethylene terephthalate and polyethylene naphthalate.

  In the case where the forming sheet base reaction layer is composed of the ultraviolet curable resin or the ultraviolet curable resin composition, the forming sheet base substrate layer is the same as that used in the primary forming sheet, It is preferable to use a UV-transparent resin film or sheet.

  In order to make the surface of the formed sheet original fabric forming layer smooth, it is effective to make the surface of the formed sheet original fabric base layer also smooth.

Shaping sheet raw base layer surface roughness S _a of the shaping layer side of, 0.3 [mu] m or more, preferably less than 15 [mu] m, 1.0 .mu.m or more and more preferably less than 15 [mu] m.

  Furthermore, in the case where the surface of the original transfer layer is made to have mirror gloss specifications, or in the case of forming a fine patterned concavo-convex pattern exhibiting diffractive gloss in a later step, 0.3 μm or more and less than 5 μm is preferable, 1.0 μm or more Less than 5 μm is more preferred. In addition, in the case where the surface of the original transfer layer is made to have a matte matte specification or in the case of forming a fine patterned uneven pattern exhibiting a matte texture in a later step, 0.3 μm or more and less than 15 μm is preferable, 1.0 μm More preferably, less than 15 μm.

Shaping sheet raw surface roughness of the S _z of shaping layer side of the anti-substrate layer, 3 [mu] m or more, preferably 250μm or less, 5 [mu] m or more, more preferably at most 150 [mu] m.

  Furthermore, in the case where the surface of the original reaction layer is made to have mirror gloss specifications, or in the case of forming a fine patterned uneven pattern exhibiting diffractive gloss in a later step, 3 μm or more and less than 20 μm are preferable, and 5 μm or more and less than 20 μm are more preferable. preferable.

  In the case where the surface of the original transfer layer is made to have a matte matte specification or in the case of forming a fine patterned uneven pattern exhibiting a matte texture in a later step, 20 μm or more and 250 μm or less is preferable, and 20 μm or more and 150 μm or less Is more preferred.

If S _a or S _z is larger than the above range, the smoothness of the formed sheet original reaction layer may be lowered, and furthermore, the application of the fine patterned concavo-convex pattern to the formed sheet original reaction layer This tends to cause unevenness in the mold, which may inhibit the development of the diffraction gloss of the design sheet produced using the shaped sheet.

If S _a or S _z is smaller than the above range, the cost for producing the formed sheet raw fabric is increased, while the effect is limited. From the viewpoint of achieving both cost and performance, the smoothness of the formed sheet raw material base layer is preferably in the above range.

  The thickness of the formed sheet raw material base layer is not particularly limited, but is preferably 20 μm or more and 900 μm or less, more preferably 25 μm or more and 200 μm or less, and 50 μm or more and 150 μm or less Even more preferred is

  If the thickness is larger than the above range, the rigidity may be too strong, and while the cost increases, the improvement of the support effect is limited. If the thickness is thinner than the above range, the supportability may be insufficient when laminating and processing the original forming sheet counteracting layer.

(Resin film or sheet)
The resin used for the formed sheet material base material layer can be used as a film or a sheet, and can also be used by coating.

  Specific examples of the resin used for the formed sheet material base layer include polyester resins such as polyethylene terephthalate (PET), polyamide resins such as various nylons, polyethylene resins, polypropylene resins, cyclic polyolefin resins Polystyrene resin, acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), polyolefin resin such as polybutene resin, polyvinyl chloride resin, polycarbonate resin, polyimide resin Polyamide imide resin, polyaryl phthalate resin, silicone resin, polysulfone resin, polyphenylene sulfide resin, polyether sulfone resin, polyurethane resin, cellulose resin, poly (meth) acrylic resin Fats, polyvinylidene chloride, acetal resins, fluorine resins, etc. can be used, and in particular, it is more preferable to use a film or sheet of polyester resin, polypropylene resin, or polyamide resin, In particular, PET films or sheets, particularly easy-adhesion PET films or sheets, are preferably used.

(Paper base)
A paper base material can be used as a constituent material of the formed sheet material base layer.

  As a specific paper substrate, for example, strong-sized exposed or non-bleached paper substrate, or pure white roll paper, kraft paper, paperboard, coated paper, cast coated paper, processed paper, high-quality paper, etc. Can be used.

In the above, as the paper substrate, those having a basis weight of about 80g / m ² ~600g / m ² position, preferably, it is desirable to use a basis weight of about 100g / m ² ~450g / m ² position.

  For pulp of paper base, soft wood pulp (N material) to obtain strength and smoothness that can withstand the process of forming large pattern unevenness pattern and fine pattern unevenness pattern in the forming layer and the process of producing synthetic leather It is preferable to mix hardwood pulp (wood L) with In that case, in order to improve smoothness, the mixing ratio of hardwood pulp (L material) is preferably 50% to 90%.

  The paper substrate is required to be neutral paper in order to obtain sufficient heat resistance of the release paper, and is preferably neutral paper sized using alkyl ketene dimer as a sizing agent.

The basis weight of the paper substrate include those having a basis weight of about 80g / m ² ~600g / m ² position, preferably, it is desirable to use a basis weight of about 100g / m ² ~450g / m ^2-position, in particular, in a synthetic leather create applications, strength, it is preferred synthetic leather processing workability, a repeated use durability and the surface of the embossing suitability 100g / m ² ~200g / m ² of release paper.

If the basis weight is less than 100 g / m ² , curling and waving will easily occur during production of the synthetic leather. On the other hand, when the basis weight is higher than 200 g / m ² , the embossing property is poor, and when the release paper is thick, the winding diameter becomes large and the working efficiency is lowered.

  The thickness of the paper substrate may be 100 μm to 900 μm, preferably 150,100 μm to 600 μm in synthetic leather production applications. However, in general, it is preferable to use one having a size of 10 μm to 200 μm.

  When a material having a relatively rough surface, such as kraft paper or wood free paper, is used as the paper base for the formed sheet raw material base layer, the smoothness on the paper base can be improved.

(Smoothing layer)
The smoothing layer is provided on the surface on the forming layer side of the forming sheet raw fabric base layer, as necessary, to smooth the surface of the forming sheet raw fabric base layer.

  The thickness of the smoothing layer is not particularly limited, but is preferably 10 μm to 60 μm.

  The smoothing layer is made of, for example, a clay coat layer or a smoothing resin layer, and may be used alone or in combination of two.

  The clay coat layer can be used without particular limitation as the clay, as long as it is generally called clay or clay. Specifically, for example, kaolin, talc, bentonite, smectite, vermiculite, mica, chlorite, woodblock clay, gylome clay, halloysite, mica and the like can be used.

  Talc is low in hardness (Mohs hardness 1) and excellent in heat resistance, so that heat resistance can be improved and dimensional stability at the time of embossing can be improved.

  On the contrary, the higher the hardness of the smoothing layer, the less the influence of the formation of the paper base in the forming sheet base reaction layer formed on the smoothing layer, and as a result, the forming sheet base fabric Since the surface of the forming layer becomes uniform, the transferability (shapeability) of the concavo-convex structure of the plate surface is improved.

The clay coat layer preferably contains calcium carbonate, titanium dioxide, amorphous silica, foamable barium sulfate, satin white and the like as pigments in addition to clay. By using calcium carbonate or titanium dioxide as the pigment, the smoothness of the surface of the clay coat layer can be further enhanced. In addition, calcium carbonate is preferably used because it is inexpensive.

  The coating liquid for applying the clay coating layer contains the above-described clay, a binder, and, if necessary, other pigments and additives, as a solvent. As the solvent, water, alcohol or the like is usually used. The binder is usually a latex binder (eg, styrene butadiene latex, acrylic latex vinyl acetate latex), a water soluble binder (eg, starch (modified starch, oxidized starch, hydroxyethyl etherified starch, phosphate ester) Starch), polyvinyl alcohol, casein, etc. are used. As the additive, a pigment dispersant, an antifoamer, an antifoaming agent, a viscosity modifier, a lubricant, a water resistant agent, a water retention agent, and the like are used.

The method of applying the clay coat layer is not particularly limited, but application methods such as air knife coating, blade coating, short dwell coating, cast coating and the like are used. The coating amount and thickness of the clay coat layer is not particularly limited, the basis weight is preferably 5g / m ² ~40g / m ² after ^{drying, 10g / m 2 ~40g / m} 2 is more preferable.

If the basis weight after drying is less than 5 g / m ² , the smoothness may be poor. If the basis weight after drying exceeds 40 g / m ² , there is a possibility that the adhesion may be reduced due to the cohesive failure of the clay coat layer, and the cost performance is inferior.

  As the smoothing resin layer, it is preferable to use a polyolefin resin. When used in combination with the clay coat layer, forming on the side of the mold layer on the clay coat layer is preferable because it is possible to obtain a surface of the base layer having a higher smoothness than the case of using only the clay coat layer.

  The formation of the smoothing resin layer is preferably a method by extrusion coating or coating.

(Anchor coat layer)
An anchor coat layer can be provided on the surface of the base material layer, if necessary, for the purpose of improving the adhesion between the formed sheet raw fabric base layer and the formed sheet original reaction layer. In the present invention, anchor coating is described as a generic term for coating treatment such as primer coating and anchor coating.

  When providing an anchor coat layer, it can also be used together with easy-adhesion processings, such as corona discharge treatment and ozone treatment.

  For example, when the base material layer has a clay coat layer as a smoothing layer, the surface of the clay coat layer has a good lubricity, so the adhesion with the extruded resin tends to be poor, but the anchor coat layer The adhesion can be enhanced by forming

  The anchor coat layer can be formed, for example, by applying a water-soluble or water-dispersible emulsion or dispersion anchor coat agent.

Examples of the anchor coating agent include polypropylene-based, modified polyolefin-based, ethylene-vinyl acetate copolymer-based, polyethyleneimine-based, polybutadiene-based, polyurethane-based, polyurethane-based, emulsion or dispersion of polyester resins, polyvinyl chloride emulsion, urethane acrylic Resin emulsion, silicone acrylic resin emulsion, vinyl acetate acrylic resin emulsion, acrylic resin emulsion, and styrene-butadiene copolymer latex, acrylonitrile-butadiene copolymer latex, methyl methacrylate-butadiene copolymer latex, chloroprene latex, polybutadiene latex Rubber latex, polyacrylate latex, polyvinylidene chloride latex, or These are carboxyl modified products of these latexes, and as water soluble anchor coating agents, polyvinyl alcohol, water soluble ethylene-vinyl acetate copolymer, polyethylene oxide, water soluble acrylic resin, water soluble epoxy resin, water soluble cellulose derivative, Aqueous solutions of water-soluble polyesters, water-soluble isocyanates, water-soluble lignin derivatives and the like can be used.

  Among these, an emulsion or dispersion of a polypropylene-based or modified polyolefin-based resin is preferable in that it can further increase the lamination strength of the polypropylene-based resin layer to paper and is excellent in heat resistance.

The method for applying the anchor coating agent can be, for example, gravure coating, reverse roll coating, knife coating, kiss coating, etc. m ^{2 to 5} g / m ² is preferred.

[Shape layer]
In the present invention, the original forming sheet raw layer is a layer made of a resin or a resin composition laminated on one surface of the original forming sheet base layer, and the target fine layer on the surface of the design sheet. It may have a surface aspect that can be formed by transferring the surface aspect of the patterned relief pattern structure.

  In the present invention, the resin or the resin composition may be non-solvent type or solvent type, and further, if necessary, dispersant, viscosity modifier, colorant, antistatic agent, inorganic substance Or organic particles may be contained.

  In the present invention, the resin or resin composition of the forming sheet base reaction layer is not particularly limited as long as it can function as the forming sheet base reaction layer, and various thermoplastic resins and heat A curable resin, an ultraviolet curable resin, etc. can be used. These resins may be used alone or in combination of two or more.

  Examples of thermoplastic resins include poly (meth) acrylic resins such as polyacrylates and polymethyl methacrylates; polyolefin resins such as polyethylene resins, polypropylene resins, and polymethylpentene resins; melamine alkyd resins, polyethylene terephthalate, and poly (ethylene terephthalate) Polyester resins such as butylene terephthalate; vinyl resins such as polyvinyl chloride; styrene resins such as polystyrene; polycarbonate resin; polyamide resin (nylon), polyvinyl alcohol and the like. These resins may be used alone or in combination of two or more.

  As a thermosetting resin, for example, unsaturated polyester resin, melamine resin, epoxy resin, polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyether (meth) acrylate, polyol (meth) Acrylate, melamine (meth) acrylate, triazine-based acrylate, silicone resin and the like can be mentioned. These resins may be used alone or in combination of two or more.

  As an ultraviolet curable resin, (meth) acrylic-type resin, an acrylic acid ester copolymer, etc. are mentioned, for example. These resins may be used alone or in combination of two or more. Furthermore, in order to adjust the curability, toughness and rigidity, it is also possible to use a urethane resin, an epoxy resin, an ester resin, etc. in combination, as long as the ultraviolet curability is not impaired.

As a general purpose application, a polypropylene resin of a thermoplastic resin is preferable. When heat resistance is required for the forming sheet, a polymethylpentene resin of a thermoplastic resin is preferable. When a high degree of forming accuracy is required for the fine patterned uneven pattern of the forming portion, it is preferable to use an ultraviolet curable resin.

  The thickness of the formed sheet original transfer layer is preferably 10 μm or more and 400 μm or less, more preferably 50 μm or more and 300 μm or less, and still more preferably 100 μm or more and 200 μm or less. If the thickness is smaller than the above range, the durability tends to be poor, and if the thickness is larger than the above range, the material cost increases.

  In the case where the forming layer is cooled and solidified, and the forming sheet raw fabric is once wound up and stored, it is preferable that the surface of the forming layer is smooth.

The surface roughness _Ra of the base sheet is preferably 0.03 μm or more and less than 5 μm, and a fine pattern which exhibits diffractive gloss in the case of making the surface of the base reflective layer mirror gloss specification or in a later step When forming a concavo-convex pattern, 0.03 μm or more and less than 0.5 μm are preferable, and when the surface of the forming layer is made to have a matte mat specification or a fine patterned concavo-convex pattern exhibiting a matte texture in a later step is shaped When using, it is preferably 0.03 μm or more and less than 5 μm.

S _z of the surface roughness of the shaping sheet raw shaping layer, 3 [mu] m or more, preferably 250μm or less, 5 [mu] m or more, more preferably at most 150 [mu] m.

  Furthermore, in the case where the surface of the original reaction layer is mirror gloss specification, or in the case of forming a fine patterned concavo-convex pattern exhibiting diffractive gloss in a later step, 3 μm or more and less than 40 μm are preferable, and 5 μm or more and less than 40 μm are more preferable. preferable.

  In addition, when the surface of the forming layer is made to have a matte matte specification or to form a fine patterned uneven pattern exhibiting a matte texture in a later step, 40 μm to 250 μm is preferable, and 40 μm to 150 μm is more preferable. preferable.

If S _a or S _z is larger than the above range, unevenness is likely to occur in the formation of the fine patterned concavo-convex pattern on the surface of the design sheet, and there is also a possibility of inhibiting the development of the diffraction gloss of the design sheet.

If S _a or S _z is smaller than the above range, the cost for producing the formed sheet raw fabric is increased, while the effect is limited. From the viewpoint of achieving both cost and performance, the smoothness of the shaped sheet forming layer is preferably in the above range.

  A mirror chill roll or the like can be used to make the surface of the original application layer a mirror gloss specification or a diffraction gloss specification, and a matte chill specification or a matte texture specification can be used to make the surface of the formation layer matte. A roll etc. can be used.

[Method for producing shaped sheet material]
The formed sheet material sheet is produced, for example, by forming a formed sheet material sheet with a forming layer made of a resin or a resin composition on one surface of the formed sheet material base layer.

  The forming method of the forming sheet raw material forming layer is not particularly limited, and examples thereof include coating methods such as extrusion coating, roll coating, reverse roll coating, micro bar coating, bar coating, knife coating, and gravure coating. be able to.

The formed sheet raw fabric having the above-described smoothness of the surface of the formed layer of the formed sheet raw fabric is, for example, formed on the formed sheet raw fabric base layer using, for example, clay coated paper. It can be obtained by extruding chill roll molding of a resin for a sheet base transfer layer.

  Here, by adjusting the smoothness of the surface of the chill roll, it is possible to adjust the smoothness of the surface of the formed sheet original forming layer. For example, after being melt-extruded and laminated, it is obtained by continuously passing between a chill roll whose surface has been mirror-finished and a pressure roll so that the formed sheet raw material forming layer contacts the chill roll of the mirror surface. be able to.

  The mirror-like roll used in that case is a mirror-based or semi-mirror-based roll on which the roll is chrome-plated and then wet-blasted and dry last treated. In addition, as long as the roll of mirror surface is the surface of the roll that is smoother than the surface of the formed sheet material base layer, it also includes the roll of ultrafine mat system. By using the roll of this mirror surface, the smoothness of the surface of the base sheet can be adjusted.

  When the forming sheet original reaction layer is made of an ultraviolet curable resin composition, examples of a method of forming the forming layer include a die coating method and a gravure coating method, and in addition, the forming sheet original fabric In a state in which the base material layer is wound around a roll, the base material layer is dipped in the flowable UV curable resin composition, and the UV curable resin composition is laminated only on one side of the base sheet for forming sheet A method of forming with a constant thickness may also be mentioned.

  As a method of imparting fluidity to the ultraviolet curable resin composition, even if the solvent is added to impart fluidity, even if resin material having fluidity is used to impart fluidity, the resin has fluidity by heating. You may

  The forming sheet material sheet produced by the above method may form a fine pattern asperity pattern continuously on the forming sheet original reaction layer as it is, or it may be taken out once as necessary. You may perform drying etc. of an original counteracting layer.

  After forming the forming sheet original forming layer, the forming sheet original forming layer is passed between the chill roll of the mirror surface or the super mirror surface and the pressing roll so that the forming layer original forming layer contacts the chill roll of the mirror surface. The surface of the mold layer can be smoothed to make it a mirror specification surface.

<Formed sheet>
A forming sheet is produced from forming sheet original fabric, has a forming layer and a base material layer, and forms a surface aspect which can form a fine pattern concavo-convex pattern by transfer in a forming layer. It is done.

  FIG. 7 is a perspective view showing an example of the primary forming sheet. By using the shaped sheet of FIG. 7, a design sheet of the pattern shown in FIG. 8 is produced.

[Base layer]
Since the formed sheet is produced by subjecting the formed sheet original reaction layer to fine pattern unevenness processing, the material configuration of the base material layer is the same as the formed sheet original fabric base layer, As shown in FIG. 7, the base material layer may have a similar fine patterned uneven pattern structure, reflecting the fine patterned uneven pattern formed in the forming layer. In particular, when the surface of the backup roll at the time of transfer has a soft configuration, it can be easily reflected.

  Depending on the structure of the fine patterned uneven pattern, the fine patterned uneven pattern of the forming layer can be formed more easily with high accuracy by reflecting the fine patterned uneven pattern on the base material layer.

[Shape layer]
In the present invention, the forming sheet forming layer is composed of a forming part and a base. The shaping portion is a thickness portion having unevenness as a handle, the base is a thickness portion to be a support portion of the shaping portion, and a clear boundary between the shaping portion and the base is Without, they form an integral forming layer.

  The structure of the surface aspect which can form a fine pattern uneven | corrugated pattern in the design sheet surface by transcription | transfer is formed in the forming sheet forming layer. Here, the structure of the surface mode of the fine pattern-forming sheet forming layer is a structure of the surface mode in which the uneven structure is reversed to the fine pattern of the uneven pattern formed on the surface of the design sheet.

  The thickness of the base of the forming sheet forming layer is not particularly limited, but is preferably 5 μm to 300 μm, more preferably 25 μm to 280 μm, and still more preferably 50 μm to 150 μm. . If the thickness is thinner than the above range, the formed sheet is likely to be torn, and if it is thicker than the above range, flexibility tends to be lacking, and the usability tends to be poor.

The thickness of the forming layer and the thickness of the base of the forming sheet forming layer are not particularly limited, and it is preferable that the thickness is appropriately determined in relation to the structure of the fine patterned uneven pattern.

[Method of producing shaped sheet]
In the present invention, the forming sheet is formed on the forming layer of the forming sheet raw fabric by transferring the surface form from the primary forming sheet forming layer to the surface form capable of forming the fine patterned concavo-convex pattern. It is made with

  The transfer of the fine pattern unevenness pattern to the forming sheet forming layer, as an example, the primary forming sheet produced above and the forming sheet raw fabric, the primary forming sheet forming layer surface and the forming sheet forming It is achieved by transferring the surface aspect of the primary forming sheet forming layer to the original forming sheet reverse forming layer by overlapping so as to face the layer surface and sandwiching and pressing with a pressing device.

  At the time of pressing, the forming sheet forming layer may be preheated if necessary, or may be pressed while heating the forming sheet, and the forming sheet may be pressurized while being cooled. May be

  When releasing the forming sheet and the primary forming sheet after pressing, the forming sheet forming layer may be cooled.

  In addition, it is possible to apply a well-known various method to a means of heating and cooling.

  As a specific heating means, for example, a method of heating one or both of a pair of pressing parts of a pressing device from the inside by steam, dielectric heating or the like, hot air is applied to the formed sheet stock before being pressurized The method, the method of heating the feed roll in front of a press apparatus by steam, dielectric heating, etc. from the inside, etc. are mentioned. Hot air is not essential, and two or more of the above-described heating means may be used in combination.

  The temperature of the heating is preferably such that the surface resin layer of the laminate tube laminate raw material is suitably softened to such an extent that it is deformed by pressure while maintaining the shape, and varies depending on the composition of the surface resin layer. It is preferable to prepare so that a type | mold sheet shaping layer may be 80-130 degreeC.

  When the temperature is too high, the forming layer becomes too soft and melts and falls, the forming layer is deformed, or the releasability between the primary forming sheet and the forming sheet is reduced, and the fine pattern unevenness is generated. There is a possibility that it becomes difficult to maintain the fine patterned uneven shape due to the occurrence of a shape defect in the formation of a pattern or the shape being broken immediately after mold release.

  The temperature of cooling is preferably such a temperature that the forming sheet forming layer becomes appropriately hard enough to maintain the shape, and varies depending on the composition of the forming layer, but the forming sheet forming layer has a temperature of 20 to 50 ° C. It is preferable to prepare so that

  As a specific cooling method, for example, a method of cooling a pressurized part of a press, a method of applying cold air after pressurization, a method of cooling a release roller cooled after pressurization, a natural cooling, etc. may be mentioned. . Cold air is not essential, and two or more of the above-mentioned cooling means may be used in combination.

  The pressure at the time of pressing with the pressing device varies depending on the type of pressing device, the type of forming layer resin of the forming sheet, and the composition of the surface resin layer of the original design sheet raw material. When sandwiching with a single flat plate, the linear pressure is preferably 5 kgf / cm or more and 380 kgf / cm or less, more preferably 5 kgf / cm or more and 265 kgf / cm or less, and further 10 kgf / cm or more and 100 kgf / cm or less preferable.

When sandwiching with two flat plates, the surface pressure is preferably ² kgf / cm ² or more and 15 kgf / cm ² or less, more preferably 4 kgf / cm ² or more and 12 kgf / cm ² or less, and 8 kgf / cm ² or more and 10 kgf / cm ^{2 2} or less is especially preferable.

  If the pressure is lower than the above range, the transfer may be insufficient depending on the fine patterned uneven pattern and there is a possibility that a dropout may occur, and if it is higher than the above plate, a part or all of the pattern may be removed depending on the fine patterned uneven pattern. There is a risk of crushing and high-precision shaping tends to be difficult.

[Pressing device for transfer]
In the present invention, when transferring the surface aspect of the primary forming sheet forming layer to the forming sheet original forming layer, the group consisting of two rolls, one roll and one flat plate, and two flat plates, A primary forming sheet and a raw forming sheet raw material are formed into a primary forming sheet forming layer and a forming sheet raw material using a pressing device having one type of paired pressure parts to be selected. The mold layer is sandwiched and pressed so as to face the mold layer.

  In the case of sandwiching by two rolls, various combinations can be selected as needed for the hardness and smoothness of the surface of each of the two rolls. The surface of both rolls can be selected to be smooth and hard, or the surface of the roll (emboss roll) on the side in contact with the primary forming sheet is smooth and hard, but the roll on the forming sheet original side (backup roll) For the purpose of the invention, it is possible to select a wide variety of products, from those having a soft surface to those with a hard surface.

  When high precision molding is required, it is preferable that the two rolls be smooth and hard and have a configuration in which the surface shape does not change due to pressure bonding.

  The same applies to the case where one roll and one flat plate are used or two flat plates, and one having a smooth and hard surface is selected on both the side in contact with the primary forming sheet and the side in contact with the forming sheet raw fabric. Although the surface on the side in contact with the primary forming sheet is smooth and hard, a wide variety of forming sheet materials can be similarly selected depending on the purpose.

  One example of a system for transferring the fine patterned relief pattern from the forming layer of the primary forming sheet to the forming layer of the forming sheet raw fabric according to the present invention is shown in FIG. In this example, a paper substrate is used as the forming sheet substrate layer, and a thermoplastic resin is applied as the forming layer.

  The primary forming sheet and the forming sheet raw fabric are stacked so that the primary forming sheet forming layer and the forming sheet raw coating / reacting layer face each other, and hot air is applied from the forming sheet raw fabric side It is heated, sent in the direction indicated by the arrow, sent between two smooth rolls whose surface is smoothed, sandwiched and heat-pressed.

  The surface shape of the primary forming sheet forming layer is transferred to the forming sheet original reaction forming layer which is appropriately softened to form a surface mode capable of forming a fine patterned uneven pattern, and then, In the formed state, cold air is applied to the formed sheet material and cooled at a position immediately after the pressure release, and the surface aspect is fixed.

  The cooled forming sheet raw fabric and the primary forming sheet are continuously released, and each is wound up, the primary forming sheet is recovered, and a surface pattern capable of forming a fine patterned uneven pattern is formed. A shaped sheet having a mold layer is obtained.

  FIG. 12 shows an example of producing a continuous sheet-like shaped sheet using the continuous sheet-like primary shaped sheet and the continuous sheet-like shaped sheet raw fabric. In the case of this form, it is possible to express a design without a connection in a fine patterned uneven pattern, and can express a high degree of design.

  As another form in the present invention, the primary forming sheet of the sheet may be fixed on the pressing part and used, and in particular, it may be used while being fixedly wound around a roll having a smooth and hard surface configuration and rotating. .

  At this time, only the formed sheet raw fabric of the continuous sheet may be drawn out, continuously transferred by heat pressure transfer, and wound, or the formed sheet of the single sheet may be rolled using the formed sheet raw fabric of the single sheet. You may produce. In this case, only a small amount of sheet-like primary shaped sheets can be prepared, which is suitable for the production of a large number of small amounts, and the cost merit is large.

  The forming sheet according to the present invention can be efficiently produced with high accuracy using the above-described pressing device.

<Preparation of design sheet>
A design sheet can be produced as follows using the forming sheet obtained above.

  As an example, the method of apply | coating the resin composition which comprises the forming layer of a design sheet surface to a forming layer of a forming sheet, mold-releasing, and obtaining a design sheet is demonstrated. The figure for demonstrating in FIG. 13 was represented.

  FIG. 8 is a perspective view showing an example of a design sheet. A design sheet is provided with a surface resin layer and a base material layer, and these are laminated.

  The base material layer of the design sheet is a layer laminated on the side opposite to the side on which the linear concavo-convex portion of the base of the surface resin layer of the design sheet is formed, and supports the surface resin layer.

As the material of the base material layer, a material suitable for supporting the surface resin layer and depending on the application of the design sheet may be used, and natural fibers such as cotton, hemp, silk, wool, rayon, acetate, etc. may be regenerated. Or synthetic fibers such as polyamide, polyester, polyacrylonitrile, polyvinyl alcohol, polyolefin, etc., woven fabric made of fibers such as glass fiber, nonwoven fabric, cloth such as nonwoven fabric (also referred to as base fabric), paper, polyester or polyolefin The resin film made of resin, metal plate (or metal foil), glass plate, glass woven fabric, etc. Generally used for the base material or base fabric of synthetic leather or artificial leather It can be selected as appropriate.

  In the production process, the base material layer is provided as necessary, and it is not necessary to be provided when the surface resin layer has sufficient self-supporting property, and the surface of the target design after production It is also possible to use only the surface resin layer attached to

  The thickness of the base layer is not particularly limited as long as it can support the surface resin layer, but can be, for example, in the range of 25 μm to 500 μm.

  Various thermoplastic resins, thermosetting resins, ionizing radiation curable resins such as ultraviolet rays or electron beams, etc. can be used for the resin composition constituting the surface sheet resin layer of the design sheet, and even if used without solvent It may be dissolved in a solvent for use.

  Although the method of the said application | coating is not specifically limited, For example, the diecoat method etc. are applicable.

  After application, the surface aspect of the surface resin layer is fixed by an appropriate curing method according to the composition, such as heat drying, ionizing radiation such as ultraviolet rays or electron beams, cooling, and the like.

Next, if necessary, the base material layer may be bonded with an adhesive to the surface of the obtained surface resin layer opposite to the side in contact with the formed sheet.
Thereby, a shaped sheet made of a surface resin layer or a design sheet made of a surface resin layer and a base material layer can be obtained.

  The primary forming sheet and the forming sheet were manufactured by experiments below, and using the obtained forming sheet, a design sheet having a fine patterned uneven pattern was manufactured to evaluate its performance.

<Production of primary formed sheet stock>
[Preparation of UV curable resin composition 1]
The following raw materials were mixed and homogenized to prepare an ultraviolet curable resin composition 1.

UV curable resin (Mitsubishi Chemical Corporation, Yupimar) 40 parts by mass Solvent (methyl ethyl ketone) 60 parts by mass

[Production of primary formed sheet raw fabric 1]
As a shaping layer, the above-mentioned ultraviolet curable resin composition 1 is applied and heat-dried and laminated on PET film A (Toray Industries, Inc., Lumirror U34, thickness 100 μm, coated side Sa 0 μm) Then, the surface of the forming layer is smoothed by passing it between the chill roll of the super mirror surface and the pressing roll so that the shaping layer is in contact with the chill roll of the super mirror surface, and a strip laminate (width 1500 mm, length The primary formed sheet original fabric 1 of the mirror specification surface which is 1500 m) was created. The S _a of the surface of the forming layer was 0.08 μm.

  The layer configuration of the primary formed sheet raw fabric 1 is as follows.

    PET film A (100 μm thickness) / UV curable resin composition 1 (30 μm thickness)

[Production of primary formed sheet raw fabric 2]
As shown in FIG. 10, a PET film A is passed through a vat containing the liquid ultraviolet curable resin composition 1 to apply the ultraviolet curable resin composition 1 on one side of the PET film A, and the thickness of the coating layer is 30 μm. Was adjusted to form a forming layer to prepare a primary forming sheet raw fabric 2.
Since the ultraviolet curable resin composition 1 was liquid, it proceeded continuously to the preparation of the primary formed sheet 5.

<Preparation of primary shaped sheet>
The following primary forming sheets 1 to 6 were produced from the primary forming sheet raw fabric 1 obtained above.
[Preparation of Primary Shaped Sheet 1]
Prepare a cylinder with a copper plating on the surface, and within the width of 170 mm, set the pitch P to 300 μm, the convex width W to 200 μm, and the depth D to 75 μm in the pattern shown in FIG. The surface of the cylinder was cut to prepare a drum-shaped mold 1.

  As shown in FIG. 11, the drum-shaped mold version 1 and the surface of the drum-shaped mold version 1 obtained from the primary mold-formed sheet raw material 1 obtained above, as shown in FIG. Is sandwiched between a hard, smooth backup roll made of metal, and is continuously heated under pressure to transfer the above-mentioned fine patterned uneven pattern onto the forming layer of the primary formed sheet raw fabric 1, and the primary formed sheet raw fabric The UV curable resin composition 1 is cured by irradiating ultraviolet rays from the substrate layer side in a state in which 1 is wound around the drum shaped printing plate 1, and then cooled with cold air to obtain a drum shaped printing plate It released from 1 and produced the primary formation sheet 1 which has a fine pattern uneven pattern. Process conditions are as follows.

Drum-shaped printing plate surface temperature: 120 ° C
Backup roll surface temperature: 20 ° C
Drum-like plate pressure: Linear pressure 270 kgf / cm
Sheet feeding speed: 5 m / min Cold air temperature: 20 ° C

[Preparation of Primary Shaped Sheet 2]
Similar to the primary formed sheet 1 except that the size of the fine patterned concavo-convex pattern was changed to a pitch P of 500 μm, a convex portion width W of 350 μm, and a depth D of 100 μm to produce the drum-like shaped plate 2 By operation, a primary formed sheet 2 was produced.

[Production of Primary Forming Sheet 3]
Next, prepare a cylinder with a copper plating on the surface, cut it with the following 33 patterns of combinations of pitch and bit apex angle on the cylinder surface with a cutting tool whose cross section is an isosceles triangle, drum shaped printing plate 3 Was produced.

  Pitch P: Three levels of 1 μm, 2 μm and 3 μm.

  Tool apex angle θ: 11 levels of 10 ° each from 70 ° to 170 °.

  Depth D: Calculated from the pitch P and the tool apex angle θ.

  Cutting: A striation pattern of 1 byte apex angle was cut per 100 mm width, and then another striation pattern was repeatedly cut with a gap of 10 mm.

As shown in FIG. 19, the drum-shaped mold version 3 and the surface of the drum-shaped mold version 3, and the surface of the drum-shaped mold version 3 obtained as described above, Is sandwiched between a hard, smooth backup roll made of metal, and is continuously heated under pressure to transfer the above-mentioned fine patterned uneven pattern onto the forming layer of the primary formed sheet raw fabric 1, and the primary formed sheet raw fabric In a state in which 1 is wound around the drum-shaped molding plate 3, ultraviolet rays are irradiated from the base material layer side to cure the ultraviolet curable resin composition 1, and then it is cooled by a cold air to obtain a drum-shaped molding plate. The mold was released from No. 3 to prepare a primary formed sheet 3 having a fine patterned uneven pattern. Process conditions are as follows.

Drum-shaped printing plate surface temperature: 120 ° C
Backup roll surface temperature: 20 ° C
Drum-like plate pressure: Linear pressure 270 kgf / cm
Sheet feeding speed: 5 m / min Cold air temperature: 20 ° C

[Preparation of Primary Shaped Sheet 4]
A part of the primary formed sheet 1 was cut to prepare a primary formed sheet 4 of a sheet.

[Production of Primary Forming Sheet 5]
The surface of the drum-shaped mold plate 3 is wound by continuously winding the primary molding sheet raw fabric 2 prepared above so that the molding layer is in contact with the drum-shaped mold plate 3, as shown in FIG. The uneven shape is transferred to the forming layer by pressure bonding, and further, in a state where the primary formed sheet raw fabric 2 is wound around the drum-shaped formed plate 3, ultraviolet rays are irradiated from the base layer side to make an ultraviolet curable resin. The composition 2 was cured and then cooled with a cooled take-out roll to produce a primary formed sheet 5 having a fine patterned relief pattern. Each process condition is as follows.

Drum-shaped printing plate surface temperature: 40 ° C
Surface temperature of take-out roll: 30 ° C.
Sheet feeding speed: 5 m / min Cold air temperature: 20 ° C

<Production of shaped sheet stock>
[Production of shaped sheet material 1]
A cast coated paper (basis weight 164 g / m ² ), which is a paper substrate on which a clay coated layer was formed, was prepared for the base material layer of the formed sheet material 1.

  A co-extruder of a blend resin of 80% by mass of a polypropylene resin and 20% by mass of a polyethylene resin (manufactured by Sun Aroma Co., Ltd.) at 310 ° C. as a smoothing resin layer on the clay coat layer via an aqueous anchor coat agent. And extrude homopolypropylene resin (manufactured by Sun Aroma Co., Ltd.) as a forming layer from the second extruder of the coextruder at a line speed of 80 m / min. Stacked.

Next, the laminate is passed between the chill roll of the super mirror surface and the pressing roll so that the cast layer is in contact with the chill roll of the super mirror surface, and the surface of the mold layer is smoothed to obtain a strip laminate of a continuous sheet (width 15
A formed sheet raw fabric 1 (a mirror specification surface) having a size of 00 mm and a length of 1500 m was produced. S _a base material layer surface (smooth surface of the resin layer) is 0.1 [mu] m, S _a of the shaping layer surface was 0.08 .mu.m.
[Production of shaped sheet material 2]
A formed sheet raw material which is a strip-like laminate (width 1500 mm, length 1500 m) of a continuous sheet in the same manner as in the formed sheet raw fabric 1 except that the ultra mirror surface roll is changed to a chill roll of ultrafine mat surface We made anti-2 (mat specification surface). S _a base material layer surface (smooth surface of the resin layer) is 0.1 [mu] m, the S _a of the shaping layer surface was 0.6 .mu.m.
[Production of shaped sheet material 3]
A part of the formed sheet raw fabric 2 was cut out to prepare a formed sheet raw fabric 3 which is a laminated sheet sheet (width 1500 mm, length 1000 mm).
[Production of shaped sheet material 4]
Base layer layer paper base material cast coated paper is changed into a common paper base material, and it is a strip laminate (width 1500 mm, length 1500 m) of a continuous sheet in the same manner as in the formed sheet raw fabric 1. , The forming sheet original fabric 4 (mat specification surface) was created. S _a base material layer surface (paper substrate layer surface) is 7 [mu] m, S _a of the shaping layer surface was 0.8 [mu] m.
[Production of shaped sheet material 5]
Substrate layer paper base substrate cast coated paper is changed to a normal paper substrate, and the ultra mirror surface roll is changed to a chill roll of ultrafine mat surface, it is operated in the same manner as in forming sheet stock 1, and continuous sheet The formed sheet original fabric 5 (mat specification surface) which is a strip | belt-shaped laminated body (width 1500mm, length 1500m) was created. S _a base material layer surface (paper substrate layer surface) is 17 .mu.m, S _a of the shaping layer surface was 8 [mu] m.

Example 1
(Production of shaped sheet 1)
Using the primary forming sheet 1 obtained above and the forming sheet raw fabric 1, as shown in FIG. 8 (3), the hot air is continuously applied from the base material side to the forming sheet raw fabric. Apply and heat, and overlay the primary forming sheet and the forming sheet raw fabric so that the forming layers are opposed to each other, the surface is smooth and hard, and the surface shape does not change due to pressure bonding. By sandwiching and heat-pressing, the fine patterned concavo-convex pattern of the primary forming sheet was added to the forming layer of the forming sheet raw fabric 1 by transfer.

  At this time, the roll in contact with the original sheet 1 of the forming sheet was heated, and the roll in contact with the primary forming sheet was cooled.

  Next, cool air is applied from the side of the base material layer of the formed sheet raw material 1 to cool it, and the formed sheet raw material 1 and the primary formed sheet 1 which are bonded by heat pressure are peeled off through a pair of rolls. , And peeled to obtain a shaped sheet 1.

  Process conditions are as follows.

Hot air temperature: 110 ° C
Surface temperature of the roll on which the primary forming sheet contacts: 30 ° C
Surface temperature of the roll on which the original sheet 1 of the forming sheet is in contact: 120 ° C
Roll pressure: Linear pressure 270 kgf / cm
Cold air temperature: 10 ° C
Sheet feeding speed: 5 m / min

(Preparation of Design Sheet 1)
The design resin composition 1 was adjusted with the following composition for the surface resin layer in which the fine pattern uneven | corrugated pattern of a design sheet is shape | molded.

Polyurethane (Dainichi Seika Kogyo Co., Ltd., Rezamin NE-8811) 100 parts by mass Colorant (Dainichi Seika Kogyo Co., Ltd., Seika Seven NET-5794 Black) 15 parts by mass Toluene 25 parts by mass Isopropyl alcohol 25 Mass part The shaping sheet 1 produced above was attached to the synthetic leather manufacturing apparatus, and the design resin composition 1 was apply | coated to the shaping layer of a shaping sheet by the diecoat method.

After the application, it was dried by heating in the range of 100 ° C. to 120 ° C. for 2 minutes. Then, it bonded to a base fabric using an adhesive agent, dried, and it was made to age | cure | ripen, it was demolded from the forming sheet 1, and the design sheet 1 was obtained.
(Evaluation)
The matte texture of the design sheet 1 obtained above was evaluated. The results are shown in Table 1.

[Examples 2 to 8, Comparative Example 1]
According to the combination of the primary forming sheet, the forming sheet raw fabric, the pressed parts, etc. described in Table 3, the forming sheet and the design sheet are manufactured in the same manner as in Example 1, and the type of fine pattern uneven pattern is The matte texture was evaluated as to the matte one, and the rainbow strength and the rainbow visual field were evaluated as to the type of the fine pattern uneven pattern having the diffractive gloss. The results are shown in Table 3.

  In Table 3, the description in the press parts has the following meaning.

    Smooth roll (hard): A metal roll having a configuration in which the surface is smooth and hard and the surface shape does not change due to pressure bonding.

    Smooth roll (hard): A roll of paper layer having a configuration in which the surface is soft and the surface shape is changed by pressure bonding.

    Flat plate (hard): A copper plate having a configuration in which the surface is smooth and hard and the surface shape does not change due to pressure bonding.

<Evaluation method>
[Mat texture]
Under a test environment with an illumination of 400 lux (equivalent to a bright office), place a 100 mm square sample cut from the design sheet on a desk, and visually observe from the upper position 500 mm by 10 test subjects (20's to 60's). It was judged by counting the number of people who felt the matte texture widely.

The direction in which the linear convex portions extend is taken as the vertical direction, and it is considered good when three or more persons feel a wide and homogeneous matte texture in both the vertical direction and the horizontal direction.
[Rainbow strength]
Evaluation of rainbow strength was performed using a variable angle spectrometer (S-OGM, Digital Fashion Co., Ltd.).

  White (xenon light source) was irradiated onto the surface of the design sheet from an incident angle of 0 degrees (the normal direction of the design sheet), and an XYZ color system for each emission angle was determined. A gain obtained by standardizing the value of Y corresponding to the lightness with the Y value of white (xenon light source) was determined.

Assuming that the direction in which the linear convex portion extends is the vertical direction, the maximum value of the normalized gain excluding regular reflection light is 0.1 or more in both the vertical direction and the horizontal direction. The range of top angle and depth of the pattern bite was determined.
[Wide field of view]
Under a test environment with an illumination of 400 lux (equivalent to a bright office), place a 100 mm square sample cut from the design sheet on a desk, and visually observe from the upper position 500 mm by 10 test subjects (20's to 60's). It was judged by counting the number of people who felt that the field of view of the rainbow was wide.

Assuming that the direction in which the linear convex portion extends is the vertical direction, in both the vertical direction and the horizontal direction, it is considered as good if three or more persons feel that the field of vision is wide, and good pattern bite apex angle and depth for each pitch I sought the range.
[Result Summary]

表３からわかるように、本発明にかかる一次賦型シートと賦型シートを用いることにより、実施例１〜８において、良好なマット質感や、回折光沢を、広い範囲で明るく観察し得る意匠シートが得られた。

As can be seen from Table 3, by using the primary forming sheet and the forming sheet according to the present invention, in Examples 1 to 8, a design sheet capable of observing a good matte texture and diffraction gloss brightly in a wide range. was gotten.

  In the comparative example 1 in which the Sa of the base material layer of the formed sheet raw fabric and the formed layer is large, the matte texture resulted in inhomogeneity.

D Fine pattern uneven pattern depth P Fine pattern uneven pattern pitch θ Fine pattern uneven pattern bite top angle 1 Primary forming sheet original fabric 2 Primary forming sheet original reflective layer 3 Primary forming sheet original fabric base layer 4 Primary Forming sheet 5 Primary forming sheet forming layer 6 Primary forming sheet base layer 7 Primary forming sheet forming layer forming part 8 Primary forming sheet forming layer base 9 Primary forming sheet fine patterned linear recess 10 Primary forming sheet fine patterned linear convex portion 11 forming sheet original fabric 12 forming sheet original reflecting layer 13 forming sheet original base layer 14 forming sheet forming layer 15 forming sheet base layer 16 Molded sheet forming layer forming portion 17 Forming sheet forming layer base 18 Forming sheet fine pattern linear recess 19 forming sheet fine pattern linear convex 20 Design sheet 21 Design sheet surface resin layer 22 Design sheet base layer 61 Primary forming sheet manufacturing device 1
62 Primary forming sheet base material winding 63 Primary forming sheet base material 64 UV curable resin composition 65 Drum shaped forming plate 66 UV irradiation device 67 Primary application forming sheet take-out roll 68 Primary forming sheet 69 Primary forming sheet Winding 71 Primary forming sheet manufacturing device 2
72 Primary forming sheet raw winding 73 Primary forming sheet feed roll 74 Hot air device 75 Backup roll 76 Cold air device 80 Forming sheet preparation system 81 Primary forming sheet winding (before use)
82 Primary form sheet (before use)
83 Primary forming sheet feed roll 84 Forming sheet raw winding 85 Forming sheet raw winding 86 Forming sheet raw feeding roll 87 Primary forming sheet side roll (emboss roll)
88 Formed sheet side roll (backup roll)
89 Take-out roll 90 Primary forming sheet (after use)
91 Primary forming sheet winding (after use)
92 forming sheet 93 forming sheet winding

Claims (10)

It is a manufacturing method of a forming sheet for forming a fine pattern concavo-convex pattern, and
The forming sheet is a laminate having a forming sheet base layer and a forming sheet forming layer which is the outermost layer on one side, and is produced using a primary forming sheet from a forming sheet raw fabric It is
The forming sheet forming layer has a surface mode capable of forming the fine patterned uneven pattern,
The formed sheet material is a laminate having a formed sheet material base layer and a formed sheet material opposite layer which is the outermost layer on one side,
As for the surface roughness of the forming sheet raw material forming layer, S _a is 0.03 μm or more and less than 5 μm,
The surface roughness of the surface on the side of the formed sheet raw material countering layer of the formed sheet raw fabric base layer is such that S _a is 0.3 μm or more and less than 15 μm,
The primary forming sheet is a laminate having a primary forming sheet base layer and a primary forming sheet forming layer which is the outermost layer on one side, and is produced from a primary forming sheet raw fabric. ,
The primary forming sheet forming layer has a surface aspect substantially the same shape as the fine pattern uneven pattern on the surface, and the primary forming sheet raw fabric is a primary forming sheet raw fabric base layer made of a transparent resin film And a primary forming sheet original counteracting layer which is the outermost layer on one side,
A method for producing a shaped sheet, wherein the primary shaped sheet raw material-imparting layer is a layer comprising an ultraviolet curable resin composition, and the method comprises the following steps 1 and 2.
Step 1) The primary forming sheet raw material forming layer capable of flowing the primary forming sheet raw fabric on the surface of a drum-shaped forming plate having a surface aspect capable of forming the fine pattern uneven pattern Wrap it so that
Transferring the surface aspect of the drum-shaped mold plate to the primary mold sheet original counter mold layer by pressure;
Subsequently, the process of irradiating the ultraviolet-ray from the said primary forming sheet raw fabric base-material layer side, hardening | curing the said primary forming sheet original-repelling layer, and producing the said primary forming sheet.
Process 2) overlapping the heated forming sheet raw fabric and the primary forming sheet so that the forming sheet original reflecting layer and the first forming sheet forming layer face each other,
Then, the step of transferring the surface aspect of the primary forming sheet forming layer to the forming sheet original reflecting layer by sandwiching and hot-pressing it with a press device to produce the forming sheet.   The method for producing a formed sheet according to claim 1, wherein in the step 2, the primary formed sheet and the formed sheet raw fabric are continuous sheets, and are continuously drawn out and heat-pressed. . In the step 2, the pressed part on the side of the pressing device in contact with the primary forming sheet is a roll having a smooth and hard surface configuration,
The primary forming sheet is a sheet, and is wound around and fixed to the surface of the roll,
The formed sheet material is a continuous sheet which is continuously fed out.
The manufacturing method of a shaping | molding sheet of Claim 1. As for the surface roughness of the surface on the side of the formed sheet raw material reflective layer of the formed sheet raw fabric base layer, the S _a is 0.3 μm or more and less than 5 μm,
Surface roughness of the surface of the embossing sheet raw shaping layer, S _a is more than 0.03 .mu.m, less than 0.5 [mu] m,
The surface roughness of the surface of the primary forming sheet raw material forming layer is such that S _a is not less than 0.03 μm and less than 0.5 μm.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-3. The surface roughness of the surface on the side of the formed sheet raw material countering layer of the formed sheet raw fabric base layer is such that S _a is 0.3 μm or more and less than 15 μm,
The surface roughness of the surface of the shaped sheet original forming layer is such that S _a is at least 0.03 μm and less than 5 μm,
The surface roughness of the surface of the primary forming sheet raw material forming layer is such that S _a is not less than 0.03 μm and less than 5 μm.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-3. The formed sheet raw fabric base layer includes a paper layer and a clay layer,
The base sheet for forming a base sheet contains a polypropylene resin or a polymethylpentene resin.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-5.   The method for producing a formed sheet according to any one of claims 1 to 6, wherein the fine patterned uneven pattern has a depth of 0.08 μm or more and 10 μm or less.   The method for manufacturing a formed sheet according to any one of claims 1 to 6, wherein the fine patterned uneven pattern has a diffractive gloss and a depth of 0.08 μm or more and 5 μm or less.   The method for manufacturing a formed sheet according to any one of claims 1 to 6, wherein the fine patterned uneven pattern has a matte texture and a depth of 5 μm or more and 10 μm or less.   A forming sheet produced by the method for producing a forming sheet according to any one of claims 1 to 9.

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