JP2024067443A - Decorative sheet, base sheet, method for manufacturing base sheet, and method for manufacturing decorative sheet - Google Patents

Abstract

[Problem] To provide a decorative sheet that allows accurate alignment. [Solution] The decorative sheet 5 includes a first layer 10 including an alignment mark region RL, and a second layer 20 superimposed on the first layer 10. The first layer 10 includes air bubbles BB in the alignment mark region RL. The second layer 20 includes a decorative layer 40. [Selected Figure] FIG.

Description

This disclosure relates to a decorative sheet, a base sheet, a method for manufacturing a base sheet, and a method for manufacturing a decorative sheet.

Patent Document 1 proposes a decorative sheet having a base layer with projections and recesses and a transfer layer located on the surface of the base layer with projections and recesses. In Patent Document 1, the projections and recesses of the base layer are used as alignment marks when producing the transfer layer and when handling the decorative sheet thereafter.

JP 2019-30993 A

However, the unevenness of the base layer may be flattened during the preparation of the transfer layer, etc. If the unevenness is flattened, the decorative sheet cannot be accurately aligned. The present disclosure aims to provide a decorative sheet that allows for accurate alignment.

The decorative sheet according to one embodiment of the present disclosure includes:
a first layer including an alignment mark area;
a second layer overlying the first layer,
the first layer includes air bubbles in the alignment mark region;
The second layer includes a decorative layer.

The base sheet according to one embodiment of the present disclosure comprises:
An alignment mark area is provided,
Air bubbles are contained in the alignment mark area.

A method for producing a base sheet according to an embodiment of the present disclosure includes:
supplying a curable resin composition to a plate surface including a plate recess;
and curing the curable resin composition.
The curable resin composition is cured in a state in which air bubbles are present in the curable resin composition.

According to this disclosure, the decorative sheet can be accurately aligned.

FIG. 1 is a diagram for explaining an embodiment of the present invention, showing a specific example of a decorative sheet. FIG. 2 is an enlarged plan view of a portion A of the decorative sheet of FIG. FIG. 3 is a cross-sectional view of the decorative sheet of FIG. 2 taken along line III-III. FIG. 4 is a plan view showing an alignment mark region of the first layer included in the decorative sheet of FIG. FIG. 5 is a cross-sectional view taken along line VV of the decorative sheet of FIG. FIG. 6 is a plan view showing a linear pattern displayed by the second layer of the decorative sheet of FIG. FIG. 7 is a perspective view showing a plate that can be used to manufacture the decorative sheet shown in FIG. FIG. 8 is a diagram showing an example of a method for producing a decorative sheet, illustrating a method for producing a first layer. FIG. 9 is a diagram showing an example of a method for producing a decorative sheet, illustrating a method for producing an alignment mark area in the first layer. FIG. 10 is a diagram showing an example of a method for producing a decorative sheet, illustrating a method for forming a print layer. FIG. 11 is a diagram showing an example of a method for producing a decorative member, illustrating a method for producing a thermoplastic resin part joined to a decorative sheet by injection molding. FIG. 12 is a diagram showing an example of a method for producing a decorative member, illustrating a method for producing a thermoplastic resin part joined to a decorative sheet by injection molding. FIG. 13 is a diagram showing an example of a method for producing a decorative member, illustrating a method for producing a thermoplastic resin part joined to a decorative sheet by injection molding. FIG. 14 is a diagram showing an example of a method for producing a decorative member, illustrating a method for producing a thermoplastic resin part joined to a decorative sheet by injection molding. FIG. 15 is a diagram showing an example of a method for manufacturing a decorative member. FIG. 16 is a cross-sectional view showing another example of the decorative sheet. FIG. 17 is a plan view showing another example of the first layer in the alignment mark region. FIG. 18 is a cross-sectional view showing still another example of the decorative sheet.

One embodiment of the present disclosure relates to the following [1] to [18].

[1] A first layer including an alignment mark area;
a second layer overlying the first layer,
the first layer includes air bubbles in the alignment mark region;
The second layer includes a decorative layer.

[2] The first layer includes a sheet-like base portion and a convex portion protruding from the base portion toward the second layer in the alignment mark region,
The decorative sheet according to [1], wherein the first layer contains the air bubbles in at least one of the convex portions and the base portion overlapping the convex portions.

[3] The decorative sheet of [2], in which the first layer contains air bubbles at positions facing the portions between the adjacent protrusions.

[4] The decorative sheet of [2] or [3], in which the protrusions are spaced apart from each other.

[5] A decorative sheet according to any one of [2] to [4], in which the width of the convex portion is greater than the width of the air bubble.

[6] A decorative sheet according to any one of [2] to [5], in which the width of the convex portion is 2 μm or more and 25 μm or less.

[7] A decorative sheet according to any one of [2] to [6], wherein the height of the convex portion is 1 μm or more and 10 μm or less.

[8] The first layer includes a second convex portion protruding toward the second layer in a region outside the alignment mark region,
The decorative sheet according to any one of [2] to [7], wherein the second convex portion is located in a portion overlapping the decorative layer.

[9] The decorative sheet of [8], in which the width of the second convex portion is greater than the width of the convex portion.

[10] The decorative sheet of [8] or [9], in which the height of the second convex portion is greater than the height of the convex portion.

[11] The second layer includes a first surface and a second surface opposite the first surface,
the second layer faces the first layer at the second surface,
The decorative sheet according to any one of [1] to [10], wherein the first surface is flat in a portion overlapping the alignment mark area.

[12] The decorative sheet according to any one of [8] to [10], wherein the decorative layer includes a molded resin layer including second recesses corresponding to the second protrusions.

[13] The decorative sheet of [12], wherein the decorative layer includes a printing layer superimposed on the molded resin layer.

[14] An alignment mark area,
A base sheet containing air bubbles in the alignment mark area.

[15] The alignment mark area is provided with a convex portion protruding in a normal direction of the base sheet,
The base sheet according to [14], wherein the air bubbles are located at least either inside the protrusions or at a position facing the protrusions.

[16] A step of supplying a curable resin composition to a plate surface including a plate recess;
and curing the curable resin composition.
A method for producing a substrate sheet, comprising curing a curable resin composition in a state in which air bubbles are present in the curable resin composition.

[17] The method for manufacturing a base sheet according to [16], wherein the plate recess includes a first plate recess located in an alignment mark formation region of the plate surface, and a second plate recess located in a linear pattern formation region of the plate surface.

[18] A step of producing the base sheet by the production method according to [16] or [17];
and forming a layer overlying the base sheet by curing the curable resin composition provided on the base sheet,
the base sheet includes an alignment mark region in which the air bubbles are contained,
The method for manufacturing a decorative sheet, wherein the curable resin composition is supplied onto the base sheet that is positioned by detecting the position of the alignment mark area.

An embodiment of the present disclosure will be described below with reference to the drawings. In the drawings attached to this specification, the scale and aspect ratios have been appropriately altered and exaggerated from their actual equivalents for the convenience of illustration and ease of understanding. Furthermore, configurations shown in some drawings may be omitted in other drawings.

In this specification, terms that specify shapes and geometric conditions and their degrees, such as "parallel," "orthogonal," and "same," as well as values of lengths and angles, are not limited to their strict meanings, but are interpreted to include the range within which similar functions can be expected.

In this specification, the terms "sheet," "film," and "plate" are not distinguished from one another solely on the basis of differences in designation.

In this specification, the term "sheet surface (film surface, plate surface)" refers to a surface that coincides with the plane of the sheet-like (film-like, plate-like) member in question when the sheet-like (film-like, plate-like) member in question is viewed as a whole. In addition, the "normal direction" used in reference to a sheet-like (film-like, plate-like) member refers to the normal direction to the sheet surface (film surface, plate surface) of the sheet-like (film-like, plate-like) member in question.

To clarify the directional relationships between the drawings, common directions are indicated in several drawings by arrows with common symbols. An arrow pointing toward the viewer in a direction perpendicular to the surface of the drawing is indicated by a symbol with a dot in a circle, as shown in Figure 1, for example. An arrow pointing toward the viewer in a direction perpendicular to the surface of the drawing is indicated by a symbol with an x in a circle, as shown in Figure 5, for example.

In this specification, when multiple upper limit candidates and multiple lower limit candidates are given for a certain parameter, the numerical range of the parameter may be constructed by combining any one of the upper limit candidates and any one of the lower limit candidates. As an example, consider the following statements: "Parameter B may be A1 or more, A2 or more, or A3 or more." and "Parameter B may be A4 or less, A5 or less, or A6 or less." In this example, the numerical range of parameter B may be A1 or more and A4 or less, A1 or more and A5 or less, A1 or more and A6 or less, A2 or more and A4 or less, A2 or more and A5 or less, A2 or more and A6 or less, A3 or more and A4 or less, A3 or more and A5 or less, or A3 or more and A6 or less.

As shown in FIG. 18, the decorative sheet 5 according to one embodiment includes a first layer 10 including an alignment mark region RL, and a second layer 20 superimposed on the first layer 10. The first layer 10 includes air bubbles BB in the alignment mark region RL. The second layer 20 includes a decorative layer 40. FIG. 18 shows the decorative sheet 5 in the alignment mark region RL. The decorative sheet 5 may include layers other than the layers described above, as in the specific examples shown in FIGS. 1 to 5. Below, one embodiment will be described with reference to the specific examples shown in FIGS. 1 to 5.

Figures 1 to 5 are diagrams illustrating a specific example of an embodiment. Figure 1 is a plan view showing a decorative sheet 5. The decorative sheet 5 is in a sheet shape. The decorative sheet 5 extends in a first direction D1 and a second direction D2 perpendicular to the first direction D1. The decorative sheet 5 includes a first surface 5a and a second surface 5b opposite to the first surface 5a. The first surface 5a and the second surface 5b are main surfaces of the decorative sheet 5. The first surface 5a and the second surface 5b face each other in a third direction D3. The third direction D3 is perpendicular to the first direction D1. The third direction D3 is perpendicular to the second direction D2. In Figure 1, the first surface 5a of the decorative sheet 5 is shown. The decorative sheet 5 has a longitudinal direction parallel to the first direction D1.

The decorative sheet 5 imparts design to the object to which the decorative sheet 5 is applied. The decorative sheet 5 is applied to various applications. The decorative sheet 5 may be applied to moving objects such as automobiles, motorcycles, bicycles, tricycles, trains, airplanes, ships, snowmobiles, industrial robots, drones, etc. The decorative sheet 5 may be applied to the exterior or interior of moving objects. The decorative sheet 5 may be applied to home appliances such as refrigerators, washing machines, microwave ovens, televisions, dishwashers, etc. The decorative sheet 5 may be applied to walls, doors, ceilings, etc. as the interior of buildings. The decorative sheet 5 may be used in its entirety as the object to which it is applied. Only a region of the decorative sheet 5 that is a part of one or both of the first direction D1 and the second direction D2 may be used as the object to which it is applied. Only a part of the decorative sheet 5 in the third direction D3, which is its thickness direction, may be used as the object to which it is applied. In this example, a part of the decorative sheet 5 in the third direction D3 may be transferred as a transfer layer to an object to be transferred.

The decorative member 50 may be formed by the decorative sheet 5 and the thermoplastic resin part 7 superimposed on the decorative sheet 5. As described in detail below, a portion of the decorative sheet 5 may be transferred to the thermoplastic resin part 7 to form the decorative member 50 including a portion of the decorative sheet 5 and the thermoplastic resin part 7.

As shown in FIG. 1, the decorative sheet 5 may be a part of a long decorative sheet 1. The long decorative sheet 1 has a longitudinal direction in the first direction D1. The long decorative sheet 1 includes a plurality of decorative sheets 5. A plurality of decorative sheets 5 may be cut from the long decorative sheet 1. In the long decorative sheet 1, a plurality of decorative sheets 5 may be adjacent to each other in the first direction D1. The long decorative sheet 1 may be wound around a winding core with a winding axis AS parallel to the second direction D2 as its center. The decorative sheet 1 wound around the winding core has a roll shape. The long decorative sheet 1 wound around the winding core is a roll 1R. In the example shown in FIG. 1, the decorative sheet 5 is pulled out in the first direction D1 from the roll 1R of the long decorative sheet 1.

"Long" means that the long decorative sheet 1 or the long base sheet 2 described later, etc., has a length of 5 m or more when the object is spread out. The long decorative sheet 1 or the long base sheet 2 may have a length of 10 m or more, or may have a length of 100 m or more. As shown in FIG. 1, the long decorative sheet 1 and the long base sheet 2 include a longitudinal direction. The "longitudinal direction" means the direction along the longest edge when the object is spread out. The long decorative sheet 1 and the long base sheet 2 may include a transverse direction. The "transverse direction" means the direction in which the shortest length is obtained when the object is spread out. In the illustrated example, the first direction D1 is the longitudinal direction of the long decorative sheet 1, the long base sheet 2, and each layer that constitutes these components. In the illustrated example, the second direction D2 is the transverse direction of the long decorative sheet 1, the long base sheet 2, and each layer that constitutes these components.

The decorative sheet 5 may be cut from the long decorative sheet 1. The decorative sheet 5 may be obtained by cutting the long decorative sheet 1 in a direction perpendicular to the longitudinal direction. In the example shown in FIG. 1, the long decorative sheet 1 may be cut in the second direction D2, as shown by the two-dot chain line in the figure.

In the example shown in Figures 1 to 5, the decorative sheet 5 includes a first layer 10 and a second layer 20 superimposed on the first layer 10. The first layer 10 and the second layer 20 each extend in a first direction D1 and a second direction D2. The second layer 20 is superimposed on the first layer 10 in a third direction D3 perpendicular to both the first direction D1 and the second direction D2. In the example shown, the third direction D3 is the stacking direction. The first surface 5a of the decorative sheet 5 is composed of the second layer 20. The second surface 5b of the decorative sheet 5 is composed of the first layer 10. The first layer 10 may include multiple layers. The second layer 20 may include multiple layers.

In the example shown in FIG. 3, the decorative sheet 5 includes a coating layer 30 between the first layer 10 and the second layer 20. The coating layer 30 may function as a release layer that includes a material with releasability, such as silicone. By including a release layer in the decorative sheet 5, the second layer 20 superimposed on the first layer 10 can be easily peeled off from the first layer 10.

In the examples shown in Figures 1 to 5, the first layer 10 is a sheet-like member extending in the first direction D1 and the second direction D2. The first layer 10 may be referred to as a base sheet. The first layer (base sheet) 10 may be a part of a long base sheet 2. The long base sheet 2 may be wound around a winding core. The long base sheet 2 may be treated as a roll 2R wound around a winding core.

The first layer 10 has a first surface 10a and a second surface 10b opposite the first surface 10a. In the illustrated example, the first surface 10a faces the second layer 20 via the covering layer 30. The second surface 10b constitutes the second surface 5b of the decorative sheet 5.

In the example shown in Figures 1 to 5, the first layer 10 includes a base layer 11 and a resin layer 12 that overlaps the base layer 11. The base layer 11 constitutes the second surface 10b of the first layer 10. The resin layer 12 constitutes the first surface 10a of the first layer 10. The base layer 11 and the resin layer 12 will be described later.

The first layer 10 includes an alignment mark region RL. In the example shown in FIG. 1, the alignment mark region RL is located at a corner of the decorative sheet 5 in the first direction D1 and the second direction D2. The alignment mark region RL may be observable through the second layer 20 when the first surface 5a of the decorative sheet 5 is viewed in plan, i.e., when observed from the third direction D3, which is the stacking direction.

In the alignment mark region RL, an alignment mark AL is formed. The alignment mark AL contains an air bubble BB, as described later. The alignment mark AL may be used to align the decorative sheet 5. That is, the position of the decorative sheet 5 may be determined by the alignment mark AL. In the example shown in FIG. 1 to FIG. 5, the position of the decorative sheet 5 in the first direction D1 may be determined by the alignment mark AL. The position of the decorative sheet 5 in the second direction D2 may be determined by the alignment mark AL. That is, the coordinates of each position in the decorative sheet 5 may be specified based on the alignment mark AL. The alignment of the decorative sheet 5 may be performed when the decorative sheet 5 is processed. The alignment of the decorative sheet 5 may be included in the process of cutting the decorative sheet 5 from the long decorative sheet 1, the process of overlapping the thermoplastic resin part 7 on the decorative sheet 5, or the process of transferring a part of the decorative sheet 5 to the thermoplastic resin part 7.

The alignment mark AL may be used to align the first layer 10. That is, the position of the first layer 10 may be determined by the alignment mark AL. In the example shown in FIG. 1 to FIG. 5, the position of the first layer 10 in the first direction D1 may be determined by the alignment mark AL. The position of the first layer 10 in the second direction D2 may be determined by the alignment mark AL. That is, the coordinates of each position in the first layer 10 may be specified with reference to the alignment mark AL. The alignment of the first layer 10 may be performed when processing the first layer 10. The alignment of the first layer 10 may be included in the process of producing the second layer 20 superimposed on the first layer 10.

The first layer 10 may include an area other than the alignment mark area RL. In the example shown in Figures 1 and 5, the first layer 10 includes a transfer area RT. The transfer area RT is located in the central part of the decorative sheet 5 in the first direction D1. The transfer area RT is located in the central part of the decorative sheet 5 in the second direction D2. The transfer area RT may be located in a part other than the central part of the decorative sheet 5 in the first direction D1. The transfer area RT may be located in a part other than the central part of the decorative sheet 5 in the second direction D2. In the illustrated example, when applying the decorative sheet 5 to an application target, only the decorative sheet 5 cut from the decorative sheet 5 may be used.

The first layer 10 may include a sheet-like base portion 10b and a first convex portion (convex portion) 10s protruding from the base portion 10b toward the second layer 20 in the alignment mark region RL. The first layer 10 may include a sheet-like base portion 10b and a second convex portion 10t protruding from the base portion 10b toward the second layer 20 in a region other than the alignment mark region RL. In the illustrated example, the first layer 10 includes a base layer 11 described later and a land portion 12b of the resin layer 12 as the base portion 10b. The first layer 10 includes a first resin convex portion 12s of the resin layer 12 described later as the first convex portion 10s in the alignment mark region RL. The first layer 10 includes a second resin convex portion 12t of the resin layer 12 as the second convex portion 10t in the transfer region RT.

In the examples shown in Figures 1 to 5, the base layer 11 extends in the first direction D1 and the second direction D2. The base layer 11 may be a portion of a long base layer. The base layer 11 supports the resin layer 12. The base layer 11 may support a layer other than the resin layer 12 of the first layer 10. The base layer 11 may support the second layer 20 of the decorative sheet 5. The base layer 11 may be flat in the alignment mark region RL. The base layer 11 may be flat in the transfer region RT. The base layer 11 may be flat in regions other than the alignment mark region RL and the transfer region RT. The base layer 11 may be a flat sheet including a pair of parallel main surfaces.

The term "flat" used for a certain component of the decorative sheet 5 means that the Ra of the component is 0.2 μm or less. Here, Ra is the arithmetic mean roughness (μm) according to JIS B 0601 (2013). Ra is measured on a 16 μm square plane using a ZYGO scanning white light interferometer (NewView 6300).

The base layer 11 may be transparent. Note that a certain component of the decorative sheet 5 being "transparent" means that the visible light transmittance of the component is 50% or more, or may be 70% or more, or 80% or more. The visible light transmittance is the average value of the total light transmittance at each wavelength when measured at an incidence angle of 0° every 1 nm in the measurement wavelength range of 380 nm to 780 nm using a haze meter (manufactured by Murakami Color Research Laboratory Co., Ltd., product number: HM-150) conforming to JIS K 7361. The incidence angle is the angle between the normal direction of the object to be measured and the optical path of the incident light.

Various materials may be used as the base layer 11. The base layer 11 may include a resin. The base layer 11 may be a single-layer or multi-layer resin film. Examples of resins contained in the base layer 11 include vinyl resins such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDF), polyvinyl alcohol (PVA), ethylene-vinyl acetate copolymer (EVA), and ethylene-vinyl alcohol copolymer (EVOH), acrylic resins such as poly(methyl meth)acrylate (PMMA) and poly(ethyl meth)acrylate (PEMA), polypropylene (PP), polyethylene (PE), polyacetal (POM), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), polyamide (PA), polyether ether ketone (PEEK), polystyrene (PS), thermoplastic polyurethane (TPU), acrylonitrile-styrene copolymer (AS), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-ethylene-styrene copolymer (AES), and polycarbonate (PC). The base layer 11 may contain only one of the above-mentioned resins, or may contain two or more of the above-mentioned resins.

From the viewpoints of the stability of support provided by the base layer 11, the formability of the first layer 10, and the formability of the decorative sheet 5, the thickness of the base layer 11 may be 12 μm or more, 25 μm or more, 125 μm or less, or 250 μm or less.

In the examples shown in Figures 3 and 4, the resin layer 12 is overlaid on the base layer 11. The resin layer 12 contains a resin as a base material 120. The resin contained in the base material 120 is transparent. The resin contained in the base material 120 may be a cured product of a curable resin composition. The cured product of the curable resin composition may be a cured product of a thermosetting resin composition or a cured product of an ionizing radiation curable resin composition. The ionizing radiation curable resin composition may be an electron beam curable resin composition or an ultraviolet ray curable resin composition. In the examples shown in Figures 3 to 5, the resin layer 12 contains a cured product of an ionizing radiation curable resin composition.

Thermosetting resin compositions are compositions that contain at least a thermosetting resin and are resin compositions that are cured by heating. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea melamine resins, epoxy resins, silicone resins, etc. In addition to these thermosetting resins, curing agents and curing catalysts, etc. may be added to the thermosetting resin compositions.

The ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter, also referred to as an "ionizing radiation curable compound"). The ionizing radiation curable functional group is a group that crosslinks and hardens when irradiated with ionizing radiation. Examples of the ionizing radiation curable functional group include functional groups having an ethylenic double bond, such as a (meth)acryloyl group, a vinyl group, and an allyl group. Examples of the ionizing radiation curable functional group include an epoxy group and/or an oxetanyl group. Ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Examples of ionizing radiation include ultraviolet rays (UV) and electron beams (EB). Examples of ionizing radiation include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

When the ionizing radiation curable compound is an ultraviolet curable compound, the ionizing radiation curable resin composition may contain additives such as a photopolymerization initiator and a photopolymerization accelerator. The photopolymerization initiator may be one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthones, etc. The photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and increase the curing speed. The photopolymerization accelerator may be one or more selected from, for example, p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, etc.

In the examples shown in Figures 2 to 4, the resin layer 12 contains a plurality of air bubbles BB dispersed within the base material 120 in the alignment mark region RL. As shown in Figure 3, each of the plurality of air bubbles BB is surrounded by the base material 120. In Figure 2, the plurality of air bubbles BB dispersed within the base material 120 are spaced apart from each other in the first direction D1 and the second direction D2.

The air bubble BB forms the alignment mark AL. The refractive index of the air bubble BB is different from the refractive index of the resin contained in the base material 120. Due to the difference in refractive index between the air bubble BB and the base material 120, light entering the alignment mark region RL may be reflected at the interface between the base material 120 and the air bubble BB. Due to the difference in refractive index between the base material 120 and the air bubble BB, light passing through the alignment mark region RL may be refracted at the interface between the base material 120 and the air bubble BB.

Due to the reflection of light at the interface between the base material 120 and the air bubbles BB, a difference occurs between the amount of light reflected from the first layer 10 in the alignment mark region RL and the amount of light reflected from the first layer 10 in the region other than the alignment mark region RL. Due to the reflection of light at the interface between the base material 120 and the air bubbles BB, a difference occurs between the amount of light transmitted through the first layer 10 in the alignment mark region RL and the amount of light transmitted through the first layer 10 in the region other than the alignment mark region RL. The alignment mark region RL in the first layer 10 can be detected by such a difference in the amount of reflected light or the difference in the amount of transmitted light. Alternatively, the alignment mark region RL in the first layer 10 can be detected by the difference in reflectance or transmittance. In other words, the alignment mark AL formed by the air bubbles BB makes it possible to align the first layer 10 and the decorative sheet 5 including the first layer 10.

The alignment mark region RL may be detected by a position detection means. The position detection means may include a photoelectric sensor. The photoelectric sensor may be capable of measuring the amount of light and reflectance of reflected light from the first layer 10. The photoelectric sensor may be capable of measuring the amount of light and transmittance of transmitted light that has passed through the first layer 10.

The number of air bubbles BB in the alignment mark region RL of the first layer 10 is different from the number of air bubbles BB in the areas other than the alignment mark region RL of the first layer 10. The number of air bubbles BB in the areas other than the alignment mark region RL of the first layer 10 may be less than the number of air bubbles BB in the alignment mark region RL of the first layer 10. The number of air bubbles BB in the areas other than the alignment mark region RL of the first layer 10 may be 50% or less, or 25% or less, of the number of air bubbles BB in the alignment mark region RL of the first layer 10. Alternatively, the number of air bubbles BB in the areas other than the alignment mark region RL may be zero. In other words, the areas other than the alignment mark region RL of the first layer 10 may not include air bubbles BB.

The number of bubbles BB used in the comparison between each region of the first layer 10 is calculated as the average number of bubbles having a maximum dimension of 1 μm or more observed in 10 different fields of view when a 100 μm square area in a plan view of each region of the first layer 10 is observed. The number of bubbles in each field of view is observed at a magnification of 1000 times using a digital microscope (Keyence Corporation: VH5500).

The area ratio of the air bubbles BB in the alignment mark region RL of the first layer 10, i.e., the area ratio of the air bubbles BB to the area of the first layer 10 when the alignment mark region RL is viewed in a plane, is different from the area ratio of the air bubbles BB in the region other than the alignment mark region RL of the first layer 10. The area ratio of the air bubbles BB in the region other than the alignment mark region RL of the first layer 10 may be smaller than the area ratio of the air bubbles BB in the alignment mark region RL of the first layer 10. The area ratio of the air bubbles BB in the region other than the alignment mark region RL of the first layer 10 may be 50% or less, or 25% or less, of the area ratio of the air bubbles BB in the alignment mark region RL of the first layer 10. The area ratio of the air bubbles BB in the region other than the alignment mark region RL of the first layer 10 may be zero. In other words, air bubbles BB may not be present in areas of the first layer 10 other than the alignment mark region RL.

The area ratio of bubbles BB in a certain region of the first layer 10 is calculated as the average value of the ratio of the area of bubbles to the total area of each visual field when a 100 μm square area in a plan view of the region is observed in 10 different visual fields. The number of bubbles in each visual field is observed at 1000x magnification using a digital microscope (Keyence Corporation: VH5500).

The width of the air bubble BB may be 1 μm or more, or 3 μm or more. The width of the air bubble BB may be 10 μm or less, or 8 μm or less. The width of the air bubble BB means the maximum length of the air bubble BB in the normal direction of the sheet-like first layer 10, that is, when observing the first layer 10 from the third direction D3 in the example shown in Figure 4.

As shown in Figures 3 to 5, the resin layer 12 includes a sheet-like land portion 12b, a plurality of first resin convex portions 12s protruding from the land portion 12b toward the second layer 20 in the alignment mark region RL, and a plurality of second resin convex portions 12t protruding from the land portion 12b toward the second layer 20 in the transfer region RT. In the illustrated example, the first resin convex portions 12s and the second resin convex portions 12t each protrude in a third direction D3 that is a normal direction of the first layer 10. The land portion 12b faces the first resin convex portion 12s in the third direction D3 at the portion where the first resin convex portion 12s protrudes. The land portion 12b faces the second resin convex portion 12t in the third direction D3 at the portion where the second resin convex portion 12t protrudes.

The land portion 12b and the first resin protrusion 12s may be integrally molded by resin molding, as described below. That is, the land portion 12b and the first resin protrusion 12s may be connected without a seam. The land portion 12b and the second resin protrusion 12t may be integrally molded by resin molding, as described below. That is, the land portion 12b and the second resin protrusion 12t may be connected without a seam.

The first resin protrusion 12s will be described below, mainly with reference to Figures 3 and 4. Note that the following description of the first resin protrusion 12s also applies to the first protrusion 10s.

In the illustrated example, the multiple first resin protrusions 12s are two-dimensionally arranged. Note that the multiple first resin protrusions 12s are "two-dimensionally arranged" means that the multiple first resin protrusions 12s are dispersed in at least two or more directions that are non-parallel to each other. The multiple first resin protrusions 12s may be arranged in at least two or more non-parallel directions. In the illustrated example, the multiple first resin protrusions 12s are two-dimensionally arranged in the first direction D1 and the second direction D2. The multiple first resin protrusions 12s are arranged in the first direction D1 and the second direction D2.

In the example shown in FIG. 4, the multiple first resin convex portions 12s are regularly arranged at a distance (pitch) LS1 in the first direction D1. The multiple first resin convex portions 12s are regularly arranged at a distance (pitch) LS2 in the second direction D2. The distances between adjacent first resin convex portions 12s in the first direction D1 may be the same. The distances between adjacent first resin convex portions 12s in the second direction D2 may be the same. The distances between adjacent first resin convex portions 12s in the first direction D1 may be different from each other. The distances between adjacent first resin convex portions 12s in the second direction D2 may be different from each other.

The distance LS1 between the first resin convex portions 12s in the first direction D1 may be 4 μm or more, or 6 μm or more. The distance LS1 between the first resin convex portions 12s in the first direction D1 may be 16 μm or less, or 10 μm or less. The distance LS2 between the first resin convex portions 12s in the second direction D2 may be 4 μm or more, or 6 μm or more. The distance LS2 between the first resin convex portions 12s in the second direction D2 may be 16 μm or less, or 10 μm or less.

The first resin protrusions 12s may have the same width in the arrangement direction. In the example shown in FIG. 4, the first resin protrusions 12s have the same width WS1 in the first direction D1. The first resin protrusions 12s have the same width WS2 in the second direction D2. The widths WS1 of the first resin protrusions 12s in the first direction D1 may be different from each other. The widths WS2 of the first resin protrusions 12s in the second direction D2 may be different from each other.

The width WS1 of the first resin convex portion 12s along the first direction D1 may be 2 μm or more, or 4 μm or more. The width WS1 of the first resin convex portion 12s along the first direction D1 may be 16 μm or less, or 10 μm or less. The width WS2 of the first resin convex portion 12s along the second direction D2 may be 25 μm or more, or 15 μm or more. The width WS2 of the first resin convex portion 12s along the second direction D2 may be 7 μm or less, or 4 μm or less.

The width of the first resin protrusion 12s may be 2 μm or more, or 4 μm or more. The width of the first resin protrusion 12s may be 25 μm or less, or 20 μm or less. The width of the first resin protrusion 12s means the maximum length of the first resin protrusion 12s in the normal direction of the sheet-like first layer 10, that is, when observing the first layer 10 from the third direction D3 in the example shown in FIG. 4, except when the direction in which the width is measured is specified, for example, "width WS1 along the first direction D1".

In the example shown in FIG. 4, when the first layer 10 is viewed in a plane, the first resin protrusion 12s has a generally elliptical shape. The shape of the first resin protrusion 12s in a plane view may be other than a generally elliptical shape. As an example, the shape of the first resin protrusion 12s in a plane view may be a rectangular shape or a circular shape.

As shown in FIG. 4, when the alignment mark region RL of the first layer 10 is viewed in a plan view, the air bubble BB and the first resin convex portion 12s may overlap. The air bubble BB that overlaps the first resin convex portion 12s in a plan view may be located within the first resin convex portion 12s. The air bubble BB that overlaps the first resin convex portion 12s in a plan view may be located within the land portion 12b facing the first resin convex portion 12s. That is, the first layer 10 may include an air bubble BB at a position facing the first resin convex portion 12s. The air bubble BB that overlaps the first resin convex portion 12s in a plan view may be located across the first resin convex portion 12s and the land portion 12b facing the first resin convex portion 12s.

The air bubble BB being "located within the first resin convex portion" means that the entire air bubble BB is located between the highest and lowest positions of the first resin convex portion 12s in the normal direction of the first layer 10. The lowest position of the first resin convex portion 12s in the illustrated example means the position of the first resin convex portion 12s that is closest to the base layer 11 along the third direction D3. The highest position of the first resin convex portion 12s in the illustrated example means the position of the first resin convex portion 12s that is farthest from the base layer 11 along the third direction D3.

As shown in FIG. 3, the air bubble BB may be located within the land portion 12b located between adjacent first resin convex portions 12s. In other words, the first layer 10 may include the air bubble BB at a position facing the portion between adjacent first resin convex portions 12s.

The height of the first resin protrusion 12s may be 1 μm or more, or 2 μm or more. The height of the first resin protrusion 12s may be 10 μm or less, or 6 μm or less. Note that the "height of the first resin protrusion" refers to the length of the first resin protrusion 12s in the normal direction of the first layer 10 (the third direction D3 in FIG. 3).

In the example shown in FIG. 3, the first resin protrusion 12s has a sidewall 13 along the third direction D3, which is the normal direction of the first layer 10. In the example shown in FIG. 5, the second resin protrusion 12t has a sidewall 14 along the third direction D3, which is the normal direction of the first layer 10.

In the example shown in FIG. 4, the width of the first resin convex portion 12s is larger than the width of the air bubble BB. The width of the first resin convex portion 12s is larger than the width of the air bubble BB located within the first resin convex portion 12s. The width of the first resin convex portion 12s is larger than the width of the air bubble BB located within the land portion 12b facing the first resin convex portion 12s. The width of the first resin convex portion 12s is larger than the width of the air bubble BB located across the first resin convex portion 12s and the land portion 12b facing the first resin convex portion 12s.

According to this specific example, it is possible to prevent the reflected light at the interface between the bubble BB and the base material 120 from being diffused too much before being released from the first layer 10. As a result, a difference in the amount of light between the reflected light in the alignment mark region RL and the reflected light in the region other than the alignment mark region RL is likely to occur. A difference in the reflectance in the alignment mark region RL and the reflectance in the region other than the alignment mark region RL is likely to occur. In addition, a difference in the amount of light between the transmitted light in the alignment mark region RL and the transmitted light in the region other than the alignment mark region RL is likely to occur. A difference in the transmittance in the alignment mark region RL and the transmittance reflectance in the region other than the alignment mark region RL is likely to occur. Therefore, the position detection means can stably detect the alignment mark region RL.

The first resin protrusion 12s may be formed by supplying the uncured curable resin composition that forms the resin layer 12 to a mold and curing the composition. The first resin protrusion 12s may be formed by embossing the curable resin composition before curing and then curing the composition. When the curable resin composition before curing is molded, air bubbles BB may remain in the curable resin composition. By curing the curable resin composition with the air bubbles BB remaining, the air bubbles BB are contained in the alignment mark region RL. In other words, the first resin protrusion 12s can produce a resin layer 12 that contains air bubbles BB as the alignment mark AL.

The second resin protrusion 12t will be described below mainly with reference to FIG. 5. Note that the following description of the second resin protrusion 12t also applies to the second protrusion 10t.

In the illustrated example, the second resin protrusions 12t are arranged one-dimensionally or linearly. The second resin protrusions 12t arranged one-dimensionally are arranged in one direction. The one direction is the arrangement direction of the second resin protrusions 12t. A one-dimensional arrangement or linear arrangement means that the target elements are arranged in one direction, and each element extends linearly in another direction that is non-parallel to the one direction. The illustrated second resin protrusions 12t extend in another direction that is non-parallel to the one direction, for example, perpendicular to the one direction. The second resin protrusions 12t have a longitudinal direction in the other direction. In the example shown in FIG. 5, the second resin protrusions 12t are arranged in the second direction D2. The second resin protrusions 12t extend linearly in the first direction D1. The second resin protrusions 12t have a longitudinal direction in the first direction D1.

The shape of the second resin convex portion 12t is transferred to the portion of the second layer 20 that overlaps with the second resin convex portion 12t. That is, the second layer 20 is formed with a concave portion corresponding to the shape of the second resin convex portion 12t. In the example shown in FIG. 5, a plurality of second concave portions 41t corresponding to the shape of the second resin convex portion 12t are formed in the portion of the second layer 20 that overlaps with the second resin convex portion 12t of the molded resin layer 41 described below. The molded resin layer 41 expresses a linear pattern 25 as shown in FIG. 6 by a collection of a plurality of second concave portions 41t.

From the viewpoint of clearly forming the linear pattern 25 in the second layer 20, the height of the second resin protrusions 12t, i.e., the protruding length of the second resin protrusions 12t in the third direction D3 into the second layer 20 in the illustrated example, may be 1 μm or more, or 2 μm or more. The height of the second resin protrusions 12t may be 8 μm or less, or 4 μm or less.

The height HT of the second resin convex portion 12t, i.e., the length in the normal direction of the first layer 10 (the third direction D3 in FIG. 5), may be smaller than the height HS of the first resin convex portion 12s. As shown in FIG. 3 and FIG. 5, the height HT of the second resin convex portion 12t may be larger than the height HS of the first resin convex portion 12s. The height HT of the second resin convex portion 12t may be 0.2 times or more, or 0.5 times or more, the height HS of the first resin convex portion 12s. The height HT of the second resin convex portion 12t may be 2.0 times or less, or 1.5 times or less, the height HS of the first resin convex portion 12s.

From the viewpoint of clearly forming the linear pattern 25 in the second layer 20, the width of the second resin protrusion 12t may be 4 μm or more, or 7 μm or more. The width of the second resin protrusion 12t may be 20 μm or less, or 15 μm or less. In the illustrated example, the width of the second resin protrusion 12t means the length along the arrangement direction of the multiple second resin protrusions 12t, i.e., the second direction D2.

3 and 5, the width of the second resin convex portion 12t is larger than the width of the first resin convex portion 12s. In the illustrated example, the width of the one-dimensionally arranged second resin convex portion 12t is larger than the width of the two-dimensionally arranged first resin convex portion 12s. That is, the length of the second resin convex portion 12t along the second direction D2 is larger than the maximum length of the first resin convex portion 12s when observed from the third direction D3. The width of the second resin convex portion 12t may be 1.1 times or more the width of the first resin convex portion 12s, or may be 1.2 times or more the width of the first resin convex portion 12s. The width of the second resin convex portion 12t may be 2.0 times or less the width of the first resin convex portion 12s, or may be 1.5 times or less the width of the first resin convex portion 12s.

The second resin protrusions 12t may be formed by supplying the curable resin composition that forms the resin layer 12 to a mold and curing the composition. The second resin protrusions 12t may be formed by embossing the curable resin composition before curing and then curing the composition.

As shown in FIG. 3, the coating layer 30 has a shape corresponding to the shape of the resin layer 12 in the alignment mark region RL. The coating layer 30 spreads along the surface irregularities of the alignment mark region RL. In the alignment mark region RL, the portion of the coating layer 30 that overlaps the first resin convex portion 12s protrudes in the third direction D3 toward the second layer 20.

As shown in FIG. 5, the coating layer 30 has a shape corresponding to the shape of the resin layer 12 in the transfer region RT. The coating layer 30 spreads along the surface irregularities of the transfer region RT. In the transfer region RT, the portion of the coating layer 30 that overlaps the second resin convex portion 12t protrudes in the third direction D3 toward the second layer 20.

The thickness of the coating layer 30 is not particularly limited. The thickness of the coating layer 30 may be 0.3 μm or more, or 0.6 μm or more. The thickness of the coating layer 30 may be 2 μm or less, or 1 μm or less.

Next, the second layer 20 will be described. In the example shown in Figures 3 and 5, the second layer 20 is a sheet-like member having a first surface 20a and a second surface 20b opposite the first surface 20a. The first surface 20a of the second layer 20 constitutes the first surface 5a of the decorative sheet 5. The second surface 20b of the second layer 20 faces the first surface 10a of the first layer 10.

The second layer 20 includes a decorative layer 40. The decorative layer 40 forms the design displayed by the decorative sheet 5. The decorative layer 40 may include multiple layers. In the example shown in Figures 3 and 5, the second layer 20 includes, as the decorative layer 40, a molded resin layer 41 and a printed layer 42 superimposed on the molded resin layer 41. In the example shown in Figure 1, the printed layer 42 is formed in a portion of the second layer 20.

The second layer 20 may include layers other than the decorative layer 40. In the example shown in FIG. 3 and FIG. 5, the second layer 20 includes an anchor layer 21 and a bonding layer 22. In the portion where the printing layer 42 is formed, the second layer 20 includes a molded resin layer 41, an anchor layer 21, a bonding layer 22, and a printing layer 42 in this order from the second surface 20b to the first surface 20a, as shown in FIG. 5. In the portion where the printing layer 42 is not formed, the second layer 20 includes a molded resin layer 41, an anchor layer 21, and a bonding layer 22 in this order from the second surface 20b to the first surface 20a, as shown in FIG. 3.

As shown in FIG. 3, the first surface 20a of the second layer 20 is flat in the portion overlapping the alignment mark region RL of the first layer 10. According to this specific example, the reflected light from the first layer 10 can be prevented from traveling in an unintended direction when it passes through the second layer 20 and is emitted from the first surface 5a of the decorative sheet 5 formed by the first surface 20a. In addition, the transmitted light that passes through the first layer 10 can be prevented from traveling in an unintended direction when it passes through the second layer 20 and is emitted from the first surface 5a of the decorative sheet 5 formed by the first surface 20a. As a result, the position detection means can stably detect the alignment mark region RL of the first layer 10.

The molded resin layer 41 has a first surface 41a and a second surface 41b opposite the first surface 41a. The molded resin layer 41 faces the anchor layer 21 at the first surface 41a. The molded resin layer 41 faces the coating layer 30 at the second surface 41b. The second surface 41b of the molded resin layer 41 constitutes the second surface 20b of the second layer 20.

As shown in FIG. 3, the molded resin layer 41 has a plurality of first recesses 41s in the portion overlapping the alignment mark region RL of the first layer 10. The second surface 41b and the second surface 20b are uneven surfaces in the portion overlapping the alignment mark region RL of the first layer 10. The plurality of first recesses 41s have a shape corresponding to the first resin protrusions 12s of the resin layer 12. The plurality of first recesses 41s have a shape complementary to the first resin protrusions 12s of the resin layer 12. The plurality of first recesses 41s have a shape with the recesses reversed to the first resin protrusions 12s of the resin layer 12.

5, the molded resin layer 41 has a plurality of second recesses 41t in the portion overlapping the transfer region RT of the first layer 10. The second surface 41b and the second surface 20b are uneven surfaces in the portion overlapping the transfer region RT of the first layer 10. The plurality of second recesses 41t have a shape corresponding to the second resin protrusions 12t of the resin layer 12. The plurality of second recesses 41t have a shape complementary to the second resin protrusions 12t of the resin layer 12. The plurality of second recesses 41t have a shape with the unevenness reversed to that of the second resin protrusions 12t of the resin layer 12. Each of the second plurality of second recesses 41t extends linearly in the first direction D1. The plurality of second recesses 41t are arranged in the second direction D2. The linear pattern 25 is formed as shown in FIG. 6 by arranging the plurality of second recesses extending linearly in the first direction D1 in the second direction D2.

Examples of resins contained in the molded resin layer 41 include vinyl resins such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDF), polyvinyl alcohol (PVA), ethylene-vinyl acetate copolymer (EVA), and ethylene-vinyl alcohol copolymer (EVOH); acrylic resins such as polymethyl (meth)acrylate (PMMA) and polyethyl (meth)acrylate (PEMA); polypropylene (PP), polyethylene (PE), polyacetal (POM), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), polyamide (PA), polyether ether ketone (PEEK), polystyrene (PS), thermoplastic polyurethane (TPU), acrylonitrile-styrene copolymer (AS), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-ethylene-styrene copolymer (AES), and polycarbonate (PC). The molded resin layer 41 may contain only one of the above-mentioned resins, or may contain two or more of the above-mentioned resins.

3 and 5, the anchor layer 21 is located between the mold-transfer resin layer 41 and the bonding layer 22 in the third direction D3. The anchor layer 21 is provided for the purpose of improving the adhesion between the mold-transfer resin layer 41 and the bonding layer 22. By improving the adhesion between the mold-transfer resin layer 41 and the bonding layer 22, the adhesion between the mold-transfer resin layer 41 and the printing layer 42 superimposed on the bonding layer 22 can be improved. The anchor layer 21 may contain a cured product of a curable resin composition. The cured product of the curable resin contained in the anchor layer 21 may be a cured product of a thermosetting resin composition or a cured product of an ionizing radiation curable resin composition. The ionizing radiation curable resin may include an ultraviolet curable resin and an electron beam radiation resin. The thickness of the anchor layer 21 is not particularly limited. The thickness of the anchor layer 21 may be 0.5 μm or more, or may be 1 μm or more. The thickness of the anchor layer 21 may be 4 μm or less, or may be 2 μm or less. The anchor layer 21 may be omitted from the second layer 20.

3 and 5, the bonding layer 22 is superimposed on the anchor layer 21. As shown in FIG. 3, the bonding layer 22 forms the first surface 20a of the second layer 20, i.e., the first surface 5a of the decorative sheet, in the region not including the printed layer 42. As shown in FIG. 5, the bonding layer 22 is located between the anchor layer 21 and the printed layer 42 in the region including the printed layer 42. The bonding layer 22 may be provided for the purpose of improving adhesion between the components of the decorative sheet 5. The bonding layer 22 may include an adhesive or a pressure-sensitive adhesive. The adhesive included in the bonding layer 22 may include one or more of an acrylic adhesive, a rubber adhesive, a urethane adhesive, and a silicone adhesive. The adhesive included in the bonding layer 22 may include one or more of an acrylic adhesive, a rubber adhesive, a urethane adhesive, and a silicone adhesive. The bonding layer 22 may be omitted from the second layer 20.

As shown in FIG. 1, the printing layer 42 includes a first printing layer 421 located on the transfer region RT of the first layer 10, and a second printing layer 422 located on the area other than the transfer region RT and the alignment mark region RL of the first layer 10.

The printed layer 42 may form a design. The design formed by the printed layer 42 may be displayed as the design of the decorative sheet 5, or the design of the decorative member including the decorative sheet 5. As a result, the printed layer 42 may improve the design of the decorative sheet 5 and the decorative member. In the illustrated example, the first printed layer 421 forms the design. The first printed layer 421 may include one or more of a colored layer and a pattern layer.

The picture layer may display figures, patterns, designs, colors, pictures, photographs, characters, marks, pictograms, letters, numbers, etc. As pictures that can harmonize the decorative sheet 5 with the object to which the decorative sheet 5 is applied, the picture layer may display wood grain or marble patterns, metallic textures, and geometric patterns.

The colored layer and the patterned layer may be made from a coating of a resin composition. The resin composition may contain a binder resin, a colorant, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent, an ultraviolet absorber, a light stabilizer, etc. The colorant may contain a pigment or a dye.

The printed layer 42 may form a second alignment mark AL2 in addition to the alignment mark AL formed by the air bubbles BB contained in the first layer 10. In the example shown in FIG. 1, the second printed layer 422 forms the second alignment mark AL2. According to the second printed layer 422 functioning as the second alignment mark AL2, a difference may occur between the amount of reflected light of the decorative sheet 5 in the portion formed by the second printed layer 422 and the amount of reflected light of the decorative sheet 5 in the portion other than the portion formed by the second printed layer 422. A difference may occur between the reflectance of the decorative sheet 5 in the portion formed by the second printed layer 422 and the reflectance of the decorative sheet 5 in the portion other than the portion formed by the second printed layer 422. According to the second printed layer 422 functioning as the second alignment mark AL2, a difference may occur between the amount of light transmitted through the decorative sheet 5 emitted from the portion of the first surface 5a formed by the second printed layer 422 and the amount of light transmitted through the decorative sheet 5 emitted from the portion other than the portion formed by the second printed layer 422 on the first surface 5a. A difference may occur between the transmittance of the decorative sheet 5 in the portion formed by the second printed layer 422 and the transmittance of the decorative sheet 5 in the portion other than the portion formed by the second printed layer 422. That is, the second alignment mark AL2 is detected based on the amount of reflected light, reflectance, amount of transmitted light, transmittance, etc., similar to the alignment mark AL. Each position in the decorative sheet 5 may be identified based on the detected second alignment mark AL2.

The position of the second alignment mark AL2 may be detected by capturing an image of the second alignment mark AL2 using an imaging means.

The second alignment mark AL2 may be used to align the decorative sheet 5. That is, the position of the decorative sheet 5 may be determined by the second alignment mark AL2. In the example shown in FIG. 1, the position of the decorative sheet 5 in the first direction D1 may be determined by the second alignment mark AL2. The position of the decorative sheet 5 in the second direction D2 may be determined by the second alignment mark AL2. That is, the coordinates of each position in the decorative sheet 5 may be specified based on the second alignment mark AL2. The alignment of the decorative sheet 5 may be performed when processing the decorative sheet 5. The alignment of the decorative sheet 5 may be included in the process of cutting the decorative sheet 5 from the long decorative sheet 1, the process of overlapping the thermoplastic resin part 7 on the decorative sheet 5, or the process of transferring a part of the decorative sheet 5 to the thermoplastic resin part 7.

The second printed layer 422 may have visible light blocking properties. Here, "visible light blocking properties" means that the visible light transmittance is 10% or less, but may also be 5% or less, or 2% or less. The visible light transmittance is determined using a haze meter (manufactured by Murakami Color Research Laboratory, product number: HM-150) as described above.

The second printed layer 422 may include a binder resin portion and light absorbing particles held in the binder resin portion. Examples of light absorbing particles include black pigments such as carbon black and titanium black. The binder resin portion of the second printed layer 422 may include a thermoplastic resin. The binder resin portion of the second printed layer 422 may include a cured product of a curable resin composition. The curable resin composition may include one or more of an ionizing radiation curable resin and a thermosetting resin. The ionizing radiation curable resin may include an ultraviolet curable resin and an electron beam radiation resin. Examples of materials for the binder resin portion of the second printed layer 422 include acrylic resins such as polymethyl methacrylate, polyurethane resins, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-acrylic copolymers, chlorinated polypropylene resins, polyester resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins, and cellulose acetate resins. The binder resin portion of the second printed layer 422 may contain one of these materials alone or a combination of two or more of them.

An example of a method for manufacturing the first layer 10 and the decorative sheet 5 described above will be described. First, a method for manufacturing the first layer 10 will be described. Next, a method for manufacturing the decorative sheet 5 including the first layer 10 will be described. After that, a method for manufacturing the decorative member 50 from the decorative sheet 5 will be described.

First, in producing the first layer 10, a plate 90 is prepared. FIG. 7 shows an example of the plate 90. The plate 90 shown in FIG. 7 has a cylindrical shape. The plate 90 is held so as to be rotatable about a central axis CA. The plate 90 has a plate surface 91 on the outer peripheral surface of the cylindrical shape. The plate surface 91 may be made of a metal such as copper. The plate surface 91 has a shape corresponding to the shape of the first surface 10a of the first layer 10. As described below, the plate surface 91 is pressed against a member forming the first layer 10, thereby producing the first layer 10 having a shape corresponding to the shape of the plate surface 91.

In the example shown in FIG. 7, the plate surface 91 includes an alignment mark formation region RLP and a linear pattern formation region RAP. The alignment mark formation region RLP and the linear pattern formation region RAP are provided at different positions on the plate surface 91. The alignment mark formation region RLP and the linear pattern formation region RAP are uneven surfaces. The plate surface 91 includes a plurality of first plate recesses 92 having a shape corresponding to the shape of the first convex portion 10s in the alignment mark formation region RLP. The plate surface 91 includes a plurality of second plate recesses 93 having a shape corresponding to the shape of the second convex portion 10t in the linear pattern formation region RAP.

The alignment mark formation region RLP may be provided in a plurality of areas in the circumferential direction of the plate 90 centered on the central axis CA. The linear pattern formation region RAP may be provided in a plurality of areas in the circumferential direction of the plate 90.

7 and 9, the first plate recess 92 is recessed in a radial direction perpendicular to the central axis CA toward the central axis CA. The first plate recesses 92 are arranged in an axial direction parallel to the central axis CA and in a circumferential direction centered on the central axis CA.

In the example shown in FIG. 7, the second plate recesses 93 are recessed in a radial direction perpendicular to the central axis CA toward the central axis CA. The second plate recesses 93 are arranged in an axial direction parallel to the central axis CA. The second plate recesses 93 extend in the circumferential direction.

The first plate recess 92 and the second plate recess 93 may be formed by etching the plate surface 91. The first plate recess 92 and the second plate recess 93 may be formed by laser drawing the plate surface 91. The second plate recess 93 may be formed by scribing the linear pattern forming area RAP of the plate surface 91.

The first plate recess 92 may be formed in the process of forming the second plate recess 93. The second plate recess 93 may be formed in the process of forming the first plate recess 92. That is, the first plate recess 92 and the second plate recess 93 may be formed in a common process. The first plate recess 92 and the second plate recess 93 may be formed in separate processes.

The first plate recesses 92 may be formed so that the spacing between the first resin protrusions 12s in the arrangement direction is the same. The first plate recesses 92 may be formed so that the first resin protrusions 12s have the same width in the arrangement direction. In the illustrated example, the spacing between adjacent first plate recesses 92 in the axial direction is the same. The spacing between adjacent first plate recesses 92 in the circumferential direction is the same. In the illustrated example, the multiple first plate recesses 92 have the same width in the axial direction. The multiple first plate recesses 92 have the same width in the circumferential direction. According to this specific example, the first plate recesses 92 can be easily formed on the plate surface 91 with a simple configuration.

Next, the first layer 10 is produced using the plate 90 described above. A first convex portion 10s formed by transferring the first plate recess 92 of the plate surface 91 may be provided in the portion of the first layer 10 that will become the alignment mark region RL. A second convex portion 10t formed by transferring the second plate recess 93 of the plate surface 91 may be provided in the portion of the first layer 10 that will become the transfer region RT. The first layer 10 may be produced as follows.

A long sheet-like member 60 that forms the base layer 11 is prepared. The sheet-like member 60 may be a film containing the material described above for the base layer 11. That is, the sheet-like member 60 may be a resin film. In the example shown in FIG. 8, the sheet-like member 60 has a longitudinal direction in the first direction D1. The sheet-like member 60 has a width direction TD that is parallel to the second direction D2. In the manufacturing process of the first layer 10 described below, the sheet-like member 60 moves in a flow direction MD that is parallel to the first direction D1.

An uncured curable resin composition 70 is supplied to the base layer 11. The curable resin composition 70 may be supplied onto the base layer 11 by various methods such as gravure printing. In the example shown in FIG. 8, the curable resin composition 70 is supplied to the sheet-like member 60 by a plate 80. As shown by the arrow in the figure, the plate 80 rotates around a central axis CB parallel to the width direction TD of the sheet-like member 60. The sheet-like member 60 passes between the rotating plate 80 and a compression roller 85 separated from the plate 80 in the third direction D3. The uncured curable resin composition is supplied from the plate surface 81 of the plate 80 onto the sheet-like member 60 moving in the flow direction MD.

Then, the plate surface 91 of the plate 90 is pressed against the curable resin composition. In the example shown in FIG. 8, the plate 90 is located downstream of the plate 80 in the flow direction MD. As shown by the arrow in the figure, the plate 90 rotates around the central axis CA. The sheet-like member 60 moving in the flow direction MD and the curable resin composition 70 on the sheet-like member 60 pass between the rotating plate 90 and the compression roller 95 separated from the plate 90 in the third direction D3. The curable resin composition 70 is supplied to the plate surface 91 of the rotating plate 90. The plate surface 91 is pressed against the curable resin composition 70 by the rotating plate 90.

As described above, the plate 90 includes a first plate recess 92 and a second plate recess 93 on the plate surface 91. When the plate surface 91 is pressed against the curable resin composition 70, as shown in FIG. 9, a convex portion 70s having a configuration complementary to the first plate recess 92 is provided to the portion of the curable resin composition 70 against which the first plate recess 92 is pressed. Meanwhile, a convex portion 70t having a configuration complementary to the second plate recess 93 is provided to the portion of the curable resin composition against which the second plate recess 93 is pressed.

The curable resin composition 70 against which the plate surface 91 is pressed contains air bubbles BB in the portion that becomes the alignment mark region RL. The air bubbles BB may be formed in the curable resin composition 70 when the first plate recess 92 is pressed against the curable resin composition 70. By arranging the plurality of first plate recesses 92 two-dimensionally apart from each other, air is more likely to remain in the first plate recess 92. By arranging the plurality of first plate recesses 92 apart in the circumferential direction of the plate 90, air is more likely to remain in the first plate recess 92. By setting the width and height of the first resin convex portion 12s, the shape of which is transferred by the first plate recess 92, to the above-mentioned range of dimensions, air is more likely to remain in the first plate recess 92. By setting the ratio of the height to the width (height/width) of the first resin convex portion 12s, the shape of which is transferred by the first plate recess 92, to 0.3 or more, air is more likely to remain in the first plate recess 92. Air remaining in the first plate recess 92 makes it easier for air bubbles to become mixed into the curable resin composition 70.

From the viewpoint of promoting the formation of air bubbles BB, the ratio of height to width (height/width) of the first resin protrusion 12s, the shape of which is transferred by the first plate recess 92, may be 0.3 or more, or 0.5 or more. The ratio of height to width (height/width) of the first resin protrusion 12s may be 1 or less.

The sheet-like member 60 and the curable resin composition 70 that is layered on the sheet-like member 60 and has the plate surface 91 pressed against it move in the flow direction MD.

The curable resin composition 70 is cured. An example of a curing process for curing the curable resin composition 70 is irradiation of ultraviolet rays onto the ultraviolet-curable resin composition. By curing the curable resin composition 70, a resin layer 12 is formed that is layered on the base layer 11. The resin layer 12 is a cured product of the curable resin composition 70. The curable resin composition 70 is cured in a state in which air bubbles BB are present in the portion that will become the alignment mark region RL. As a result, a resin layer 12 containing air bubbles BB is obtained in the alignment mark region RL.

The curing process may be performed on the curable resin composition 70 that is pressurized between the plate 90 and the sheet-like member 60. The curing process may be performed on the coating of the curable resin composition 70 after it has been given a shape by the plate 90.

The first resin convex portion 12s shown in FIG. 3 and FIG. 4 is formed by curing the convex portion 70s having a complementary configuration to the first plate concave portion 92. As shown in FIG. 3 and FIG. 4, the first resin convex portions 12s are separated from each other in the first direction D1. As shown in FIG. 8 and FIG. 9, the first direction D1 is parallel to the flow direction MD of the curable resin composition 70 superimposed on the sheet-like member 60. According to this specific example, the air bubbles BB located in the convex portion 70s tend to remain in the curable resin composition 70 moving in the flow direction MD. By the air bubbles BB remaining in the convex portion 70s, the air bubbles BB tend to remain in the first resin convex portion 12s after the curing process. Therefore, according to this specific example, the first layer 10 containing the air bubbles BB in the first resin convex portion 12s can be easily produced.

In the illustrated example, the convex portion 70t having a configuration complementary to the second plate concave portion 93 is cured to form the second resin convex portion 12t shown in FIG. 5. The second resin convex portion 12t constitutes the second convex portion 10t of the first layer 10. The plate surface 91 is pressed against the curable resin composition 70 to produce a resin layer 12 including the first resin convex portion 12s and the second resin convex portion 12t. By producing the resin convex portions 12s and 12t having different uses using the plate 90, the manufacturing time and manufacturing costs of the first layer 10 can be reduced.

As shown in Figures 8 and 9, the sheet-like member 60 is separated from the plate surface 91 in the radial direction of the plate 90. The land portion 12b is formed by hardening the curable resin composition 70 located between the sheet-like member 60 and the plate surface 91. The land portion 12b is molded integrally with the first resin convex portion 12s. The land portion 12b is molded integrally with the second resin convex portion 12t. The land portion 12b is exposed in a portion where neither the first resin convex portion 12s nor the second resin convex portion 12t is provided.

In this manner, a first layer (base material sheet) 10 containing air bubbles in the alignment mark region RL is obtained. A long base material sheet 2 containing the first layer 10 may be produced by roll-to-roll processing.

Then, the first layer 10 is peeled off from the plate 90. A first resin composition is supplied onto the surface of the first layer 10 that was in contact with the plate 90, forming a coating of the first resin composition. The coating of the first resin composition is dried or cured to form the coating layer 30. The coating layer 30 protrudes in the portion overlapping the first resin convex portion 12s. The coating layer 30 protrudes in the portion overlapping the second resin convex portion 12t. The coating layer 30 may include a thermoplastic resin. The coating layer 30 may include a cured product of a curable resin composition. The preparation of the coating layer 30 may be omitted, and the second layer 20 may be formed on the first layer 10.

Next, a second layer 20 is fabricated to overlay the first layer 10. The second layer 20 may be fabricated as follows.

A second resin composition is supplied onto the first layer 10 and the coating layer 30 to form a coating film of the second resin composition. The second resin composition may be a curable resin composition. The curable resin composition may be a thermosetting resin composition or an ionizing radiation curable resin composition. An example of an ionizing radiation curable resin composition is an ultraviolet curable resin composition. The curable resin composition is cured on the first layer 10 and the coating layer 30. A shape-imparting resin layer 41 is produced by the cured product of the curable resin composition. The produced shape-imparting resin layer 41 is bonded to the first layer 10 or the coating layer 30.

The molded resin layer 41 has a shape corresponding to the shape of the coating layer 30 that overlaps the first resin convex portion 12s of the resin layer 12 in the portion that overlaps the alignment mark region RL. As a result, as shown in FIG. 3, a first concave portion 41s is formed in the portion of the molded resin layer 41 that overlaps the alignment mark region RL.

The molded resin layer 41 has a shape corresponding to the shape of the coating layer 30 that overlaps the second resin convex portion 12t of the resin layer 12 in the portion that overlaps the transfer region RT. As a result, as shown in Figures 5 and 6, a second concave portion 41t is formed in the portion of the molded resin layer 41 that overlaps the transfer region RT.

Then, the anchor layer 21 and the bonding layer 22 are formed on the molded resin layer 41. The anchor layer 21 may be produced by supplying a resin composition onto the molded resin layer 41, forming a coating of the resin composition, and drying or curing the coating. The bonding layer 22 may be produced by supplying a resin composition onto the anchor layer 21, forming a coating of the resin composition, and drying or curing the coating.

Next, the printing layer 42 is formed on the bonding layer 22. To form the printing layer 42 at a precise position on the bonding layer 22, the laminate 4 including the first layer 10, the moldable resin layer 41, the anchor layer 21, and the bonding layer 22 in this order may be aligned. The laminate 4 may be aligned, for example, as follows, using an alignment mark AL formed by an air bubble BB in the alignment mark region RL of the first layer 10.

Figure 10 is an example of a printing machine 200 that forms a printed layer 42. The printing machine 200 includes a plate cylinder 201, an impression cylinder 202 that presses the laminate 4 against the plate cylinder 201, a roller 203 that determines the movement direction of the laminate 4, a correction roller 204, a position detection means 205 that can detect the alignment mark region RL of the first layer 10, and a correction device 206 that can receive a signal from the position detection means 205. The printing machine 200 can form a first printed layer 421 on the laminate 4. The printing machine 200 can form a second printed layer 422 on the laminate 4.

The plate cylinder 201 has a cylindrical shape. The plate cylinder 201 is held so that it can rotate around a central axis CX. The plate cylinder 201 has a plate surface on a portion of the outer circumferential surface of the cylindrical shape. By pressing the plate surface against the bonding layer 22 of the laminate 4, a coating film that forms the printing layer 42 is formed on the bonding layer 22 of the laminate 4.

The laminate 4 includes a first surface 4a on which the printing layer 42 is formed, and a second surface 4b opposite the first surface 4a. In the illustrated example, the first surface 4a is formed by the bonding layer 22. The second surface 4b is formed by the first layer 10. The second surface 10b of the first layer 10 is the second surface 4b of the laminate 4. The position detection means 205 faces the second surface 4b of the laminate 4.

The position detection means 205 detects the alignment mark region RL of the first layer 10 before the plate surface is pressed against the bonding layer 22 of the laminate 4. As described above, the position detection means 205 can detect the alignment mark region RL based on the difference in the amount of reflected light from the first layer 10 between the alignment mark region RL and a region other than the alignment mark region RL, which is caused by the air bubble BB that forms the alignment mark AL. The position detection means 205 may also detect the alignment mark region RL based on the difference in the amount of transmitted light through the first layer 10 between the alignment mark region RL and a region other than the alignment mark region RL, which is caused by the air bubble BB that forms the alignment mark AL.

The detection signal of the alignment mark region RL by the position detection means 205 is transmitted to the correction device 206. Based on the detection signal of the alignment mark region RL, the correction device 206 calculates the position where the printed layer 42 should be formed in the movement direction of the laminate 4. Based on the position where the printed layer 42 should be formed, the correction device 206 calculates the distance that the laminate 4 should move before reaching the plate cylinder 201. Based on the distance that the laminate 4 should move, the correction device 206 transmits a signal to move the correction roller 204 in the direction shown by the dashed arrow in the figure.

Based on the calculation results by the correction device 206, the correction roller 204 operates to adjust the distance that the laminate 4 moves before reaching the plate cylinder 201. In this way, the laminate 4 is aligned in the direction of movement of the laminate 4. This allows the printing layer 42 that constitutes the decorative layer 40 to be formed at a predetermined position identified based on the alignment mark region RL.

In this manner, a decorative sheet 5 is produced that includes a first layer 10 and a second layer 20 superimposed on the first layer 10. A long decorative sheet 1 that includes multiple decorative sheets 5 may be produced by roll-to-roll production.

The conventional decorative sheet disclosed in JP2019-30993A included a base layer having a convex portion, and a transfer layer overlapping the base layer, the transfer layer having a protruding portion overlapping the convex portion of the base layer. This decorative sheet was aligned by detecting the position of the protruding portion in the transfer layer. The protruding portion was detected by the difference in the amount of light between the amount of light reflected from the protruding portion and the amount of light reflected from the portion of the transfer layer other than the protruding portion. More specifically, due to light scattering at the protruding portion, the amount of light reflected from the protruding portion was reduced compared to the amount of light reflected from the portion of the transfer layer other than the protruding portion.

However, it is conceivable that the convex portions of the base layer may be flattened to some extent due to the weight of other layers, including the transfer layer, that overlap the base layer. When the convex portions are flattened, the protruding portions that overlap the convex portions of the transfer layer may also be flattened. When the protruding portions are flattened, it becomes difficult to detect the above-mentioned difference in light quantity in the transfer layer, which may result in a problem in which the decorative sheet cannot be aligned.

In contrast, the decorative sheet 5 according to this embodiment includes a first layer 10 including an alignment mark region RL, and a second layer 20 superimposed on the first layer 10. The first layer 10 includes air bubbles BB in the alignment mark region RL. The second layer 20 includes a decorative layer 40. In the example shown in FIG. 3, the decorative sheet 5 includes a base layer 11 and a resin layer 12 superimposed on the base layer 11. The air bubbles BB are held within the matrix 120 of the resin layer 12.

According to this specific example, when light that has entered the resin layer 12 reaches the air bubble BB contained in the alignment mark region RL, it may be refracted at the interface between the air bubble BB and the base material 120 that holds the air bubble BB. Alternatively, the light that has reached the air bubble BB contained in the alignment mark region RL may be reflected at the interface between the base material 120 and the air bubble BB. In other words, the optical characteristics differ between the alignment mark region RL and other regions. For example, any of the following optical characteristics may differ between the alignment mark region RL and other regions.
- Amount of reflected light - Amount of transmitted light - Reflectance - Transmittance - Amount of diffuse reflected light - Amount of diffuse transmitted light - Diffuse reflectance - Diffuse transmittance.By measuring any of these optical characteristics, the position detection means 205 can detect the position of the alignment mark region RL.

Therefore, regardless of the surface shape of the decorative sheet 5, the first layer 10 and the decorative sheet 5 including the first layer 10 can be accurately aligned by the air bubbles BB contained in the resin layer 12 (first layer 10). This decorative sheet 5 can have a pair of main surfaces 5a, 5b that are parallel flat surfaces. According to this example, when the long decorative sheet 1 is wound up and handled as a roll 1R, the rolled shape is stable.

Next, a method for manufacturing a decorative member 50 using a decorative sheet 5 will be described with reference to Figures 11 to 15. In one specific example of a method for manufacturing a decorative member 50 described below, the thermoplastic resin part 7 and the decorative sheet 5 are joined by injecting an injection resin into the decorative sheet 5 included in the long decorative sheet 1 supplied by roll-to-roll.

As shown in FIG. 11, an injection molding device 210 is prepared. The injection molding device 210 includes a molding die 211. The molding die 211 includes a first die 211A and a second die 211B. The molding die 211 can be in an open state in which the first die 211A and the second die 211B are separated from each other, and a closed state in which the first die 211A and the second die 211B are in contact with each other. In the closed state, as shown in FIG. 12, a cavity 212 is formed between the first die 211A and the second die 211B. The first die 211A has a gate 213 that leads to the cavity 212. The gate 213 is connected to a supply device for injection resin 214 (not shown). Injection resin 214 is supplied to the cavity 212 through the gate 213.

In the example shown in FIG. 11, the injection molding device 210 includes a position detection means 215 capable of detecting the alignment mark region RL provided on the decorative sheet 5, and a control device 216 capable of receiving a signal from the position detection means 215. The control device 216 can switch the mold 211 between an open state and a closed state. The control device 216 can rotate the first roll 217 and the second roll 218 to move the decorative sheet 5. The control device 216 can stop the rotation of the first roll 217 and the second roll 218 to stop the decorative sheet 5.

As shown in FIG. 11, the decorative sheet 5 moves from the first roll 217 to the second roll 218 as the first roll 217 and the second roll 218 rotate. As the decorative sheet 5 moves from the first roll 217 to the second roll 218, the decorative sheet 5 passes between the first die 211A and the second die 211B. After passing between the first die 211A and the second die 211B, the decorative sheet 5 faces the position detection means 215 on the first surface 5a.

The position detection means 215 detects the alignment mark region RL included in the decorative sheet 5 moving from the first roll 217 to the second roll 218. The detection signal of the alignment mark region RL by the position detection means 215 is transmitted to the control device 216. Based on the detection signal of the alignment mark region RL, the control device 216 calculates the position where the decorative sheet 5 should stop so that it will be bonded to the thermoplastic resin part 7 in the part that overlaps the transfer region RT of the second layer 20. The control device 216 stops the rotation of the first roll 217 and the second roll 218 so that the decorative sheet 5 stops at the calculated position.

Next, as shown in FIG. 12, the molding die 211 is closed. In the closed state, the decorative sheet 5 included in the long decorative sheet 1 is housed in the cavity 212. In the illustrated example, the first surface 5a of the decorative sheet 5 faces the first die 211A of the molding die 211. The second surface 5b of the decorative sheet 5 faces the second die 211B of the molding die 211.

Next, as shown in FIG. 13, injected resin 214 is injected into cavity 212 through gate 213. The injected resin 214 is cooled in cavity 212 and solidifies by welding to decorative sheet 5. From the solidified injected resin 214, a thermoplastic resin portion 7 bonded to decorative sheet 5 is obtained. The thermoplastic resin portion 7 is bonded to the second layer 20 of decorative sheet 5.

After that, as shown in FIG. 14, the first mold 211A and the second mold 211B are separated from each other. As shown in FIG. 14 and FIG. 15, the thermoplastic resin part 7 and the second layer 20 bonded to the thermoplastic resin part 7 are peeled off from the first layer 10. In the illustrated example, the coating layer 30 located between the first layer 10 and the second layer 20 functions as a release layer, thereby facilitating the peeling of the first layer 10 and the second layer 20. That is, in the above-mentioned specific example, the decorative sheet 5 and the long decorative sheet 1 are transfer sheets. The decorative sheet 5 and the long decorative sheet 1 include the second layer 20 as a transfer layer to be transferred, and the first layer 10 as a support layer that supports the second layer 20 until it is peeled off. The thermoplastic resin part 7 is a transferee to which the second layer 20 is transferred.

In this way, the decorative member 50 is manufactured using the decorative sheet 5. Note that the present invention is not limited to the above example, and the decorative member 50 may be manufactured by injecting an injection resin into a sheet of decorative sheet 5 cut from a long decorative sheet 1.

When cutting the long decorative sheet 1, the decorative sheet 5 as part of the long decorative sheet 1 may be aligned in the first direction D1 by the second printed layer 422 forming a part of the first surface 5a. The decorative sheet 5 as part of the long decorative sheet may be aligned in the first direction D1 by the alignment mark AL. The decorative sheet 5 as part of the long decorative sheet 1 may be aligned in the second direction D2 by the second printed layer 422 forming a part of the first surface 5a. The decorative sheet 5 as part of the long decorative sheet may be aligned in the second direction D2 by the alignment mark AL.

In the embodiment described above, the decorative sheet 5 includes a first layer 10 including an alignment mark region RL, and a second layer 20 superimposed on the first layer 10. The first layer 10 includes air bubbles BB in the alignment mark region. The second layer 20 includes a decorative layer 40. According to this specific example, the decorative sheet 5 has different optical properties between the alignment mark region RL and the region other than the alignment mark region RL due to the air bubbles BB held in the first layer 10. This allows the alignment mark region RL to be detected regardless of the surface shape of the decorative sheet 5. Therefore, such a decorative sheet 5 allows for stable and accurate alignment.

One embodiment has been described with reference to specific examples, but the above-mentioned specific examples do not limit the embodiment. The above-mentioned one embodiment can be implemented with various other specific examples, and various omissions, substitutions, changes, additions, etc. can be made within the scope of the gist of the embodiment.

Below, an example of a modification will be described with reference to the drawings. In the following description and the drawings used in the following description, parts that can be configured similarly to the above-mentioned specific example will be designated by the same reference numerals as those used for the corresponding parts in the above-mentioned specific example, and duplicated descriptions will be omitted.

In one specific example of the decorative sheet 5 described above, the second layer 20 includes a molded resin layer 41 and a printed layer 42 as the decorative layer 40, but this is not limited to this. As shown in FIG. 16, the second layer 20 does not need to include a printed layer 42 as the decorative layer 40. In the illustrated example, the second layer 20 includes a molded resin layer 41, an anchor layer 21, and a bonding layer 22 in this order from the second surface 20b to the first surface 20a in the portion overlapping the transfer region RT of the first layer 10.

The decorative sheet 5 shown in FIG. 16 may be aligned by an air bubble BB formed in the alignment mark region RL. Alignment of the decorative sheet 5 may be included in the process of cutting the decorative sheet 5 from the long decorative sheet 1, may be included in the process of overlaying the thermoplastic resin part 7 on the decorative sheet 5, or may be included in the process of transferring a portion of the decorative sheet 5 to the thermoplastic resin part 7.

In one specific example of the decorative sheet 5 described above, the multiple first resin convex portions 12s (first convex portions 10s) were arranged in a square pattern in the first direction D1 and the second direction D2. That is, the multiple first resin convex portions 12s were arranged at a constant pitch in the first direction D1 and also at a constant pitch in the second direction D2 perpendicular to the first direction D1. However, the arrangement pattern of the first resin convex portions 12s in the alignment mark region RL is not limited to the square arrangement shown in FIG. 4. The multiple first resin convex portions 12s may be arranged in a staggered pattern as shown in FIG. 17. In the example shown in FIG. 17, the multiple first resin convex portions 12s are arranged at a constant pitch in the first direction D1 to form the multiple first resin convex portions 12s in the first row AR1. The multiple first resin convex portions 12s are arranged at a constant pitch in the first direction D1 to form the multiple first resin convex portions 12s in the second row AR2. The first resin protrusions 12s in the first row AR1 and the first resin protrusions 12s in the second row AR2 are alternately arranged in the second direction D2. The first resin protrusions 12s in the first row AR1 are arranged in a square array. The first resin protrusions 12s in the second row AR2 are arranged in a square array. The first resin protrusions 12s in the first row AR1 and the first resin protrusions 12s in the second row AR2 are arranged in the first direction D1 at the same pitch. The first resin protrusions 12s in the first row AR1 and the first resin protrusions 12s in the second row AR2 are arranged with a shift in the first direction D1 by half the arrangement pitch in the first direction D1.

In one specific example of the first layer (base sheet) 10 described above, the resin layer 12 includes a plurality of one-dimensionally arranged second resin convex portions 12t as the second convex portions 10t. However, the arrangement pattern of the second resin convex portions 12t is not limited to this. The second resin convex portions 12t may be arranged two-dimensionally. That is, the second resin convex portions 12t may be distributed in at least two or more directions that are non-parallel to each other. The two-dimensionally arranged second resin convex portions 12t may form a plurality of two-dimensionally arranged second concave portions 41t in the mold-transfer resin layer 41. Various two-dimensionally arranged patterns may be expressed by a collection of a plurality of two-dimensionally arranged second concave portions 41t. The two-dimensionally arranged pattern may represent one or more of letters, pictures, marks, illustrations, characters, and pictograms.

The width of the two-dimensionally arranged second resin protrusions 12t may be greater than the width of the two-dimensionally arranged first resin protrusions 12s. Note that the width of the two-dimensionally arranged second resin protrusions 12t means the maximum length of the second resin protrusions 12t when observing the sheet-like first layer 10 from the normal direction of the first layer 10.

In one specific example of the first layer (substrate sheet) 10 described above, the resin layer 12 containing the air bubbles BB was formed by curing the curable resin composition 70 against which the first plate recess 92 was pressed. However, the method of forming the resin layer 12 containing the air bubbles BB is not limited to this. The resin layer 12 containing the air bubbles BB may be formed by applying a resin composition containing the air bubbles BB in the binder resin to the base layer 11.

In one specific example of the decorative sheet 5 described above, the first layer 10 included a base layer 11 and a resin layer 12 overlapping the base layer 11. That is, the first layer 10 included multiple layers. However, as shown in FIG. 18, the first layer 10 may be a single layer.

In one specific example of the decorative sheet 5 described above, the second layer 20 included a resin-patterned layer 41 and a printed layer 42 superimposed on the resin-patterned layer 41 as the decorative layer 40. That is, the decorative layer 40 included multiple layers. However, as shown in FIG. 18, the decorative layer 40 may be a single layer.

In one specific example of the decorative sheet 5 described above, the decorative sheet 5 includes a covering layer 30 between the first layer 10 and the second layer 20. As already described and as shown in FIG. 18, the covering layer 30 may be omitted from the decorative sheet 5.

In one specific example of the decorative sheet 5 described above, the second layer 20 includes an anchor layer 21 and a bonding layer 22. As already described and as shown in FIG. 18, these layers may be omitted from the second layer 20.

Below, an embodiment of the present disclosure will be described in more detail using an example, but the present disclosure is not limited to this example.

The decorative sheets according to Examples 1 to 5 and the decorative sheet according to Comparative Example 1 were produced. The produced decorative sheets had a first surface and a second surface opposite to the first surface. The produced decorative sheets had a first layer and a second layer superimposed on the first layer. The first layer had a first surface and a second surface opposite to the first surface. The second layer had a first surface and a second surface opposite to the first surface. The first layer included a base layer and a resin layer superimposed on the base layer. The second layer included a molded resin layer. The second layer was composed only of the resin molded layer. The second surface of the produced decorative sheets was composed of the base layer. The first surface of the produced decorative sheets was composed of the molded resin layer. In the produced decorative sheets, the resin layer was located between the base layer and the molded resin layer. The decorative sheet produced had a longitudinal direction that was aligned with the longitudinal direction of the long member obtained by roll-to-roll. The decorative sheet produced did not include a covering layer. The decorative sheet produced did not include an anchor layer. The decorative sheet produced did not include a bonding layer. The decorative sheet produced did not include a printing layer. The decorative sheets of Examples 1 to 5 and the decorative sheet of Comparative Example 1 had the above configurations in common.

Example 1
A plate was prepared. The plate surface of the plate was formed by etching. The plate surface included first plate recesses. The first plate recesses were two-dimensionally arranged in an axial direction parallel to the central axis of the plate and in a circumferential direction of the plate centered on the central axis. The first plate recesses were arranged in a square array. The depth of the first plate recesses, i.e., the length of the first plate recesses in the radial direction perpendicular to the central axis, was 4.6 μm. The plate surface did not include second plate recesses.

The manufacturing method described above with reference to FIG. 7 and FIG. 8 was adopted for manufacturing the first layer using the plate. The base layer was a part of a long polyethylene terephthalate film manufactured by roll-to-roll. The resin layer was a cured product of ultraviolet-curable resin. The first layer included an alignment mark area. The resin layer included a plurality of first resin convex portions corresponding to the shape of the first plate concave portion. The plurality of first resin convex portions constituted a plurality of first convex portions. The plurality of first resin convex portions were arranged in both the first direction, which was the longitudinal direction, and the second direction, which was the width direction. The plurality of first resin convex portions were arranged two-dimensionally. The plurality of first resin convex portions were arranged in a square array as shown in FIG. 4. The dimension of the alignment mark area in which the plurality of first resin convex portions were formed was 19 mm along the longitudinal direction and 19 mm in the width direction. Each first resin convex portion had a length of 16 μm in the longitudinal direction. Each first resin convex portion had a length of 16 μm in the width direction. The distance between two adjacent first resin protrusions in the longitudinal direction was 16 μm. The distance between two adjacent first resin protrusions in the width direction was 16 μm. The height of the first resin protrusions along the third direction was 4.6 μm.

The molded resin layer was formed on the resin layer by the method described above. That is, the UV-curable resin composition was supplied onto the first surface of the first layer formed by the resin layer, and the coating of the UV-curable resin composition was cured on the first surface to produce the molded resin layer. In this manner, the decorative sheet according to Example 1 was obtained. The first surface of the decorative sheet formed by the molded resin layer was flat.

Example 2
The decorative sheet of Example 2 had the same configuration as the decorative sheet of Example 1, except for the length of the first resin convex portion in the longitudinal and width directions, the spacing between adjacent first resin convex portions in the longitudinal and width directions, and the height of the first resin convex portions.

In the decorative sheet of Example 2, each first resin protrusion had a length of 8 μm in the longitudinal direction. Each first resin protrusion had a length of 8 μm in the width direction. The distance between two adjacent first resin protrusions in the longitudinal direction was 8 μm. The distance between two adjacent first resin protrusions in the width direction was 8 μm. The height of the first resin protrusions along the third direction was 3.3 μm.

Example 3
The decorative sheet of Example 3 had the same configuration as the decorative sheet of Example 1, except for the length of the first resin convex portion in the longitudinal and width directions, the spacing between adjacent first resin convex portions in the longitudinal and width directions, and the height of the first resin convex portions.

In the decorative sheet of Example 3, each first resin protrusion had a length of 4 μm in the longitudinal direction. Each first resin protrusion had a length of 4 μm in the width direction. The distance between two adjacent first resin protrusions in the longitudinal direction was 4 μm. The distance between two adjacent first resin protrusions in the width direction was 4 μm. The height of the first resin protrusions along the third direction was 2.6 μm.

Example 4
The decorative sheet according to Example 4 had the same configuration as the decorative sheet according to Example 1, except for the arrangement pattern of the first resin convex portions.

In the decorative sheet according to Example 4, the first resin convex portions were irregularly arranged in the longitudinal direction. The first resin convex portions were irregularly arranged in the width direction. The alignment mark region in which the first resin convex portions were formed had a dimension of 19 mm along the longitudinal direction and 19 mm in the width direction. When the decorative sheet according to Example 4 was viewed in plan, the area of the first resin convex portions accounted for 50% of the area of the alignment mark region. The irregularly arranged first resin convex portions had a length of 8 μm or more in the longitudinal direction. The irregularly arranged first resin convex portions had a length of 8 μm or more in the width direction. That is, the alignment mark region was divided into small regions having dimensions of 8 μm in the longitudinal direction and 8 μm in the width direction, and the presence or absence of the first resin convex portions in the small regions was irregularly determined. The height of the first resin convex portions along the third direction was 3.3 μm.

Example 5
The decorative sheet according to Example 5 had the same configuration as the decorative sheet according to Example 1, except for the arrangement pattern of the first resin protrusions and the height of the first resin protrusions.

In the decorative sheet of Example 5, the multiple first resin protrusions were arranged in a staggered pattern as described with reference to FIG. 17. The first resin protrusions were designed to be formed in an area having a length of 8 μm in the longitudinal direction and a length of 8 μm in the width direction. However, when preparing the plate surface of the plate, the amount of erosion by etching was less than designed. In the prepared plate, the multiple first plate recesses formed on the plate surface were spaced apart from each other. The multiple first resin protrusions of the first layer prepared using this plate were spaced apart from each other.

<Comparative Example 1>
Except for the size of the first resin convex portions, the decorative sheet according to Comparative Example 1 had the same configuration as the decorative sheet according to Example 5. In the decorative sheet according to Comparative Example 1, the height of the first resin convex portions along the third direction was 3.5 μm.

In the decorative sheet according to Comparative Example 1, the multiple first resin protrusions were arranged in a staggered pattern as described with reference to FIG. 17. The first resin protrusions were designed to be formed in an area having a length of 8 μm in the longitudinal direction and a length of 8 μm in the width direction. However, when preparing the plate surface of the plate, the amount of erosion by etching was greater than designed. In the prepared plate, the multiple first plate recesses formed on the plate surface were connected to each other. The multiple first resin protrusions of the first layer prepared using this plate were connected to each other. Two adjacent first resin protrusions in two directions inclined at 45° to the longitudinal direction were connected to each other.

<Evaluation 1>
The alignment mark area in which the first resin convex portion was formed was observed from the first surface along the normal direction using a digital microscope (Keyence Corporation: VH5500). The observation area had dimensions of 100 μm × 100 μm. The number of bubbles observed in the observation area was counted according to the width of the bubbles. The bubbles found were classified according to their maximum width (μm). The count and classification results are shown in the "Evaluation 1" column of Table 1. In Table 1, the number of bubbles having a width of 7 μm or more is listed in the "7 μm or more" column of Table 1. In Table 1, the number of bubbles having a width of 4 μm or more and less than 7 μm is listed in the "4 μm or more and less than 7 μm" column of Table 1. In Table 1, the number of bubbles having a width of 1 μm or more and less than 3 μm is listed in the "1 μm or more and less than 3 μm" column of Table 1.

<Evaluation 2>
As described below, a photoelectric sensor was used to measure the amount of light (lm·S) reflected from the decorative sheet in the area where the first resin convex portion was provided and in the area where the first resin convex portion was not provided. The photoelectric sensor included an amplifier (manufactured by Keyence Corporation: CZ-V21a) and a sensor head (manufactured by Keyence Corporation: CZ-H37S) electrically connected to the amplifier. The prepared decorative sheet was placed on a stand so that the first surface faced upward. Black cardboard was provided between the decorative sheet and the stand. The sensor head was placed 16 mm above the first surface. Light was irradiated from the light-emitting portion of the sensor head toward the decorative sheet with an incident angle of 90°, and the amount of light (lm·S) of the reflected light was measured by the light-receiving portion. In each of Examples 1 to 5 and Comparative Example 1, the amount of light (lm·S) of the reflected light was obtained at three different points in the alignment mark area. The amount of light (lm·S) of the reflected light in areas other than the alignment mark area was also measured.
The average light quantity (lm·S) of the reflected light at three different points in the alignment mark region where the first resin convex portion was provided was compared with the average light quantity (lm·S) of the reflected light in the region where the first resin convex portion was not provided, and the evaluation was performed based on the following evaluation criteria. The comparison results are shown in the "Evaluation 2" column in Table 1.
(Evaluation criteria)
AAA: The ratio of the average amount of reflected light in the alignment mark region to the average amount of reflected light in regions other than the alignment mark region was 160% or more.
AA: The ratio of the average amount of reflected light in the alignment mark region to the average amount of reflected light in regions other than the alignment mark region was 120% or more and less than 160%.
A: The ratio of the average amount of reflected light in the alignment mark region to the average amount of reflected light in regions other than the alignment mark region was 110% or more and less than 120%.
B: The ratio of the average amount of reflected light in the alignment mark region to the average amount of reflected light in regions other than the alignment mark region was less than 110%.

1: Long decorative sheet, 5: Decorative sheet, 5a: First surface, 5b: Second surface, 7: Thermoplastic resin part, 10: First layer (base sheet), 10s: First convex part (convex part), 10t: Second convex part, 11: Base layer, 12: Resin layer, 12s: First resin convex part, 12t: Second resin convex part, 20: Second layer, 40: Decorative layer, 50: Decorative member, 90: Plate, 91: Plate surface, 92: First plate recess, 93: Second plate recess, AL: Alignment mark, RL: Alignment mark area, BB: Air bubble

Claims (18)

a first layer including an alignment mark area;
a second layer overlying the first layer,
the first layer includes air bubbles in the alignment mark region;
The second layer includes a decorative layer. the first layer includes a sheet-like base portion and a convex portion protruding from the base portion toward the second layer in the alignment mark region,
The decorative sheet according to claim 1 , wherein the first layer includes the air bubbles in at least one of the protrusions and the base portion overlapping the protrusions. The decorative sheet according to claim 2, wherein the first layer contains air bubbles at positions facing the portions between the adjacent protrusions. The decorative sheet according to claim 2, wherein the protrusions are spaced apart from each other. The decorative sheet according to claim 2, wherein the width of the protrusions is greater than the width of the air bubbles. The decorative sheet according to claim 2, wherein the width of the protrusions is 2 μm or more and 25 μm or less. The decorative sheet according to claim 2, wherein the height of the protrusions is 1 μm or more and 10 μm or less. the first layer includes a second convex portion protruding toward the second layer in a region outside the alignment mark region,
The decorative sheet according to claim 2 , wherein the second convex portion is located in a portion overlapping the decorative layer. The decorative sheet according to claim 8, wherein the width of the second convex portion is greater than the width of the first convex portion. The decorative sheet according to claim 8, wherein the height of the second convex portion is greater than the height of the convex portion. the second layer includes a first surface and a second surface opposite the first surface;
the second layer faces the first layer at the second surface,
The decorative sheet according to claim 1 , wherein the first surface is flat in a portion overlapping the alignment mark area. The decorative sheet according to claim 8, wherein the decorative layer includes a molded resin layer including a second recess corresponding to the second protrusion. The decorative sheet according to claim 12, wherein the decorative layer includes a printed layer superimposed on the molded resin layer. An alignment mark area is provided,
A base sheet containing air bubbles in the alignment mark area. The alignment mark area is provided with a convex portion that protrudes in a normal direction of the base sheet,
The base sheet according to claim 14 , wherein the air bubbles are located at least either inside the protrusions or at positions facing the protrusions. supplying a curable resin composition to a plate surface including a plate recess;
and curing the curable resin composition.
A method for producing a substrate sheet, comprising curing a curable resin composition in a state in which air bubbles are present in the curable resin composition. The method for manufacturing a base sheet according to claim 16, wherein the plate recess includes a first plate recess located in an alignment mark formation area of the plate surface, and a second plate recess located in a linear pattern formation area of the plate surface. A step of producing the base sheet by the production method according to claim 16;
and forming a layer overlying the base sheet by curing the curable resin composition provided on the base sheet,
the base sheet includes an alignment mark region in which the air bubbles are contained,
The method for manufacturing a decorative sheet, wherein the curable resin composition is supplied onto the base sheet that is positioned by detecting the position of the alignment mark area.

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