JP2022057604A - Method for manufacturing decorative sheet and apparatus for manufacturing decorative sheet - Google Patents

Abstract

To provide a method for manufacturing a decorative sheet having visually excellent three-dimensional feeling by synchronization of a pattern of a pattern layer and a recess.SOLUTION: A method for manufacturing a decorative sheet 10 includes: a preparation step of preparing a base material 1 having a pattern layer 2 having a feature part 2a and a non-feature part 2b on one surface; a laminate step of laminating a transparent resin layer 3 on the pattern layer 2; and a shaping step of shaping a recess D synchronized with the feature part 2b of the pattern layer 2 from a side opposite to a side having the pattern layer 2 of the transparent resin layer 3.SELECTED DRAWING: Figure 3

Description

The present invention relates to a method for producing a decorative sheet and an apparatus for producing a decorative sheet.

In building materials, furniture, home appliances, etc., when it is desired to decorate the members to be used, a decorative board to which a decorative sheet with a design is attached is generally used.

In such a decorative sheet, in order to give a visual design, a recess may be formed by embossing or the like to give a three-dimensional visual effect.

For example, in Patent Document 1, a decorative sheet for a floor is used by attaching it to the surface of a veneer decorative floor board having a veneer attached to a base material, and a transparent protective layer is formed on the surface of a transparent or translucent synthetic resin film. The synthetic resin film and the transparent protective layer are disclosed with a decorative sheet for a floor, which is characterized in that an uneven shape due to embossing is imparted to the synthetic resin film and the transparent protective layer.

In recent years, there has been a demand for a decorative sheet having a visually superior three-dimensional effect, and the floor decorative sheet of Patent Document 1 is not yet sufficient, and there is room for further improvement.

Japanese Unexamined Patent Publication No. 2019-60159

The present invention solves the above-mentioned problems, and provides a method for manufacturing a decorative sheet and a device for manufacturing a decorative sheet, which have a visually excellent three-dimensional effect by synchronizing the pattern on the pattern layer with the recesses. The purpose is to do.

The method for manufacturing a decorative sheet of the present invention is a method for manufacturing a decorative sheet having recesses, which is a preparatory step for preparing a base material having a pattern layer having a characteristic portion and a non-characteristic portion on one surface, the above-mentioned pattern layer. A laminating step of laminating the transparent resin layer on the top, and a shaping step of forming a recess synchronized with the characteristic portion of the pattern layer from the side opposite to the side of the transparent resin layer having the pattern layer. It is characterized by having.
The method for producing a decorative sheet of the present invention further includes, after the shaping step, a detection step of detecting the position information between the characteristic portion of the pattern layer and the recess synchronized with the characteristic portion of the pattern layer. It is preferable to feed back the position information to the delivery adjusting mechanism provided in front of the shaping step to adjust the position of the characteristic portion of the pattern layer and the position of the recess synchronized with the feature portion of the pattern layer. ..
Further, it is preferable to have a coating step of coating the surface protective layer on the transparent resin layer between the laminating step and the shaping step.
Further, in the decorative sheet manufacturing apparatus of the present invention, a recess is provided on one of the base materials while heating the decorative sheet having a characteristic portion and a non-characteristic portion and a transparent resin layer. A shaping mechanism for forming a concave portion synchronized with a characteristic portion of the pattern layer from the side opposite to the side of the transparent resin layer having the pattern layer, which is a decorative sheet manufacturing apparatus. At the rear, a detection mechanism for detecting the position information of the characteristic portion of the pattern layer and the recess synchronized with the feature portion of the pattern layer, and the position information are fed back to the front portion of the shaping mechanism. It is characterized by being provided with a delivery adjusting mechanism for adjusting the delivery of the decorative sheet.

INDUSTRIAL APPLICABILITY The present invention can provide a method for manufacturing a decorative sheet and a device for manufacturing a decorative sheet, which have a visually excellent three-dimensional effect by synchronizing the pattern on the pattern layer with the concave portion.

(A) to (c) are cross-sectional views schematically showing an example of a recess of a decorative sheet manufactured by the method for manufacturing a decorative sheet of the present invention. It is a drawing explaining the detection process in the manufacturing method of the decorative sheet of this invention. It is sectional drawing which shows typically an example of the decorative sheet manufactured by the manufacturing method of the decorative sheet of this invention.

<Manufacturing method of decorative sheet>
Hereinafter, a method for producing a decorative sheet of the present invention will be described.
In the following description, the lower and upper limits of the numerical range represented by "-" mean "greater than or equal to or less than" (for example, if α to β, it is greater than or equal to α and less than or equal to β).

The method for manufacturing a decorative sheet of the present invention is a method for manufacturing a decorative sheet having recesses, which is a preparatory step for preparing a base material having a pattern layer having a characteristic portion and a non-characteristic portion on one surface, the above-mentioned pattern layer. A laminating step of laminating the transparent resin layer on the top, and a shaping step of forming a recess synchronized with the characteristic portion of the pattern layer from the side opposite to the side of the transparent resin layer having the pattern layer. It is characterized by having.
In the method for producing a decorative sheet of the present invention, it is preferable that all the steps are performed by roll-to-roll.
Hereinafter, each step constituting the method for producing the decorative sheet of the present invention will be described.

[Preparation process]
The method for producing a decorative sheet of the present invention includes a preparatory step of preparing a base material having a pattern layer having a characteristic portion and a non-characteristic portion on one surface.
Hereinafter, the base material and the pattern layer used in the preparation step will be described.

(Base material)
Examples of the base material include low-density polyethylene (including linear low-density polyethylene), medium-density polyethylene, high-density polyethylene, ethylene-α-olefin copolymer, homopolypropylene, polymethylpentene, polybutene, and ethylene-propylene. Polyethylene-based resins such as polymers, propylene-butene copolymers, ethylene-vinyl acetate copolymers, ethylene-vinyl acetate copolymers saponified products, or mixtures thereof, polyethylene terephthalates, polybutylene terephthalates, polyethylene naphthalates, Polyethylene naphthalate-isophthalate copolymer, thermoplastic ester-based resins such as polycarbonate and polyarylate, acrylic thermoplastic resins such as methyl polymethacrylate, ethyl polymethacrylate, ethyl polyacrylate, butyl polyacrylate and the like. , Nylon-6, Nylon-66 and other polyamide-based thermoplastic resins, or polyimide, polyurethane, polystyrene, acrylonitrile-butadiene-styrene resin and the like.
These may be used alone or in combination of two or more.
Among them, the olefin resin is preferable in that the printability of the pattern layer is excellent and the cost is low.

The base material may be colored. In this case, a colorant (pigment or dye) can be added to the base material to color it.
As the colorant, for example, inorganic pigments such as titanium dioxide, carbon black and iron oxide, organic pigments such as phthalocyanine blue, and various dyes can be used.
These can be selected from known or commercially available ones or two or more kinds. Further, the amount of the colorant added may be appropriately set according to the desired color and the like.

The base material contains various additives such as a filler, a matting agent, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, and a light stabilizer, if necessary. May be.

The thickness of the base material is not particularly limited, but is preferably 40 μm or more and 200 μm or less.
The base material may be composed of either a single layer or a multilayer.

(Picture layer)
The pattern layer is a layer that imparts decorativeness to the decorative sheet.

The pattern layer may be, for example, a pattern layer formed by printing various patterns using ink and a printing machine, or may be a layer in which a concealing layer and a pattern layer are combined. good.

By providing the concealing layer, when the above-mentioned base material is colored or has uneven color, it is possible to give an intended color and adjust the surface color.
In addition, by providing a pattern layer, stone grain patterns that imitate the surface of rocks such as wood grain patterns and marble patterns (for example, Travertin marble patterns), fabric patterns that imitate cloth textures and cloth-like patterns, tiled patterns, and brickwork A pattern or the like, or a pattern such as a parquet or a patchwork in which these are combined can be added to the decorative sheet.
These patterns are formed by multicolor printing with ordinary yellow, red, blue, and black process colors, and also by multicolor printing with special colors prepared by preparing the individual colors that make up the pattern. To.

As the ink composition used for the pattern layer, a binder resin mixed with a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent or the like is used.

The binder resin is not particularly limited, and for example, urethane resin, acrylic resin, urethane-acrylic resin, urethane-acrylic copolymer resin, vinyl chloride / vinyl acetate copolymer resin, vinyl chloride / vinyl acetate / acrylic co-weight. Combined resin, acrylic resin, polyester resin, nitrocellulose resin and the like are preferable. As the binder resin, any one of these can be used alone or in combination of two or more.

Examples of the colorants include carbon black (black), iron black, titanium white, antimony white, chrome yellow, titanium yellow, petals, cadmium red, ultramarine, cobalt blue and other inorganic pigments, quinacridone red, isoindolinone yellow, and the like. Organic pigments such as phthalocyanine blue, metal pigments made of scaly foil pieces such as dyes, aluminum and brass, titanium dioxide-coated mica, and pearl gloss pigments made of scaly foil pieces such as basic lead carbonate are preferable. Can be mentioned.
These can be used alone or in combination of two or more.

The pattern layer has a characteristic portion and a non-characteristic portion.
The characteristic portion refers to a portion having a feature capable of recognizing the pattern of the pattern layer. For example, when the pattern layer is a wood grain pattern, the wood grain conduit, knots, annual rings and spots correspond to the above. When the pattern layer is a stone pattern, a pattern (crack pattern) expressed by stripes or cracks of different crystal components in the rock corresponds to it.
Further, a pattern serving as a mark may be added to the end portion of the pattern layer, and this may be used as the characteristic portion.
Further, the non-feature portion means a portion other than the feature portion.

The thickness of the pattern layer is not particularly limited, and is preferably 0.1 μm or more, more preferably 0.5 μm or more and 600 μm or less, for example. When the thickness of the pattern layer is within the above range, an excellent design can be imparted to the obtained decorative sheet, and concealment can be imparted.

Examples of the method for forming the pattern layer include a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an electrostatic printing method, and an inkjet printing method. When forming a concealing layer, for example, various methods such as a roll coating method, a knife coating method, an air knife coating method, a die coating method, a lip coating method, a comma coating method, a kiss coating method, a flow coating method, and a dip coating method are used. A coating method and the like can also be mentioned.

[Laminating process]
The method for producing a decorative sheet of the present invention includes a laminating step of laminating a transparent resin layer on the pattern layer.
First, the transparent resin layer laminated by the laminating step will be described.

(Transparent resin layer)
The transparent resin layer is preferably a layer formed of a thermoplastic resin.
The transparent resin layer is not particularly limited as long as the pattern layer can be seen, and includes any of colorless transparent, colored transparent, translucent and the like.

Examples of the thermoplastic resin include olefin resins such as polyethylene, polypropylene, polybutene, polymethylpentene, and olefin thermoplastic elastomers, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and ethylene glycol-terephthalic acid-isophthalic acid. Polymer resin, terephthalic acid-ethylene glycol-1,4 cyclohexanedimethanol copolymer resin, polyester resin such as polyester-based thermoplastic elastomer, polymethyl (meth) acrylate, methyl (meth) acrylate-butyl (meth) acrylate common weight Examples thereof include a coalesced resin, an acrylic resin such as a methyl (meth) acrylate-styrene copolymer resin, a polycarbonate resin, a polyvinyl chloride, a polystyrene, and an ionomer.
Among them, polyethylene or polypropylene is more preferable because it has high tensile strength, excellent chemical resistance, and excellent production process.
In addition, in this specification, (meth) acrylate means acrylate or methacrylate.

The polyethylene may be a homopolymer of ethylene, or an α-olefin such as ethylene and another comonomer copolymerizable with ethylene (for example, propylene, 1-butene, 1-hexene, 1-octene). It may be a copolymer with vinyl acetate, vinyl alcohol, etc.).
Examples of the polyethylene resin include high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), ultra-low-density polyethylene (VLDPE), and ultra-high molecular weight polyethylene (ultra-high molecular weight polyethylene). UHMWPE), crosslinked polyethylene (PEX) and the like.
These polyethylenes may be used alone or in combination of two or more.

The polypropylene may be a homopolymer of propylene, or α-olefins such as propylene and other comonomer copolymerizable with propylene (eg, ethylene, 1-butene, 1-hexene, 1-octene; It may be a copolymer with vinyl acetate, vinyl alcohol, etc.).
These polypropylenes may be used alone or in combination of two or more.
In the present invention, a homopolypropylene homopolymer is particularly preferable from the viewpoint of excellent scratch resistance and bending processability.

The transparent resin layer may be composed of one layer or two or more layers.

The thickness of the transparent resin layer is preferably 30 μm or more and 200 μm or less, more preferably 40 μm or more and 180 μm or less, and further preferably 60 μm or more and 120 μm or less, from the viewpoint of obtaining excellent scratch resistance and bending workability.

When the transparent resin layer is composed of two or more layers, the total thickness of the transparent resin layer is preferably 30 μm or more and 200 μm or less, more preferably 40 μm or more and 180 μm or less, and further preferably 60 μm or more and 120 μm or less.

When the transparent resin layer is composed of a plurality of layers, the types of resins to be formed may be the same or different, and the thickness of the base material composed of the plurality of resins may be the same or different. You may.
The method of laminating the transparent resin layer in two or more layers is not limited to a general method, and examples thereof include a dry laminating method and an extrusion heat laminating method.

The transparent resin layer may be subjected to surface treatment such as saponification treatment, glow discharge treatment, corona discharge treatment, plasma discharge treatment, ultraviolet (UV) treatment, and flame treatment within a range not deviating from the gist of the present invention. ..

(Laminating mechanism)
The laminating step can be performed by, for example, the laminating mechanism described below.
As the laminating mechanism, a dry laminating method may be used, or an extrusion heat laminating method may be used.

As the adhesive used in the dry laminating method, for example, a water-based adhesive, a heat-sensitive adhesive, a pressure-sensitive adhesive, a hot melt adhesive, or the like can be appropriately selected and used.
The method for applying the adhesive is not particularly limited, and for example, a roll coating method, a comma coating method, a curtain coating method, a squeeze coating method, a blade coating method, a gravure coating method, or the like can be appropriately selected and used. ..

As the extrusion heat laminating method, it is also possible to use a roll press type continuous laminating method in addition to the method of contacting a metal plate and pressing it under normal pressure. In particular, when a continuous laminating method using a metal endless belt or a heat drum made of metal or a curable resin is used, there is no surface warpage or waviness, and the adhesion between layers is good and it is hardened densely. It has the advantage that it can be integrated and can be continuously manufactured at high speed.

[Shaping process]
The method for producing a decorative sheet of the present invention includes a shaping step of forming a recess synchronized with a characteristic portion of the pattern layer from the side opposite to the side of the transparent resin layer having the pattern layer.
First, the concave portion formed by the shaping step will be described.

(Recess)
The recess formed by the shaping step has a shape synchronized with the characteristic portion of the pattern layer.
The recess may have a shape that is a model of the outer shell of the characteristic portion of the pattern of the pattern layer, a shape that simplifies the outer shell of the characteristic portion of the pattern of the pattern layer, or a reduced outer shell of the characteristic portion. Alternatively, it may have an enlarged similar shape.

1 (a) to 1 (c) are cross-sectional views schematically showing an example of a recess of a decorative sheet manufactured by the method for manufacturing a decorative sheet of the present invention.
The positional relationship between the recess (D) and the characteristic portion of the pattern layer may be any of FIGS. 1 (a) to 1 (c).
That is, as shown in FIG. 1 (a), the feature portion 2a of the pattern layer 2 and the recess (D) may be positioned so as to overlap each other in the stacking direction, as shown in FIG. 1 (b). In addition, the feature portion 2a of the pattern layer 2 and the recess (D) may be partially overlapped with each other, and as shown in FIG. 1 (c), the feature portion 2a of the pattern layer 2 and the feature portion 2a It may be positioned so that it does not overlap with the recess (D).
However, even in FIG. 1 (c), the recess (D) is located in the vicinity of the feature portion 2a of the pattern layer 2 when viewed in a plan view. The term "neighborhood" means that the position of the feature portion 2a and the position of the recess (D) having a shape corresponding to the feature portion 2a are 70 mm or less when viewed in a plan view.
These can be appropriately set depending on the design of the pattern layer 2.
It should be noted that the tuning relationship between the recess (D) and the feature portion 2a does not necessarily have to be established on the entire surface of the design, and if the overall design feeling is not impaired, there is a partial non-tuning region. You may.

(Excipient mechanism)
Examples of the shaping mechanism include a method of embossing from the side of the transparent resin layer opposite to the side having the pattern layer to shape a recess synchronized with the characteristic portion of the pattern layer. ..

Examples of the embossing include a well-known single-wafer embossing method and a method of embossing with a rotary embossing machine.
As the pattern used in the embossing process, a design that synchronizes with the above-mentioned pattern layer can be appropriately selected and used.

When the embossing is performed, it is preferable to adjust the position of the characteristic portion of the pattern layer and the position of the recess corresponding to the characteristic portion of the embossing of the pattern layer.
The position of the recess corresponding to the characteristic portion of the embossed pattern layer corresponds to, for example, a wood grain conduit, a node, an annual ring and a spot in the case of a wood grain pattern, and a rock in the case of a stone grain pattern. The pattern (crack pattern) expressed by the stripes and cracks of different crystal components in the above corresponds.
Further, a pattern to be a mark may be added to the end of the pattern used in the embossing process, and the position may be adjusted in correspondence with the pattern to be a mark given to the end of the pattern layer described above.

The temperature at the time of the embossing is not particularly limited, but a temperature at which the so-called embossing return at which the recesses disappear during the heat-pressing molding is preferable.
The heating method is not particularly limited, and for example, an infrared heater or the like can be used.

[Detection process]
The method for producing a decorative sheet of the present invention further includes, after the shaping step, a detection step of detecting the position information between the characteristic portion of the pattern layer and the recess synchronized with the characteristic portion of the pattern layer. It is preferable to feed back the position information to the delivery adjusting mechanism provided in front of the shaping step to adjust the position of the characteristic portion of the pattern layer and the position of the recess synchronized with the feature portion of the pattern layer. ..

FIG. 2 is a drawing illustrating an example of a detection step in the method for manufacturing a decorative sheet of the present invention.
As shown in FIG. 2, the preforming sheet 11 is conveyed by the conveying mechanism 20 and heated, and then the shaping mechanism 40 forms a recess synchronized with the characteristic portion of the pattern layer, and the decorative sheet 10 is formed. Is obtained. After that, the detection mechanism 50 detects the position information of the characteristic portion of the pattern layer and the recess synchronized with the feature portion of the pattern layer (detection step), and feeds back the position information to the sending adjustment mechanism 30. , The position of the characteristic portion of the pattern layer and the position of the recess synchronized with the characteristic portion of the pattern layer are adjusted.

In the detection step, the position information between the characteristic portion of the pattern layer obtained by the shaping step and the recess synchronized with the feature portion of the pattern layer, that is, the positional relationship in the actual decorative sheet is detected, and the position is described. The information is fed back to the delivery adjusting mechanism provided in front of the shaping step to adjust the positions of the pattern layer and the recess. Therefore, the information before shaping the concave portion has an excellent position adjusting ability as compared with the method of adjusting the elongation of the decorative sheet.

The position of the characteristic portion of the pattern layer and the position of the recess synchronized with the characteristic portion of the pattern layer may be appropriately set according to the required product.
For example, when the positional deviation of several mm is detected, the positional relationship between the characteristic portion of the pattern layer and the recess may be adjusted, and when the positional deviation of several μm is detected, the characteristic portion of the pattern layer may be adjusted. The positional relationship of the recesses may be adjusted.

The feeding adjustment mechanism is not particularly limited as long as the feeding of the preformation sheet can be adjusted, and for example, a feeding roll or the like can be used.
As a method of adjusting the position of the characteristic portion of the pattern layer and the position of the recess synchronized with the characteristic portion of the pattern layer (feeding adjustment mechanism), for example, the speed of the feeding adjustment mechanism is changed to perform the shaping. The position can be adjusted by correcting the tension of the front seat 11.

The detection mechanism is not particularly limited, and for example, the position information may be detected by a camera, a laser sensor, or the like.

[Coating process]
The method for producing a decorative sheet of the present invention preferably includes a coating step of coating a surface protective layer on the transparent resin layer between the laminating step and the shaping step.
First, the surface protective layer will be described.

(Surface protective layer)
The surface protective layer is a layer that imparts durability (scratch resistance, stain resistance, weather resistance, etc.) to the obtained decorative sheet, and by having the surface protective layer, the protection of the pattern layer is more preferably performed. This makes it possible, and it is possible to suitably prevent deterioration of the design due to scratches.
The surface protective layer may have a single layer structure, a plurality of layer structures made of the same or different materials, or the materials shown below may be appropriately mixed.

The surface protective layer is not particularly limited, and examples thereof include those made of a two-component curable resin and a crosslinked cured product of an ionizing radiation curable resin composition.
The crosslinked cured product is preferably transparent, and as long as it is transparent, it may be translucent or colored as long as the pattern layer can be visually recognized.

As the two-component curable resin, the binder resin of the adhesive primer layer may be used.
The ionizing radiation curable resin includes, for example, an oligomer having a radically polymerizable unsaturated bond or a cationically polymerizable functional group in the molecule (hereinafter, also includes so-called prepolymers, macromonomers and the like) and / or a radical in the molecule. Monomers having a polymerizable unsaturated bond or a cationically polymerizable functional group are preferably used. Here, the ionizing radiation means an electromagnetic wave or a charged particle having an energy capable of polymerizing or cross-linking a molecule, and usually, an electron beam (EB) or an ultraviolet ray (UV) is generally used.

Examples of the oligomer or monomer include compounds having a (meth) acryloyl group, a radically polymerizable unsaturated group such as a (meth) acryloyloxy group, and a cationically polymerizable functional group such as an epoxy group in the molecule. These oligomers and monomers can be used alone or in admixture of a plurality of types. In addition, in this specification, the said (meth) acryloyl group means an acryloyl group or a methacryloyl group.

Examples of the oligomer having a radically polymerizable unsaturated group in the molecule include oligomers such as urethane (meth) acrylate, polyester (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, and triazine (meth) acrylate. Can be preferably used, and urethane (meth) acrylate oligomers are more preferable. As the molecular weight, a molecular weight of about 2.5 to 100,000 is usually used.

As the monomer having a radically polymerizable unsaturated group in the molecule, for example, a polyfunctional monomer is preferable, and a polyfunctional (meth) acrylate is more preferable.
Examples of the polyfunctional (meth) acrylate include diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, bisphenol A ethylene oxide-modified di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and trimethylolpropane. Ethylene oxide tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate {5-functional (meth) acrylate}, dipentaerythritol hexa (meth) acrylate {six-functional (meth) acrylate} And so on. Here, the polyfunctional monomer means a monomer having a plurality of radically polymerizable unsaturated groups.

It is more preferable that the ionizing radiation curable resin composition contains an ionizing radiation curable resin component composed of a urethane acrylate oligomer and a polyfunctional monomer, and the ionizing radiation curable resin component is a urethane acrylate oligomer / polyfunctional monomer (mass ratio). ) Is particularly preferably 6/4 to 9/1. Within this mass ratio range, the scratch resistance can be improved.
If necessary, a monofunctional monomer may be appropriately used in addition to the ionizing radiation curable resin component.
Examples of the monofunctional monomer include methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, and phenoxyethyl (meth) acrylate.

When the ionizing radiation curable resin composition is crosslinked with ultraviolet rays, it is preferable to add a photopolymerization initiator to the ionizing radiation curable resin composition.
When the ionizing radiation curable resin composition is a resin system having a radically polymerizable unsaturated group, acetophenones, benzophenones, thioxanthones, benzoins, and benzoin methyl ethers are used alone or mixed as the photopolymerization initiator. Can be used.
When the ionizing radiation curable resin composition is a resin system having a cationically polymerizable unsaturated group, the photopolymerization initiator includes an aromatic diazonium salt, an aromatic sulfonium salt, an aromatic iodonium salt, a metatheron compound, and a benzoin. Sulfonates and the like can be used alone or as a mixture. The amount of these photopolymerization initiators added is about 0.1 to 10 parts by mass with respect to 100 parts by mass of the ionizing radiation curable resin component.

If necessary, various additives may be further added to the ionizing radiation curable resin composition. Examples of these additives include urethane resin, polyvinyl acetal resin, polyester resin, polyolefin resin, styrene resin, polyamide resin, polycarbonate resin, acetal resin, vinyl chloride-vinyl acetate copolymer resin, vinyl acetate resin, and acrylic. Thermoplastic resins such as resins and cellulose resins, lubricants such as silicone resins, waxes and fluororesins, UV absorbers such as benzotriazole, benzophenone and triazine, light stabilizers such as hindered amine radical traps, dyes and pigments. Colorants and the like.

As the electron beam source of ionizing radiation, for example, Cockcroft-Walton type, Van de Graaff type, resonance transformer type, insulated core transformer type, or various electron beam accelerators such as linear type, dynamitron type, and high frequency type can be used. It can be used to irradiate electrons with an energy of 70 to 1000 keV. Further, the irradiation dose of ionizing radiation is preferably, for example, about 1 to 10 Mrad.
As the ultraviolet source of the ionized radiation, for example, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, or a metal halide lamp can be used, and the wavelength of the ultraviolet light is usually 190 to 380 nm. The wavelength range is mainly used.

The thickness of the surface protective layer is not particularly limited, but a preferable lower limit is 1 μm, a preferable upper limit is 50 μm, a more preferable lower limit is 10 μm, a more preferable upper limit is 40 μm, a further preferable lower limit is 13 μm, and a further preferable upper limit is 13 μm. It is 35 μm.
If the thickness of the surface protective layer is less than 1 μm, sufficient durability (scratch resistance, stain resistance, weather resistance, etc.) may not be imparted, and if it exceeds 50 μm, the transmittance is lowered and the pattern is printed. The visibility of the layered pattern may be reduced.

The coating step is not particularly limited, and for example, the ionizing radiation curable resin composition may be applied and irradiated with ionizing radiation.
As the coating method, various coating methods such as a roll coating method, a knife coating method, an air knife coating method, a die coating method, a lip coating method, a comma coating method, a kiss coating method, a flow coating method, and a dip coating method can be used.

[Cosmetic sheet]
The decorative sheet produced by the method for producing a decorative sheet of the present invention has a transparent resin layer laminated with a base material having a pattern layer having a characteristic portion and a non-characteristic portion on one surface, and is transparent. A recess is provided on the side of the resin layer opposite to the side having the pattern layer.
FIG. 3 is a cross-sectional view schematically showing an example of a decorative sheet manufactured by the method for manufacturing a decorative sheet of the present invention.
In the example of the decorative sheet shown in FIG. 3, the decorative sheet 10 is provided with the pattern layer 2 on one surface of the base material 1, and has the transparent resin layer 3 on the pattern layer 2.
The pattern layer 2 has a feature portion 2a and a non-feature portion 2b.
Further, the transparent resin layer 3 has a recess (D) synchronized with the characteristic portion of the pattern layer 2 on the side opposite to the side having the pattern layer 2. The pattern layer 2 has a recess located in the stacking direction of the recess (D) on the side opposite to the side having the base material 1.
Further, although not shown in FIG. 3, it is preferable that the decorative sheet 10 has a surface protective layer on the transparent resin layer 3.
The recesses located in the stacking direction of the recesses (D) may or may not have the recesses as shown in FIG.

(Other layers)
The decorative sheet 10 may have a primer layer and an adhesive layer, if necessary.
The primer layer and the adhesive layer may be used in each layer, for example, between the base material and the pattern layer, between the pattern layer and the transparent resin layer, or between the transparent resin layer and the surface protective layer. It can be provided between layers.

The primer layer can be formed by applying a known primer. Examples of the primer agent include a urethane resin-based primer made of an acrylic-modified urethane resin (acrylic urethane-based resin) and the like, and a urethane-cellulose resin (for example, a resin obtained by adding hexamethylene diisocyanate to a mixture of urethane and nitrified cotton. ), A resin-based primer made of a block copolymer of acrylic and urethane, and the like. Additives may be added to the primer, if necessary. Examples of the additive include a filler such as calcium carbonate and clay, a flame retardant such as magnesium hydroxide, an antioxidant, a lubricant, a foaming agent, an ultraviolet absorber, and a light stabilizer. The blending amount of the additive can be appropriately set according to the product characteristics.

The primer layer may contain an ultraviolet absorber, if necessary.
As the ultraviolet absorber, a known ultraviolet absorber can be appropriately selected and used.

The thickness of the primer layer is not particularly limited, but is preferably 0.01 to 10 μm, more preferably 0.1 to 1 μm, for example.

As a method for forming the primer layer, the resin-based primer may be applied and cured by ionizing radiation or the like.
As the coating method and the curing method, a known method may be appropriately selected and used.

The adhesive layer is not particularly limited, and a known adhesive may be used. For example, polyurethane, acrylic, polyolefin, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ionomer, etc., as well as butadiene-acrylic nitrile rubber, neoprene rubber, natural rubber, etc. Can be mentioned. These adhesives may be used alone or in combination of two or more.

The thickness of the adhesive layer after drying is preferably about 0.1 to 30 μm, more preferably about 1 to 5 μm.

As a method for forming the adhesive layer, the adhesive may be applied and cured by ionizing radiation or heat.
As the coating method and the curing method, a known method may be appropriately selected and used.

The decorative sheet 10 may have a backer layer on the lowermost layer of the base material (the side opposite to the side on which the pattern layer is laminated) from the viewpoint of imparting scratch resistance and impact resistance.
As the backer layer, a known backer layer disclosed in Japanese Patent Application Laid-Open No. 2014-188941 or the like can be appropriately selected and used.
When the backer layer is provided, the backer layer may be laminated on the side opposite to the side on which the pattern layer of the base material is laminated after the shaping step or the detection step, and in the preparation step, the backer layer may be laminated. A base material having a backer layer laminated on the side opposite to the side on which the pattern layer is laminated may be prepared.

<Manufacturing equipment for decorative sheets>
In the decorative sheet manufacturing apparatus of the present invention, a decorative sheet in which a decorative sheet having a characteristic portion and a non-characteristic portion and a decorative sheet provided with a transparent resin layer are recessed while being heated is provided on one of the base materials. In the manufacturing apparatus of the above, from the side opposite to the side of the transparent resin layer having the pattern layer, to the shaping mechanism for shaping the concave portion tuned to the characteristic portion of the pattern layer, to the rear part of the shaping mechanism. , A detection mechanism that detects the position information between the characteristic portion of the pattern layer and the recess synchronized with the feature portion of the pattern layer, and feeds the position information back to the front portion of the shaping mechanism to provide a decorative sheet. It is characterized by being provided with a delivery adjusting mechanism for adjusting the delivery.

As the shaping mechanism, the detecting mechanism and the adjusting mechanism, those described in the above-mentioned method for manufacturing a decorative sheet can be appropriately used.

<Decorative board>
The decorative sheet produced by the method for producing a decorative sheet of the present invention can be laminated on an adherend to obtain a decorative board having a visually excellent three-dimensional effect and excellent durability. ..

Examples of the adherend include wood boards such as single wood boards, wood plywood boards, particulate boards, and MDF (medium density fiber boards); plaster boards such as plaster boards and plaster slag boards; calcium silicate boards and asbestos slate boards. Cement plates such as lightweight foamed concrete plates and hollow extruded cement plates; Fiber cement plates such as pulp cement plates, asbestos cement plates, and wood piece cement plates; Ceramic plates such as pottery, porcelain, earthenware, glass, and amber; Iron plates, zinc-plated steel plates , Polyvinyl chloride sol coated steel plate, aluminum plate, metal plate such as copper plate; thermoplastic resin plate such as polyolefin resin plate, polyvinyl chloride resin plate, acrylic resin plate, ABS plate, polycarbonate plate; phenol resin plate, urea resin plate, Thermo-curable resin plates such as unsaturated polyester resin plate, polyurethane resin plate, epoxy resin plate, melamine resin plate; phenol resin, urea resin, unsaturated polyester resin, polyurethane resin, epoxy resin, melamine resin, diallyl phthalate resin, etc. Examples thereof include a so-called FRP plate in which a resin is impregnated and cured by impregnating and curing a glass fiber non-woven fabric, cloth, paper, or other various fibrous base materials, and these may be used alone, or two or more of these may be laminated. It may be used as a composite substrate.
In addition, thermoplastic resin plates and thermosetting resin plates can be used as necessary for coloring materials (pigments or dyes), fillers such as wood powder and calcium carbonate, matting agents such as silica, foaming agents, flame retardants, and talc. Various additives such as lubricants such as, antistatic agents, antioxidants, ultraviolet absorbers, and light stabilizers may be contained.
The thickness of the adherend is not particularly limited.

The method for laminating the decorative sheet of the present invention on the adherend is not particularly limited, and examples thereof include means for laminating via the above-mentioned primer layer and the above-mentioned adhesive layer. Be done.

Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to this example.

(Example)
Prepare a base material (60 μm thick, colored polypropylene sheet) that has been subjected to corona discharge treatment on both sides, and apply ink to add 5 parts by mass of hexamethylene diisocyanate to 100 parts by mass of urethane-nitrated cotton mixed resin on one side. A 2 μm thick primer layer is formed, and an ink containing 8 parts by mass of hexamethylene diisocyanate and 70 parts by mass of titanium oxide is applied to 100 parts by mass of acrylic urethane resin on the other surface to form a 2 μm thick concealing layer (non-characteristic). Part) was formed.
Next, an ink obtained by adding a coloring pigment to an acrylic urethane resin is applied onto the concealing layer to form a pattern layer (wood grain pattern, characteristic portion) having a thickness of 1 μm, whereby a pattern having a characteristic portion and a non-characteristic portion is formed. A base material having a layer on one side was prepared (preparation step).
Next, an ink obtained by adding 11 parts by mass of hexamethylene diisocyanate to 100 parts by mass of an acrylic polyol-urethane mixed resin was applied to form an adhesive layer having a thickness of 2 μm, and a polypropylene resin was applied onto the adhesive layer by a T-die extruder. Was heated, melted and extruded to form a transparent resin layer having a thickness of 100 μm (lamination step). Further, an ink obtained by adding 6 parts by mass of hexamethylene diisocyanate to 100 parts by mass of an acrylic polyol-urethane mixed resin was applied onto the transparent resin layer to form a primer layer having a thickness of 2 μm.
Then, an acrylate-based electron beam-curable resin is applied onto the primer layer by a gravure coating method so that the solid content becomes 30 g / m ² , and then dried. A surface protective layer made of an electron beam curable resin was formed by irradiating with a wire (coating step).
Further, embossing was performed from the surface protection layer side to shape the recesses synchronized with the design layer (shape step) to prepare a decorative sheet.
When the prepared decorative sheet was confirmed, the pattern of the pattern layer and the recess were synchronized, and it had a visually excellent three-dimensional effect.

The laminating step, coating step, and shaping step are continuously performed by roll-to-roll, and after the shaping step, the position of the characteristic portion of the pattern layer and the pattern layer are determined by using a detection mechanism (camera). The positional relationship with the position of the recess tuned to the characteristic part of was confirmed. When the positional deviation between the characteristic portion and the concave portion of the pattern layer is detected, the position can be adjusted by changing the speed of the delivery adjusting mechanism to correct the tension of the pre-formation sheet.

According to the present invention, it is possible to provide a method for manufacturing a decorative sheet and a device for manufacturing a decorative sheet having a visually excellent three-dimensional effect by synchronizing the pattern on the pattern layer with the concave portion.

1 Base material 2 Picture layer 2a Characteristic part 2b Non-characteristic part 3 Transparent resin layer 10 Decorative sheet 11 Preformation sheet 20 Conveyance mechanism 30 Delivery adjustment mechanism 40 Shaped mechanism 50 Detection mechanism

Claims (4)

A method for manufacturing a decorative sheet having recesses.
A preparatory step for preparing a base material having a pattern layer having a characteristic portion and a non-characteristic portion on one surface.
A laminating process of laminating a transparent resin layer on the pattern layer, and
A method for producing a decorative sheet, which comprises a shaping step of forming a recess synchronized with a characteristic portion of the pattern layer from a side of the transparent resin layer opposite to the side having the pattern layer. After the shaping step, the detection step further comprises a detection step of detecting the position information of the characteristic portion of the pattern layer and the recess synchronized with the feature portion of the pattern layer.
A claim that feeds back the position information to a delivery adjusting mechanism provided in front of the shaping step to adjust the position of the characteristic portion of the pattern layer and the position of the recess synchronized with the feature portion of the pattern layer. The method for manufacturing a decorative sheet according to 1. The method for producing a decorative sheet according to claim 1 or 2, further comprising a coating step of coating a surface protective layer on the transparent resin layer between the laminating step and the shaping step. An apparatus for manufacturing a decorative sheet in which a decorative sheet having a characteristic portion and a non-characteristic portion and a decorative sheet having a transparent resin layer are provided with recesses while being heated on one of the base materials.
A shaping mechanism that shapes a recess synchronized with the characteristic portion of the pattern layer from the side of the transparent resin layer opposite to the side having the pattern layer.
At the rear of the shaping mechanism, a detection mechanism for detecting the position information of the characteristic portion of the pattern layer and the recess synchronized with the feature portion of the pattern layer, and
A decorative sheet manufacturing apparatus comprising a delivery adjusting mechanism that feeds back the position information to the front portion of the shaping mechanism to adjust the delivery of the decorative sheet.

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