JP2022165269A - Decorative sheet, method for manufacturing the decorative sheet, molded article, and method for manufacturing the molded article - Google Patents

Abstract

To provide a decorative sheet improved in designability, a method for manufacturing the decorative sheet, a molded article, and a method for manufacturing the molded article.SOLUTION: A decorative sheet includes a substrate layer, a design layer showing a prescribed design, a texture layer having an uneven shape, and a protection layer formed on the outermost surface of the sheet. A method for manufacturing a decorative sheet comprises: a step for forming the texture layer having the uneven shape on the substrate layer having a principal surface; and a step for forming the protection layer on the texture layer. A molded article includes the decorative sheet and a resin layer. A method for manufacturing the molded article comprises: a step for disposing the decorative sheet in a metal mold; and a step for ejecting resin into the metal mold to integrate the resin and the decorative sheet.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present disclosure relates to a decorative sheet, a method for manufacturing a decorative sheet, a molded article, and a method for manufacturing a molded article.

2. Description of the Related Art A decorative sheet is known that has a texture of a printed pattern and a three-dimensional effect by laminating a plurality of layers. For example, the paint-like decorative sheet described in Patent Document 1 has a configuration in which a concealing solid print layer and a wood grain pattern print layer are sequentially laminated on a paper-based base material, and an ultraviolet curable resin layer having transparency is further laminated. be.

In the painted decorative sheet described in Patent Literature 1, after the wood grain pattern printed layer is formed, the sheet is embossed to give the sheet an uneven shape.

JP-A-8-132582

In the painted decorative sheet described in Patent Document 1, the uneven shape is limited, and there is room for improvement in terms of design.

The present disclosure provides a decorative sheet with improved design, a method for manufacturing a decorative sheet, a molded product, and a method for manufacturing a molded product.

A decorative sheet according to the present disclosure includes a base material layer, a design layer representing a predetermined design, a texture layer having an uneven shape, and a protective layer formed on the outermost surface.

In the method for manufacturing a decorative sheet according to the present disclosure, a substrate layer having a main surface has at least one of a recess projecting in a direction intersecting the main surface and a recess recessed in a direction intersecting the main surface. The method includes forming a textured layer having an uneven shape, and forming a protective layer on the textured layer.

A molded article according to the present disclosure includes the decorative sheet described above and a resin layer.

A method for manufacturing a molded product according to the present disclosure includes the steps of placing the decorative sheet described above in a mold, and injecting resin into the mold to integrate the resin and the decorative sheet.

According to the present disclosure, it is possible to provide a decorative sheet with improved design, a method for manufacturing a decorative sheet, a molded article, and a method for manufacturing a molded article.

Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Embodiment 1 of the present disclosure Flowchart showing the manufacturing method of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a part of the manufacturing process of the decorative sheet of FIG. Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 1 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 2 of Embodiment 1 Schematic diagram showing texture data for forming the texture layer of the decorative sheet of FIG. 5A Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 3 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional structure of a decorative sheet according to Modification 4 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 5 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 6 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet according to Modification 7 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional structure of a decorative sheet according to Modification 8 of Embodiment 1 Schematic cross-sectional view showing a cross-sectional configuration of a molded product according to Embodiment 2 A flow chart showing a method for manufacturing the molded product of FIG. Schematic cross-sectional view showing part of the manufacturing process of the molded product of FIG. Schematic cross-sectional view showing part of the manufacturing process of the molded product of FIG. Schematic cross-sectional view showing part of the manufacturing process of the molded product of FIG. Schematic cross-sectional view showing part of the manufacturing process of the molded product of FIG.

A decorative sheet according to one aspect of the present disclosure includes a base layer, a design layer representing a predetermined design, a texture layer having an uneven shape, and a protective layer formed on the outermost surface.

With such a configuration, it is possible to provide a decorative sheet with improved design.

The texture layer may have uneven shapes with different heights.

With such a configuration, it is possible to provide a decorative sheet having a texture close to that of natural materials.

The textured layer may have irregularities arranged at different intervals.

With such a configuration, it is possible to provide a decorative sheet having a texture close to that of natural materials.

A method for manufacturing a decorative sheet according to an aspect of the present disclosure includes forming a base layer having a main surface with at least one of recesses protruding in a direction intersecting the main surface and recesses recessed in a direction intersecting the main surface. and forming a textured layer having a textured surface, and forming a protective layer on the textured layer.

With such a configuration, it is possible to provide a method for manufacturing a decorative sheet with improved design. Moreover, it is possible to manufacture a decorative sheet having a texture close to that of natural materials.

The texture layer may be formed by inkjet printing.

With such a configuration, it is possible to prevent printing misalignment and manufacture a decorative sheet with high design.

The protrusions or recesses may be formed at different heights.

With such a configuration, it is possible to manufacture a decorative sheet having a texture close to that of natural materials.

The protrusions or recesses may be arranged at different intervals.

With such a configuration, it is possible to manufacture a decorative sheet having a texture close to that of natural materials.

Furthermore, a step of forming a design layer representing a predetermined design on the base layer may be included.

With such a configuration, it is possible to further improve the design.

Furthermore, a step of forming a design layer forming a predetermined design on the texture layer may be included.

With such a configuration, it is possible to further improve the design.

The design layer may be formed by inkjet printing based on image data representing a predetermined design.

Such a configuration enables simplification of the manufacturing process.

The recesses or protrusions of the texture layer may be formed based on data obtained by converting the image data into two gradations.

With such a configuration, misalignment between the design layer and the texture layer can be prevented, and a decorative sheet with a higher design property can be manufactured.

A molded product according to an aspect of the present disclosure includes the decorative sheet described above and a resin layer.

With such a configuration, it is possible to provide a molded product with improved design.

A method for manufacturing a molded product according to an aspect of the present disclosure includes the steps of placing a decorative sheet in a mold, and injecting resin into the mold to integrate the resin and the decorative sheet. .

With such a configuration, it is possible to provide a method for manufacturing a molded product with improved design.

Embodiments will be described below with reference to the drawings.

(Embodiment 1)
[overall structure]
FIG. 1 is a schematic cross-sectional view of a decorative sheet 1 according to Embodiment 1 of the present disclosure. The decorative sheet 1 includes a base material layer 2, a design layer 3, a texture layer 4, and a protective layer 5. In this embodiment, the decorative sheet 1 is formed by laminating the design layer 3 on the base material layer 2, laminating the texture layer 4 on the design layer 3, and laminating the protective layer 5 on the texture layer 4. . Note that the design layer 3 and the texture layer 4 may be stacked in different order.

The base material layer 2 is a part that serves as a support for the decorative sheet 1 . As the substrate layer 2, for example, a general transparent resin such as polyethylene terephthalate (PET), polycarbonate (PC), or acrylic resin (PMMA) can be used.

The design layer 3 exhibits a predetermined design such as wood, stone, cork, cloth, natural leather, or artificial leather. The design layer 3 is formed by printing a predetermined design on the main surface 2a of the base material layer 2 by a technique such as inkjet printing, gravure printing, or screen printing. The predetermined design of the design layer 3 can be generated using, for example, digital data such as image data. Digital data can be created by converting a predetermined design (such as a wood grain pattern) indicated by the design layer 3 into digital data using a device such as a scanner.

The design layer 3 preferably has a thickness of 1 μm or more and 40 μm or less. More preferably, the design layer 3 has a thickness of about 20 μm. In this case, the predetermined design (wood grain pattern, etc.) of the design layer 3 can be made to look more like the real thing.

The texture layer 4 is a layer having an uneven shape and imparting unevenness to the surface of the decorative sheet 1 . In the present embodiment, as shown in FIG. 1, texture layer 4 has a plurality of protrusions 4a protruding in a direction intersecting major surface 2a. Since the decorative sheet 1 has the texture layer 4, when the predetermined design is, for example, a wood grain pattern, unevenness such as a vessel pattern or a wood texture pattern can be expressed. The texture layer 4 is preferably made of a transparent material or a material that does not interfere with the color of the design layer 3 .

The texture layer 4 can be formed by methods such as inkjet printing, screen printing, gravure printing, and UV molding, for example. The textured layer 4 is preferably produced by inkjet printing. In this case, the texture layer 4 can be formed without preparing a printing plate. Further, when the design layer 3 is formed by inkjet printing, if the texture layer 4 is formed by inkjet printing, the design layer 3 and the texture layer 4 can be formed using the same inkjet printer. Therefore, misalignment between the design layer 3 and the texture layer 4 can be prevented.

The height h1 of the protrusions of the texture layer 4 is preferably 5 μm or more. More preferably, the thickness is 10 μm or more and 150 μm or less. In this case, the predetermined design of the design layer 3 can be made more three-dimensional. More preferably, the thickness is 20 μm or more and 120 μm or less. In this case, the adhesion to the protective layer 5 can be improved, and the durability of the decorative sheet 1 can be improved.

The protective layer 5 is a layer that protects the surface of the decorative sheet 1 . The protective layer 5 is made of resin such as acrylic resin, for example. Moreover, the protective layer 5 preferably has a structure containing a hard coat material. The thickness of the protective layer 5 is preferably 1 μm or more and 50 μm or less. More preferably, the thickness is 30 μm or more and 45 μm or less. By setting the thickness of the protective layer 5 within this range, the protective layer 5 can follow the protrusions 4a of the texture layer 4, and the protective layer 5 and the texture layer 4 can be brought into close contact with each other.

[Production method]
A method of manufacturing the decorative sheet 1 will be described with reference to FIGS. 2 to 3I. FIG. 2 is a flow chart showing a method for manufacturing the decorative sheet 1 of FIG. 3A to 3I are schematic cross-sectional views showing part of the manufacturing process of the decorative sheet 1 of FIG.

First, as shown in FIGS. 3A and 3B, the substrate layer 2 is prepared, and the design layer 3 showing a predetermined design is formed on the main surface 2a of the substrate layer 2 (step S11). The design layer 3 can be formed by inkjet printing, for example, using digital data 7 of wood grain patterns as shown in FIG. 3C.

Next, as shown in FIG. 3D, the texture layer 4 having an uneven shape (projections 4a) is formed on the design layer 3 (step S12). The texture layer 4 can be formed, for example, by inkjet printing. Texture layer 4 is formed based on texture data 8 as shown in FIG. 3E. The texture data 8 is data obtained by discriminating the color densities of the digital data 7 and converting them into two gradations. For example, the projections 4a are formed by inkjet printing in the portions shown in black in the texture data 8 of FIG. 3E. The height h1 of the convex portion 4a can be changed in accordance with the width or length of the black portion of the texture data 8, or the like. Alternatively, the texture data 8 can be generated as grayscale data, and the height of the convex portion 4a can be changed according to the grayscale gradation.

The texture data 8 is generated based on the color densities of the digital data 7 . Therefore, in steps S11 and S12, the convex portions 4a of the texture layer 4 can be formed at positions matching the predetermined design (wood grain pattern) of the design layer 3. FIG. Therefore, it is possible to visually and tactilely reduce the deviation between the design layer 3 and the texture layer 4 . Moreover, in the case of inkjet printing, the design layer 3 and the texture layer 4 can be formed without using a printing plate.

Next, the protective layer 5 is formed on the texture layer 4 (step S13). In order to form the protective layer 5, first, the release layer 12 is laminated on the polymer film 11, and the protective layer 5 is laminated on the release layer 12 to form the intermediate layer 16 (FIG. 3F). The protective layer 5 can be formed using a general printing technique such as screen printing or coater coating.

Subsequently, as shown in FIG. 3G, the intermediate layer 16 and the textured layer 4 are thermocompression bonded using a thermocompression bonding device 14 such as a laminator or a hot press. Then, the protective layer 5 of the intermediate layer 16 is transferred to the texture layer 4 as shown in FIG. 3H. Since the protective layer 5 is a thin film, it is transferred by thermocompression so as to follow the shape of the protrusions 4a of the texture layer 4. As shown in FIG. Then, as shown in FIG. 3I, the decorative sheet 1 is completed by peeling the polymer film 11 together with the peeling layer 12 .

[effect]
According to the embodiment described above, it is possible to provide a decorative sheet with improved design and a method for manufacturing a decorative sheet.

Since the decorative sheet 1 has the texture layer 4, it is possible to reproduce a design having an uneven shape such as a wood grain pattern, and the designability of the decorative sheet can be improved.

By forming the design layer 3 and the texture layer 4 by inkjet printing, it is possible to prevent misalignment between the design layer 3 and the convex portions 4a of the texture layer 4, thereby further enhancing the design. Moreover, in the case of inkjet printing, the decorative sheet 1 can be manufactured without using a printing plate, so manufacturing costs can be reduced.

In addition, although the embodiment mentioned above demonstrated the example which the design layer 3 is formed continuously, it is not limited to this. FIG. 4 is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1A according to Modification 1 of Embodiment 1. As shown in FIG. For example, as shown in FIG. 4, the design layer 3a may be partially formed.

Further, in the above-described embodiment, an example in which the texture layer 4 is formed with the convex portions 4a has been described, but the present invention is not limited to this. FIG. 5A is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1B according to Modification 2 of Embodiment 1. FIG. FIG. 5B is a schematic diagram showing texture data 81 for forming the texture layer 41 of the decorative sheet 1A of FIG. 5A. For example, as shown in FIG. 5A, the textured layer 41 may be provided with recesses 41b that are recessed in a direction that intersects the main surface. For example, by inverting the white and black of the two-tone texture data 8 described with reference to FIG. Using the texture data 8 of FIG. 3E, the texture layer 4 is formed in the black portion. Therefore, the portion of the texture data 8 that turns black on black becomes the convex portion 4a. On the other hand, when the white and black of the texture data 8 are reversed, texture data 81 with white lines on a black background is obtained as shown in FIG. 5B. In this case, the white line portion is formed as the concave portion 41b.

The depth of the recesses 41b of the texture layer 41 is preferably 5 μm or more. More preferably, the thickness is 10 μm or more and 150 μm or less. In this case, the predetermined design of the design layer 3 can be made more three-dimensional. More preferably, the thickness is 20 μm or more and 120 μm or less.

Further, in the above-described embodiment, an example in which the design layer 3 is laminated on the base material layer 2 and the texture layer 4 is laminated on the design layer 3 to form the decorative sheet 1 has been described, but the present invention is limited to this. not. FIG. 6 is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1C according to Modification 3 of Embodiment 1. As shown in FIG. As shown in FIG. 6, the texture layer 4 may be first formed on the base material layer 2 and the design layer 31 may be formed on the texture layer 4 . When the texture layer 4 and the design layer 31 are formed by inkjet printing, the texture layer 4 and the design layer 31 can be printed without using a printing plate. Therefore, like the decorative sheet 1C shown in FIG. 6, the order of lamination of the design layer 31 and the texture layer 4 can be reversed.

Further, in the embodiment described above, an example in which the convex portions 4a of the texture layer 4 are formed at equal intervals has been described, but the present invention is not limited to this. FIG. 7A is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1D according to Modification 4 of Embodiment 1. FIG. FIG. 7B is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1E according to Modification 5 of Embodiment 1. As shown in FIG. As shown in FIG. 7A, the convex portions 42a of the texture layer 42 may be arranged at different intervals. Alternatively, as shown in FIG. 7B, the recesses 43b of the texture layer 43 may be arranged at different intervals.

Also, in the above-described embodiment, an example in which the heights of the convex portions 4a of the texture layer 4 are formed to be equal has been described, but the present invention is not limited to this. FIG. 8A is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1F according to Modification 6 of Embodiment 1. FIG. FIG. 8B is a schematic cross-sectional view showing a cross-sectional configuration of a decorative sheet 1G according to Modification 7 of Embodiment 1. As shown in FIG. As shown in FIG. 8A, the convex portions 44a of the texture layer 44 may be formed with different heights. Also, as shown in FIG. 8B, the recesses 45b of the texture layer 45 may be formed with different depths.

FIG. 9 is a schematic cross-sectional view showing a decorative sheet 1H according to Modification 8 of Embodiment 1. As shown in FIG. As shown in FIG. 9 , a functional layer 13 may be formed between the protective layer 5 and the design layer 3 and texture layer 4 . The functional layer 13 is a layer having an arbitrary function such as, for example, an ultraviolet cut layer, a layer to which an additive such as a filler is added, a colored layer, or a pattern layer. The functional layer 13 can be formed on the protective layer 5 of the intermediate layer 16 shown in FIG. 3F using a general printing technique, and transferred to the textured layer 4 together with the protective layer 5 by thermocompression. Since the decorative sheet 1H has the functional layer 13, it is possible to freely change the appearance, touch, gloss, etc. of the decorative sheet 1H.

(Embodiment 2)
Embodiment 2 will be described with reference to FIGS. 10 to 12D. In addition, in Embodiment 2, the same code|symbol is attached|subjected and demonstrated to the same or equivalent structure as Embodiment 1. FIG. In addition, in the second embodiment, the description overlapping with the first embodiment is omitted.

FIG. 10 is a schematic cross-sectional view showing the cross-sectional configuration of a molded product 22 according to Embodiment 2. As shown in FIG. FIG. 11 is a flow chart showing a method of manufacturing the molded product 22 of FIG. 12A to 12D are schematic cross-sectional views showing part of the manufacturing process of the molded product 22 of FIG. In Embodiment 2, a molded product using the decorative sheet described in Embodiment 1 and a manufacturing method thereof will be described.

As shown in FIG. 10, the molded product 22 includes the decorative sheet 1 (see FIG. 1) described in Embodiment 1 and the resin layer 15. As shown in FIG. A molded product 22 is formed by laminating the decorative sheet 1 on the resin layer 15 .

The resin layer 15 is made of transparent resin such as ABS resin, acrylic resin (PMMA), or polycarbonate (PC). The resin constituting the resin layer 15 is not limited to those described above, and any resin that can be injection-molded can be used.

[Production method]
A method for manufacturing the molded product 22 will be described with reference to FIGS. 11 to 12D.

First, the decorative sheet 1 is placed in the mold 23 (step S21). The mold 23 is a mold for insert molding. At this time, the decorative sheet 1 is arranged so that the protective layer 5 of the decorative sheet 1 faces the bottom surface of the mold 23, as shown in FIG. 12A. After placing the decorative sheet 1, the mold 23 is clamped as shown in FIG. 12B.

Next, the resin 15a is injected into the mold 23 to integrate the resin 15a and the decorative sheet 1 (step S22). As shown in FIG. 12C, the injection molding resin 15a is poured from the gate 111 provided in the mold 23. As shown in FIG. After curing the resin 15a, as shown in FIG. 12D, the mold 23 is opened, and the molded product 22 integrally formed with the decorative sheet 1 is taken out from the mold 23. As shown in FIG. In this way, a molded product 22 in which the decorative sheet 1 and the resin layer 15 are laminated is completed.

[effect]
According to the embodiment described above, it is possible to provide a molded product with improved design and a method for manufacturing the molded product.

INDUSTRIAL APPLICABILITY The present disclosure contributes to improving the designability in fields requiring decoration such as the exterior of various home electric appliances using a display or the interior of an automobile.

1, 1A-1H Decorative sheet 2 Base material layer 2a Main surface 3, 3a, 31 Design layer 4, 41-45 Texture layer 4a, 42a, 44a Convex part 41b, 43b, 45b Concave part 5 Protective layer 7 Digital data 8 Texture Data 11 polymer film 12 release layer 13 functional layer 14 thermocompression device 15 resin layer 16 intermediate layer 22 molded product 23 mold

Claims (13)

a substrate layer;
a design layer representing a predetermined design;
a texture layer having an uneven shape;
a protective layer formed on the outermost surface;
comprising
decorative sheet. The texture layer has uneven shapes with different heights,
The decorative sheet according to claim 1. The texture layer has uneven shapes arranged at different intervals,
The decorative sheet according to claim 1 or 2. A texture layer having an uneven shape having at least one of protrusions projecting in a direction intersecting the main surface and recesses recessed in a direction intersecting the main surface is formed on a base layer having a main surface. a step;
forming a protective layer on the textured layer;
including,
A method for manufacturing a decorative sheet. forming the texture layer by inkjet printing;
The method for manufacturing the decorative sheet according to claim 4. forming the protrusions or the recesses with different heights;
The method for manufacturing the decorative sheet according to claim 4 or 5. arranging the protrusions or the recesses at different intervals;
The method for manufacturing the decorative sheet according to claim 4 or 5. moreover,
forming a design layer representing a predetermined design on the base layer;
including,
A method for manufacturing a decorative sheet according to any one of claims 4 to 7. moreover,
forming a design layer that forms a predetermined design on the texture layer;
including,
A method for manufacturing a decorative sheet according to any one of claims 4 to 7. forming the design layer by inkjet printing based on image data representing the predetermined design;
A method for manufacturing the decorative sheet according to claim 8 or 9. Forming the concave portion or the convex portion of the texture layer based on data obtained by converting the image data into two gradations;
The method for manufacturing the decorative sheet according to claim 10. A decorative sheet according to any one of claims 1 to 3;
a resin layer;
comprising
Molding. placing the decorative sheet according to any one of claims 1 to 3 in a mold;
a step of injecting a resin into the mold to integrate the resin and the decorative sheet;
including,
A method of manufacturing molded articles.

Images