JP2019059143A - Production method of molding sheet for molding fine uneven 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 uneven pattern can be formed so as to obtain a pattern with high designing property, and a molding sheet produced by the method.SOLUTION: The molding sheet is produced from an original sheet by using an embossing roll, and the sheet is a laminate having a base layer having a surface roughness of 0.3 to less than 15 μm on a molding layer side, and a molding layer having a roughness of 0.03 to less than 5 μm. The embossing roll has a surface aspect capable of imparting the fine uneven pattern on the surface thereof. The production method comprises nipping the original sheet between the embossing roll and a backup roll so as to bring the molding layer of the original sheet into contact with the surface of the embossing roll, and pressing so as to transfer the fine uneven pattern on the surface of the embossing roll to the molding layer of the molding original sheet.SELECTED DRAWING: Figure 1

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 which is the outermost layer on one side, which is produced from the forming sheet raw fabric, and the forming layer is transferred by transfer from an embossing roll. It has the surface aspect which can shape | mold the said fine pattern uneven | corrugated pattern.
The forming sheet is a forming sheet capable of forming a pattern asperity pattern visible on the surface, diffraction gloss due to diffraction phenomenon, and matte texture.

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).

  In addition, with the purpose of forming a pattern (pattern) on the surface of the skin layer of resin leather, two types of embossed patterns (first embossed pattern and second embossed pattern) having different depths are formed on the surface of the release layer A release sheet that has been proposed has been proposed (see Patent Document 3).

  However, it is difficult to perform uniform transfer due to non-uniform transfer pressure when forming the fine relief shape, or the fine relief shape may be crushed due to the transfer pressure being too large, or it may be missing during mold release Problems are likely to occur, and there is a limit to the shallowness and fineness of the fine asperity shape.

Patent 3098799 JP, 2010-253779, A Japanese Patent Application Publication No. 2013-518738

  A method for producing a shaped sheet having high formability capable of forming a fine patterned relief pattern for obtaining a handle with high designability at low cost without using special equipment, and produced by the method Provide a shaped sheet.

  The present inventors diligently studied to solve the above-mentioned problems, and the method for producing a shaped sheet in the present invention is for obtaining a handle with high designability at low cost without using special equipment. It has been found that it is possible to provide a shaped sheet having high formability capable of forming a fine patterned uneven pattern.

That is, the present invention is characterized by the following points.
1. It is a manufacturing method of a forming sheet which can form a fine pattern uneven pattern,
The shaped sheet is
A laminate having a base material layer and a forming layer which is the outermost layer on one side,
It is manufactured from the forming sheet material using an embossing roll,
It has a surface aspect capable of forming the fine pattern uneven pattern on the forming layer of the forming sheet,
The shaped sheet raw fabric is
A base material layer having _a surface roughness S _a of 0.3 μm or more and less than 15 μm on the surface on the forming layer side;
A laminate having a forming layer having _a surface roughness S _a of at least 0.03 μm and less than 5 μm,
The emboss roll has a surface mode capable of forming the fine patterned uneven pattern on the surface,
The manufacturing method is
The forming sheet material is sandwiched between an embossing roll and a backup roll such that the forming layer of the forming sheet material is in contact with the surface of the embossing roll, and the fineness of the surface of the embossing roll is obtained. Transferring the patterned relief pattern to the forming layer of the forming sheet material;
Manufacturing method of shaped sheet.
2. The emboss roll has a drum-like shaped plate,
The manufacturing method of a forming sheet as described in said 1.
3. In the step 3, the backup roll has a surface configuration to which the large pattern asperity pattern of the embossing roll can be transferred by pressure bonding.
The manufacturing method of a shaping | molding sheet as described in said 1 or 2.
4. The formed sheet material is a continuous sheet and is continuously fed out.
The manufacturing method of a shaping | molding sheet in any one of said 1-3.

5. The shaped sheet raw fabric is
The surface roughness S _a of the surface of the base material layer on the side of the base sheet on which the base sheet is applied is 0.3 μm or more and less than 5 μm,
The surface roughness S _a of the surface of the forming layer is 0.03 μm or more and less than 0.5 μm,
The manufacturing method of a shaping | molding sheet in any one of said 1-4.
6. The shaped sheet raw fabric is
The base layer comprises a paper layer and a clay layer,
The shaping layer contains a polypropylene resin or a polymethylpentene resin
5. Manufacturing method of shaped sheet in any one of said 1-5.
7. The fine patterned uneven pattern has a depth of 0.08 μm or more and 10 μm or less.
5. Manufacturing method of shaped sheet in any one of said 1-6.
8. The fine patterned concavo-convex pattern has a diffractive gloss and a depth of 0.08 μm or more and 5 μm or less.
7. Manufacturing method of shaped sheet in any one of said 1-7.
9. The fine patterned uneven pattern has a matte texture and a depth of 5 μm or more and 10 μm or less.
The manufacturing method of a shaping | molding sheet in any one of said 1-8.
10. The fine patterned uneven pattern is located on a smooth substantially flat surface,
The manufacturing method of a shaping | molding sheet in any one of said 1-9.
11. 11. A shaped sheet produced by the method for producing a shaped sheet according to any one of 1 to 10 above.

According to the method for producing a shaped sheet of the present invention, it is possible to produce a shaped sheet capable of shaping a fine patterned uneven pattern for obtaining a pattern having high designability at low cost without using special equipment. It is possible.
In the present invention, a shaped sheet having a shallower and finer pattern than in the past can be produced with high accuracy by using the shaped sheet raw fabric having the base layer and the resin layer smoother than in the past. .

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 synergistic effect can also produce a shaped sheet having a shallower and finer pattern with higher accuracy.
Furthermore, by adding the heating means at the time of forming, it is possible to form and process a concavo-convex pattern with higher precision and stability than conventional. Further, the addition of the cooling means at the time of peeling makes it possible to prevent the dropout of the asperity pattern more stably than in the past, and to form and fix the fine pattern asperity pattern with high accuracy. And by these synergistic effects, it is also possible to produce a shaped sheet having a shallow and fine pattern.

In addition, the shaped sheet according to the manufacturing method of the present invention is a design sheet for use as a decorative member for imparting a wrinkled pattern, a diffraction gloss or a matte texture, and further, various types requiring high designability and tactile sense. Design sheets applicable to products in the field can also be made, for example, for use in making laminated tube containers of toothpaste, food, cosmetics, pharmaceuticals, etc. contents. 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 a figure explaining a fine pattern. It is a figure explaining a fine pattern. It is a figure explaining a forming sheet. It is an enlarged view explaining a fine pattern. It is an overhead view explaining a fine pattern. It is an enlarged view explaining a fine pattern (mat texture). It is a bird's-eye view explaining a fine pattern (mat texture). It is a figure explaining a forming sheet. It is a figure explaining a design sheet. It is a figure explaining the preparation method of a fine pattern concavo-convex pattern transcription completed forming 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 addition, in each figure, in order to make it easy to understand, the magnitude | size and ratio of a member may be changed or exaggerated and described. In addition, in order to make it easy to read, unnecessary parts and repetitive reference numerals may be omitted.
Further, in each of the drawings, the shaping 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.
Further, in each drawing, the concavo-convex pattern is illustrated as a pattern having clear corners, but rounded corners may be used.

Thereafter, in the present invention, the fine patterned uneven pattern is formed by transferring from the shaped sheet and the shaped sheet the one on which the surface aspect capable of forming the fine patterned uneven pattern is formed on the forming layer of the formed sheet raw fabric. The designated sheet is referred to as a design sheet.
Moreover, each of a forming sheet and a design sheet is produced from a forming sheet raw fabric and a design sheet raw fabric.
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.
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.

<Surface pattern>
The present invention is a method of manufacturing a forming sheet capable of forming a pattern of relief patterns. The pattern uneven pattern is a fine pattern uneven pattern having an embossed uneven shape.
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 pattern concavo-convex pattern refers to the pattern on the design sheet in a narrow sense, but the aspect of the reversed concavo-convex structure before transfer is also referred to as the fine pattern concavo-convex pattern similarly . In addition, although it is assumed that the acute angle portion is rounded by transfer, it is regarded as substantially the same shape before and after transfer, and is similarly described as a fine patterned uneven pattern.
The fine patterned uneven pattern can also obtain various design effects by combining the pattern, the size and the forming position.
For example, the area of the fine pattern relief pattern can be increased or decreased to make the fine pattern effect more noticeable.
The fine pattern uneven pattern will be described below.

[Fine handle pattern]
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.
By having a fine patterned uneven pattern on the surface of the design sheet, the design sheet has matte texture appearance, diffraction gloss and tactile identification, and the consumer, particularly the elderly, does not slide the container using the design sheet. It offers the advantage of being easy to hold.
As the shape pattern of the fine pattern concavo-convex pattern on the surface of the design sheet, it is possible to use a point dispersion shape, a stripe shape, an array of islands of quadrangular pyramid, a non-geometrical pattern such as a cocoon or crocodile leather.

The cross-sectional shape of the fine patterned concavo-convex pattern can be various shapes, for example, 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 as shown in FIG. It can be mentioned.
For example, as shown in FIG. 2, triangular linear projections and flat linear recesses may be formed. The pattern of the design sheet shown in FIG. 2 is produced by using a shaped sheet having the surface aspect shown in FIG.

FIG. 4 shows an enlarged cross-sectional view 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.
The depth D of the fine patterned relief pattern is preferably 0.08 μm or more and 10 μm or less.

  In the present invention, the form of the fine patterned uneven pattern on the surface of the design sheet is a convex portion, for the reason of the manufacturing method of transferring the fine patterned uneven pattern 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 observed in a bright and wide field of view, without being a clear aspect.

Fig.5 (a), (b) is the top view which looked at the fine pattern uneven | corrugated patterned part of the surface resin layer of a design sheet from the top, and the aspect which the linear convex part and linear recessed part of fine patterned uneven pattern extend is It appears.
FIG. 5 (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. 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 differs depending on the fine patterned concavo-convex pattern, in the case of the patterns of FIGS. 5 (a) and 5 (b), the range of α is preferably 0 ° or more and 1 ° or less. FIG. 5A 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, and in some cases, a fine patterned uneven pattern is formed only on the smooth substantially flat surface of the surface resin layer surface of the original sheet. It is also preferable to finish with high accuracy.

(Fine pattern in case of diffraction gloss)
The fine pattern concavo-convex pattern when it is desired to obtain the diffraction gloss on the surface of the design sheet is, as shown in FIG. The base is provided with an isosceles triangular cross section having an apex on the opposite side to the base, and the shape is extended in one direction while maintaining the isosceles triangular cross section, and a wide range of cross sectional shapes are substantially triangular Is preferred.
The depth D of the fine patterned uneven 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.
Furthermore, for example, in the case where the fine patterned concavo-convex pattern has linear convex portions with an isosceles triangular cross section, when the pitch P is 1 μm to 3 μm, the apex angle θ at the apex of the isosceles triangle is 80 degrees or more and 160 degrees or less are preferable, and when the pitch P is larger than 3 μm and 10 μm or less, 90 degrees or more and 160 degrees or less are preferable.

(Fine pattern in case of matte texture)
The fine pattern asperity pattern to obtain matte texture on the surface of the design sheet is, for example, a substantially trapezoidal wave shape, a substantially rectangular wave shape as shown in FIG. It is preferably in the form of a substantially square pole.
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 100 μm or more and 5000 μm or less. Moreover, in the case where the plan view when viewed from above is a fine patterned uneven pattern giving a matte texture as shown in FIG. 6b, the width W of the convex portion is 100 μm or more and 1000 μm or less, as it is excellent in touch feeling. preferable.

<Pressing device for transfer of uneven pattern>
In the present invention, when transferring the embossed asperity shape including the fine pattern asperity pattern to the forming sheet material, the pressure applied to the pair of two rolls, one roll and one flat plate, and two flat plates, etc. A press with parts can be used.
As a pair of pressure parts, in the case of two rolls, in the case of using one roll and one flat plate, the case of using two flat plates may be used.
The forming mold of the transfer source is one of a pair of pressed parts, and one of the pressed parts is a surface mode of the embossed uneven shape such as an emboss roll or a roll on which a drum-shaped formed plate is attached It is possible to use one having In this case, the forming layer of the transfer receiving sheet is sandwiched and pressed so as to be in contact with the surface form of the embossed asperity shape of the pressure component.
In the case of sandwiching by a pair of pressing parts, various combinations can be selected as needed for the hardness and smoothness of the surface of the pressing part on the backup side.

In the present invention, it is possible to use both of the structure having a soft surface and the structure having a hard surface as the backup pressure parts.
In the case where it is desired to form a particularly fine pattern or when high-precision forming is required, it is preferable that the backup-side pressurized parts have a configuration that is smooth and hard and that the surface shape does not change due to pressure bonding. .
In the present invention, an emboss roll is, in a narrow sense, a roll having a surface aspect of an embossed structure having irregularities on the surface, but a roll on which a drum-shaped forming plate is attached or a primary forming sheet is in contact. Also referred to as a generic term that includes the smooth roll on the side and the paired combination with the backup roll.

A backup roll is a pair of rolls used simultaneously with the said embossing roll, and is a roll on the side which a to-be-transferred sheet contacts. 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 has a surface configuration that can be transferred by pressure bonding to the surface embossing asperities of a roll on which an embossing roll or a drum-shaped embossed plate is attached. The transfer may be temporary or permanent.
In the case where a backup roll having a soft surface is used, the surface embossed asperity shape may be reflected not only on the forming layer but also on the base layer of the sheet to which the embossed asperity shape is transferred.
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 has a surface configuration in which the surface embossing asperity shape of the roll on which the embossing roll or the drum-shaped embossed forming plate is attached is not transferred by pressure bonding.
In the case where a backup roll having a hard surface is used, in the transferred sheet, the surface embossing asperity shape can be mainly reflected in the forming layer.

<Outline of the method for producing a shaped sheet>
In the method for producing a shaped sheet according to the present invention, a shaped layer of a shaped sheet raw fabric including a base material layer having a specific surface roughness and a forming layer having a specific surface roughness is formed into a concavo-convex pattern The relief pattern is pressed onto a printing plate having the above-mentioned structure to transfer the relief pattern on the shaping layer, thereby forming a surface aspect on which the relief pattern can be shaped on the shaping layer.
As the uneven pattern, a fine patterned uneven pattern is transferred to the formed sheet material.

<Formed sheet raw fabric>
The formed sheet material is a laminate having 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 single sheet, or may be in the form of a continuous sheet as if it was rolled.

[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 forming layer of the forming sheet raw fabric, and heat resistance and surface smoothness are particularly required. In the case, it is preferable to use a polyester base such as polyethylene terephthalate or polyethylene naphthalate.

(Smoothness)
In order to smooth the surface of the forming layer of the formed sheet material, it is effective to make the surface of the base layer of the formed sheet material smooth, and the base material of the formed sheet material. The surface roughness S _a on the forming layer side of the layer is preferably 0.3 μm or more and less than 15 μm, and more preferably 1.0 μm or more and less than 15 μm.
0.3 μm or more and less than 5 μm is preferable, and 1.0 μm or more and less than 5 μm when making the surface of the original applied layer a mirror gloss specification or when forming a fine patterned uneven pattern exhibiting diffractive gloss in a later step 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 15 μm or less is preferable, and 1.0 μm The thickness is more preferably 15 μm or less.

Shaping sheet raw base layer surface roughness S _z of the shaping layer side of, 3 [mu] m or more, and is preferably less than 250 [mu] m, 5 [mu] m or more, and more preferably less than 150 [mu] m.

  In the case of making the surface of the original applied layer a 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 20 μm are more preferable, and 5 μm or more and less than 20 μm are more preferable .

In addition, in the case where the surface of the original reaction 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, 3 μm or more and less than 250 μm is preferable, and 5 μm or more and less than 150 μm 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 It is more preferable that
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.
Also, if necessary, films or sheets of two or more resins may be used in combination.
When the forming layer of the forming sheet raw fabric is made of an ultraviolet curable resin or an ultraviolet curable resin composition, an ultraviolet transparent resin film or sheet is used for the base layer of the forming sheet raw fabric. Is preferred.

  Specific examples of the UV-transparent 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; 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, polyamideimide Resin, polyaryl phthalate resin, silicone resin, polysulfone resin, polyphenylene sulfide resin, polyether sulfone resin, polyurethane resin, cellulose resin, poly (meth) a Lil resins, polyvinylidene chloride, acetal resins, fluorine-based resins, resins other, and the like.

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

(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, preferably having a basis weight of about 80g / m ² ~600g / m ^2-position, more preferably to use a basis weight of about 100g / m ² ~450g / m ² of desirable.

  As pulp for paper base, softwood pulp (N material) and hardwood pulp (to obtain strength and smoothness that can withstand the process of forming a fine pattern asperity pattern in the shaping layer and the process of producing synthetic leather) What mixed L material) is preferable. 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, preferably having a basis weight of about 80g / m ² ~600g / m ^2-position, more preferably it is desirable to use a basis weight of about 100g / m ² ~450g / m ² of but especially, in the synthetic leather create applications, strength, synthetic leather processing workability, more preferably from repetitive use durability and the surface of the embossing suitability of release paper is ^{100g / m 2 ~200g / m 2} .

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 is preferably 100 μm to 900 μm, more preferably 150 μm to 600 μm in synthetic leather production applications, but generally 10 μm to 200 μm may be used. preferable.
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.
The thickness of the smoothing resin layer is not particularly limited, but is preferably 10 μm to 60 μm.

(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.
10 micrometers or more and 400 micrometers or less are preferable, 50 micrometers or more and 300 micrometers or less are more preferable, and 100 micrometers or more and 200 micrometers or less are still more preferable. 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.

(Smoothness)
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 more preferable, and a fine patterned concavo-convex pattern exhibiting a matte texture in a post process or a matte texture is applied When molding, it is preferably 0.03 μm or more and less than 5 μm.

Shaping sheet raw shaping layer surface roughness of the S _z of, 3 [mu] m or more, and is preferably less than 250 [mu] m, 5 [mu] m or more, and more preferably less than 150 [mu] m.

  In the case where the surface of the original applied layer has mirror gloss specifications 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 more preferable, and 5 μm or more and less than 40 μm .

Further, when the surface of the forming layer is made to have a matte mat specification or when forming a fine patterned uneven pattern exhibiting a matte texture in a later step, 3 μm or more and less than 250 μm are preferable, and 5 μm or more and less than 150 μm are more 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>
In the present invention, the forming sheet is a sheet on which a fine patterned uneven pattern is transferred to the raw material forming sheet, and a surface mode capable of forming the fine patterned uneven pattern is formed on the forming layer.
The formed sheet may be in the form of a continuous sheet such as a roll, or may be in the form of a sheet. The sheet-like formed sheet may be produced from a sheet-like formed sheet raw fabric, or may be obtained by cutting a continuous sheet-shaped formed sheet.

  FIG. 7 shows a perspective view showing an example of the 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 uneven pattern structure by reflecting the 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 forming sheet forming layer is a structure of the surface mode in which the uneven structure is reversed with the fine patterned uneven pattern formed on the surface of the design sheet.

The thickness of the base of the shaped sheet forming layer is not particularly limited, but is preferably 5 μm or more and 300 μm or less, more preferably 25 μm or more and 280 μm or less, and still more preferably 50 μm or more and 150 μm or less. 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 portion of the forming sheet forming layer or the thickness of the base portion is not particularly limited, and it is preferable that the thickness is appropriately determined in relation to the structure of the fine patterned uneven pattern.

<Design sheet>
In the present invention, the design sheet is a sheet in which the fine patterned uneven pattern is transferred to the raw material of the designed sheet, and the surface pattern of the fine patterned uneven pattern is formed on the surface resin layer (forming layer).
The design sheet may be in the form of a continuous sheet like a roll, or may be in the form of a sheet. The sheet-like design sheet may be produced from a sheet-like design sheet raw fabric, or may be obtained by cutting a continuous sheet-like design sheet.

FIG. 8 is a perspective view showing an example of a design sheet. A design sheet is provided with a surface resin layer and, if necessary, a base material layer, and these are laminated.
The thickness of the surface resin layer is not particularly limited, and varies depending on the application and the depth of the fine patterned relief pattern.
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.
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.

  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.

  For the resin composition constituting the surface resin layer, various thermoplastic resins, thermosetting resins, ionizing radiation curable resins such as ultraviolet rays or electron beams, etc. can be used, depending on the type and use of resin leather. Can be selected appropriately.

  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.

<Transfer process of fine pattern uneven pattern>
The transfer process of the fine pattern uneven pattern is a transfer process of the fine pattern uneven pattern to the forming sheet material.
In the present step, in the forming layer of the forming sheet raw fabric, there is a surface mode which can form a fine pattern uneven pattern by transferring a surface mode from a pressing part of a pressing device having a fine pattern uneven pattern on the surface. It is formed.

  The transfer of the fine patterned relief pattern to the forming layer of the forming sheet raw fabric is, as an example, sent to the pressing device so that the forming layer is in contact with the embossed side pressing part of the pressing device; This is achieved by transferring the surface aspect of the emboss side pressing part to the forming layer of the forming sheet material by sandwiching and pressing, preferably by hot pressing, by the press device.

FIG. 9 is an example of producing a continuous shaped sheet using a pair of rolls comprising an emboss roll and a backup roll, and a continuous sheet-like formed sheet stock. In the case of this form, it is possible to express a seamless design on the shaped sheet, and to express high designability.
In FIG. 9, as indicated by the arrows between the emboss roll and the backup roll, the formed sheet stock is continuously fed so that the formed layer is on the emboss roll side. Here, on the surface of the embossing roll, a fine patterned uneven structure capable of transferring the fine patterned uneven structure is formed on the forming layer of the formed sheet raw fabric. That is, the fine patterned uneven structure on the surface of the embossing roll has the same shape or substantially the same shape as the fine patterned uneven structure on the surface of the intended design sheet.

  The fed forming sheet material is sandwiched between the embossing roll and the backup roll, and the forming layer of the forming sheet material is formed into a surface shape along the surface shape of the embossing roll by pressure, and is continuous. Release and take out.

  If necessary, it is possible to heat and cool the formed sheet raw fabric, and by heating, the formed layer becomes soft and formation of the surface shape becomes easy, and the surface shape is fixed by cooling. Becomes easier.

  In the present invention, depending on the material configuration of the forming sheet material, forming is possible only by pressing, and in the case where the softening point of the resin in the forming layer is high, the embossing roll is further heated. It is also possible to improve the finishing accuracy by adding a mold, and further by adding a hot air, heating of a feed roll, and a cooling mechanism.

Various known methods can be applied to the heating means and the cooling means.
As a specific heating method, for example, a method of heating the emboss roll from the inside, a method of applying hot air to the raw forming sheet before being sandwiched between the emboss roll and the backup roll, the feed roll in front of the emboss roll is heated Examples of the method include a method of sandwiching the formed sheet material with a feed roll and an emboss roll. Further, methods of heating the respective rolls include steam and dielectric heating. Furthermore, it is also possible to apply combining 2 or more types of the above-mentioned heating means.

  The temperature of the heating is preferably such that the forming layer of the forming sheet raw fabric is appropriately softened to the extent that it is deformed by pressure while maintaining the shape, depending on the composition of the forming layer of the forming sheet raw fabric Although different, it is preferable to prepare so that a forming sheet original fabric may be 80-130 degreeC. When the temperature is too high, the forming layer of the formed sheet material becomes too soft, and the molten resin falls from the formed sheet material, or the releasability from the emboss roll decreases, resulting in a shape defect Or the shape collapses immediately after mold release, making it difficult to maintain the uneven shape. When the temperature is too low, the forming layer of the forming sheet raw fabric is too hard, making it difficult to form a concavo-convex shape or requiring a higher pressure than usual.

The temperature of the cooling may be such a temperature that the forming layer becomes appropriately hard enough to maintain the shape according to the resin component of the forming layer of the forming sheet raw fabric, and It is preferable to prepare so that it may become 50 degreeC.
As a specific cooling method, for example, a method of cooling an emboss roll, a method of applying a cold air to a formed sheet material after being sandwiched by the emboss roll and a backup roll, cooling after being sandwiched by the emboss roll and backup roll The method of cooling a forming sheet original fabric with the mold release roll, natural free cooling, etc. are mentioned. In the case of cooling with a mold release roll, the green sheet may be sandwiched between the mold release roll and the embossing roll. It is also possible to apply two or more of the above-mentioned cooling means in combination.

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 still more preferably 10 kgf / cm or more and 100 kgf / cm or less.
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.

<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.
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 resin composition constituting the resin sheet on the surface of the design sheet can be used by dissolving various thermoplastic resins, thermosetting resins, ionizing radiation curable resins such as ultraviolet rays or electron beams, etc. in a solvent without using them. It is good.

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 forming sheet was produced by experiment below, and also the design sheet which has the following fine pattern uneven | corrugated pattern was produced using the obtained forming sheet, and performance evaluation was performed.
Fine pattern unevenness pattern: diffraction gloss, matte

Preparation of Roll Embossing Device for Fine Pattern Roughness Pattern
The following drum-like shaped plates 1 to 3 were prepared as pressing parts on the emboss side, and smooth rolls (hard), smooth rolls (soft), and flat plates (hard) were prepared as pressing parts on the backup side. .
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 (soft): A roll of paper with a configuration in which the surface is soft and the surface shape changes 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.

[Production of Drum-shaped Plate 1]
Prepare a cylinder with a copper plating on the surface, and within the width of 170 mm, in the pattern shown in Fig. 3 as a fine pattern relief pattern, pitch P is 300 μm, height W is 200 μm, depth D is 7 μm. The surface of the cylinder was cut to prepare a drum-shaped mold 1.

[Production of Drum-shaped Plate 2]
A drum-like shaped printing plate is used except that the size of the fine patterned uneven pattern is changed to a pitch P of 500 μm, a convex portion width W of 350 μm, and a depth D of 10 μm to produce the drum-like shaped plate 2 The same procedure as 1 was repeated to produce a drum-shaped mold 2.

[Production of Drum-like Plate 3]
Next, prepare a cylinder with a copper plating on the surface, and cut a linear pattern of 44 types of combinations of the following pitches and bit apex angles on the cylinder surface with a cutting tool whose cross section is an isosceles triangle: Was produced.

Pitch P: 4 levels of 1 μm, 2 μm, 3 μm and 9 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.

<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 form a continuous sheet of strip (1500 mm in width). , A length of 1500 m), and a shaped sheet material 1 (mirror specification surface) was prepared. S _a base material layer surface (smooth surface of the resin layer) is 1.5 [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 1.5 [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
(Preparation of shaped sheet)
The roll embossing device for fine pattern concavo-convex patterns was prepared by using the drum-shaped printing form 1 and the smooth roll (hard) prepared above as pressing parts.
The formed sheet material sheet 1 obtained above is continuously heated and pressed in a fine pattern asperity pattern roll embossing device so that the formed layer hits the drum-shaped formed plate 1 as shown in FIG. The formed sheet was transferred to the forming layer of the mold sheet original fabric 1 to prepare a forming sheet 1.
At this time, hot air was applied to the formed sheet material sheet 1 to heat it, the smooth roll (hard) was heated, and the drum-shaped formed plate 1 was cooled.

After hot pressing, cool air is applied from the side of the base material layer of the formed sheet raw fabric 1 to cool, and the formed sheet raw fabric 1 and the drum-shaped formed printing plate 1 which are hot pressed and adhered are peeled off. The forming sheet 1 which has a surface aspect which can form a fine pattern concavo-convex pattern was obtained. The process conditions are as follows: Hot air temperature: 110 ° C
Drum shaped plate 1 surface temperature: 30 ° C
Smooth roll (hard) surface temperature: 120 ° C
Roll pressure: Linear pressure 270 kgf / cm
Sheet feeding speed: 5 m / min Cold air temperature: 10 ° C

(Preparation of design sheet)
Polyurethane (Dainichi Seika Kogyo Co., Ltd., Rezamin NE-8811) and coloring agent (Dainichi Seika Kogyo Co., Ltd.) for the surface resin layer on which the fine pattern concavo-convex pattern of the design sheet is formed The design resin composition 1 was adjusted with the following composition using Seika Seven NET-5794 black).
Polyurethane 100 parts by mass Colorant 15 parts by mass Toluene 25 parts by mass Isopropyl alcohol 25 parts by mass

The shaped sheet 1 produced above was attached to a synthetic leather manufacturing apparatus, and the design resin composition 1 was applied to the shaped layer of the shaped sheet by a die coating 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 3.

[Examples 2 to 7, Comparative Example 1]
In the same manner as in Example 1 according to the combination of the pressed parts, the formed sheet material and the like described in Table 3, the formed sheet and the design sheet are prepared, and the type of the fine pattern uneven pattern is a mat The evaluation of the matte texture was performed, and the evaluation of the rainbow strength and the rainbow field size was performed for the type of the fine pattern uneven pattern having a diffractive gloss. The results are shown in Table 3.

<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 protrusions of the fine patterned uneven pattern extend is taken as the longitudinal direction, and it is considered good when three or more persons feel a wide and homogeneous matte texture in both the longitudinal direction and the lateral direction.

<Evaluation of rainbow strength of diffraction gloss>
The evaluation of the rainbow strength of the diffraction gloss was performed by the variable angle spectroscopy measurement. Using a variable angle spectrometer (S-OGM, Digital Fashion Co., Ltd.), irradiate white (xenon light source) from an incident angle of 0 degrees (normal direction of the diffractive gloss sheet) to the diffractive structure layer of the diffractive gloss sheet Then, the 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. The intensity of the rainbow was determined by the maximum value of the normalized gain excluding specular reflection.
The longitudinal direction and the lateral direction were evaluated, with the direction in which the linear convex portion extends as the longitudinal direction.
The case where the gain is 0.2 or more is considered good.

<Evaluation of the field of view of diffraction gloss>
The visual inspection was performed in the following procedure about the field of the diffraction gloss, and it judged.
A sample of 100 mm square was cut out from the design sheet and placed on a desk, and the width of the field of view of the rainbow was judged from the upper position of 500 mm. Under the test environment with an illumination of 400 lux (equivalent to a bright office), the number of people in 10 subjects (20's to 60's) who felt that the field of vision was wide was counted.
With the direction in which the linear convex portions extend as the vertical direction, evaluation was performed in both the vertical direction and the horizontal direction.
It was considered good if six or more people felt the field of vision was wide.

[Result Summary]
As can be seen from Table 3, by using the shaped sheet according to the present invention, in Examples 1 to 7, a design sheet capable of observing a good matte texture and diffraction gloss brightly in a wide range was obtained.
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.

DESCRIPTION OF SYMBOLS 1 fine pattern linear concave part 2 fine pattern linear convex part 11 forming sheet 12 forming sheet forming part 13 forming sheet base part 14 forming sheet forming layer forming part 15 forming sheet forming layer base 16 Formed sheet fine pattern linear concave portion 17 Formed sheet fine pattern linear convex portion 21 design sheet 22 design sheet surface resin layer 23 design sheet base layer 31 shaped sheet manufacturing apparatus 32 shaped sheet original winding 33 shaped sheet Raw material 34 Feeding roll 35 Hot air device 36 Embossing roll 37 Backup roll 38 Cold air device 39 Shaped sheet 39 Shaped sheet winding

Claims (11)

It is a manufacturing method of a forming sheet which can form a fine pattern uneven pattern,
The shaped sheet is
A laminate having a base material layer and a forming layer which is the outermost layer on one side,
It is manufactured from the forming sheet material using an embossing roll,
It has a surface aspect capable of forming the fine pattern uneven pattern on the forming layer of the forming sheet,
The shaped sheet raw fabric is
A base material layer having _a surface roughness S _a of 0.3 μm or more and less than 15 μm on the surface on the forming layer side;
A laminate having a forming layer having _a surface roughness S _a of at least 0.03 μm and less than 5 μm,
The emboss roll has a surface mode capable of forming the fine patterned uneven pattern on the surface,
The manufacturing method is
The forming sheet material is sandwiched between an embossing roll and a backup roll such that the forming layer of the forming sheet material is in contact with the surface of the embossing roll, and the fineness of the surface of the embossing roll is obtained. The manufacturing method of a forming sheet including the process of transcribe | transferring a pattern uneven pattern to the forming layer of the said forming sheet original fabric. The emboss roll has a drum-like shaped plate,
The manufacturing method of a shaping | molding sheet of Claim 1. In the step 3, the backup roll has a surface configuration to which the large pattern asperity pattern of the embossing roll can be transferred by pressure bonding.
The manufacturing method of a shaping | molding sheet of Claim 1 or 2. The formed sheet material is a continuous sheet and is continuously fed out.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-3. The shaped sheet raw fabric is
The surface roughness S _a of the surface of the base material layer on the side of the base sheet on which the base sheet is applied is 0.3 μm or more and less than 5 μm,
The surface roughness S _a of the surface of the forming layer is 0.03 μm or more and less than 0.5 μm,
The manufacturing method of a shaping | molding sheet in any one of Claims 1-4. The shaped sheet raw fabric is
The base layer comprises a paper layer and a clay layer,
The shaping layer contains a polypropylene resin or a polymethylpentene resin
The manufacturing method of a shaping | molding sheet in any one of Claims 1-5. The fine patterned uneven pattern has a depth of 0.08 μm or more and 10 μm or less.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-6. The fine patterned concavo-convex pattern has a diffractive gloss and a depth of 0.08 μm or more and 5 μm or less.
The manufacturing method of a shaping | molding sheet in any one of Claims 1-7.   The method for manufacturing a formed sheet according to any one of claims 1 to 8, wherein the fine patterned uneven pattern has a matte texture and a depth of 5 μm or more and 10 μm or less. The fine patterned uneven pattern is located on a smooth substantially flat surface,
The manufacturing method of a forming sheet as described in any one of Claims 1-9.   A shaped sheet produced by the method for producing a shaped sheet according to any one of claims 1 to 10.

Images