JP4266049B2 - Method for producing decorative sheet having concavo-convex pattern - Google Patents

Description

[0001]
[Field of the Invention]
The present invention has a concavo-convex pattern that is applied to the manufacture of parts for home appliances such as console panels, center clusters, switchboards and other automobile interior parts, building materials such as walls and pillars, and display panels such as rice cookers and washing machines. The present invention relates to a method for manufacturing a decorative sheet.
[0002]
[Prior art]
Conventionally, in order to provide a three-dimensional design on the surface of molded products such as automobile interior parts and building materials, a decorative sheet having a concavo-convex pattern with a height difference of about 0.5 to 100 μm is used and inserted into an injection mold. A method of injecting molten resin from the back side, a method of applying an adhesive and lapping on the surface of the molded product, a heat-sensitive or pressure-sensitive adhesive layer as a layer structure, The method of sticking by adding was performed.
[0003]
Some of the decorative sheets used for decoration have a printed layer such as a pattern layer and a metal thin film layer on the concavo-convex pattern surface formed on the base sheet, and the manufacturing method thereof includes (1) Base After forming one surface of the sheet into a concavo-convex shape by embossing, a method of forming a printed layer such as a pattern layer and a metal thin film layer on the concavo-convex pattern surface, or (2) a pattern on one surface of the substrate sheet A method of forming a printed layer such as a layer and a metal thin film layer, and then shaping the surface of the base sheet on which the vapor deposition pattern is formed into an uneven shape by embossing is known.
[0004]
[Problems to be solved by the invention]
However, the conventional method for producing a decorative sheet having a concavo-convex pattern has the following problems in production. In the case of the manufacturing method of (1) above, when a deep concavo-convex pattern with an elevation difference of 1 to 5 μm is formed on the base sheet 1 (see FIG. 23), general-purpose such as offset printing, gravure printing, and screen printing In the printing method, the printing ink 9 on the side surface of the concave and convex portion 1a hangs down, and the printing ink 9 is not placed near the entrance of the concave portion 1a, or the thickness of the printing ink 9 and the area covered with the printing ink 9 on the bottom surface of the concave portion 1a May increase (see FIG. 24). Furthermore, when the unevenness pattern is extremely deeply engraved with a height difference exceeding 5 μm, the general-purpose printing method cannot even print in the recesses 1a of the uneven pattern (see FIG. 25).
[0005]
Moreover, in the case of the manufacturing method of said (2), when a deeply carved uneven | corrugated pattern is formed in a base material sheet, a metal thin film layer may be cracked at the time of embossing. Moreover, since a metal thin film layer is extended by embossing and thickness becomes thin, it may show locally.
[0006]
Accordingly, an object of the present invention is to solve the above-described problem, and a desired printed layer can be accurately formed in the concave and convex portions of the concavo-convex pattern on the base sheet, and the metal thin film layer can be cracked. It is providing the manufacturing method of the sheet | seat for decoration which has an uneven | corrugated pattern which does not show through.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, the method for producing a decorative sheet having a concavo-convex pattern according to the present invention is such that one surface of a base sheet is formed into a concavo-convex shape by embossing so that the height difference exceeds 5 μm and is 50 μm or less. In a method for producing a decorative sheet having a pattern and having at least a printed layer and a metal thin film layer formed on the concavo-convex pattern surface, printing that overlaps at least part of or all of the concave portions of the concavo-convex pattern on the substrate sheet The layer was formed before embossing, and the metal thin film layer was formed after embossing.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the method for producing a decorative sheet having a concavo-convex pattern according to the present invention will be described in detail with reference to the drawings.
[0009]
FIGS. 1 to 10, FIGS. 12 to 14, and FIGS. 16 to 22 are diagrams showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention, and FIGS. 11 and 15 illustrate the concavo-convex pattern according to the present invention. It is a figure which shows one Example of the peeling process after integrating the decorative sheet | seat which has with a molded article. In the figure, 1 is a substrate sheet, 1a is a concave portion, 1b is a convex portion, 2 is a printed layer, 2a is a pattern layer, 2b is an anchor layer, 2c is a release layer, 2d is a release layer, 2e is a solvent-soluble resin layer 3 is a metal thin film layer, 4 is an embossing roll, 5 is a rubber roll, 6 is a molded product, 7 is a convex solvent-soluble resin layer, and 8 is a convex pattern layer.
[0010]
A feature of the method for producing a decorative sheet having a concavo-convex pattern according to the present invention is that a metal layer is formed before embossing by forming a printed layer 2 that overlaps at least a part or all of the concavo-convex recesses 1a on the base sheet 1. The thin film layer 3 is formed after embossing (see FIG. 1).
[0011]
The material of the base sheet 1 is usually a resin sheet such as acrylic resin, vinyl chloride resin, urethane resin, nylon resin, polypropylene resin, polyethylene resin, polyester resin, vinyl acetate resin, or a composite of each of the above sheets. What is used as the base material sheet 1 of the decorative sheet can be used.
[0012]
The printed layer 2 at least overlaps with a part or the whole of the concave portion 1a of the concave and convex pattern after embossing. Therefore, it is a flexible layer that does not crack even by embossing. The printing layer 2 is formed as a single layer or two or more layers. As the material of the printing layer 2, materials suitable for the function of the layer are used as described later. As a printing method of the printing layer 2, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method can be used.
[0013]
After the printing layer 2 is formed on the base material sheet 1, the surface having the printing layer 2 of the base material sheet 1 is shaped into an uneven shape by embossing. As the embossing means, a sheet to be shaped between rotating rolls composed of an embossing roll 4 having an uneven pattern engraved on the cylinder surface and a rubber roll 5 coated with rubber on the cylinder surface is formed on the base sheet 1. A method is generally used in which the surface having the printing layer 2 is fed so as to be on the embossing roll 4 side and heated and pressed by being sandwiched between both rolls. By carrying out like this, the uneven | corrugated pattern contrary to the engraving of the embossing roll 4 is formed in the surface at the side of the embossing roll 4 of the base material sheet 1, and the printing layer 2 is provided along the uneven | corrugated pattern surface of the base material sheet 1. It becomes a form. Since the printed layer 2 is formed on the base sheet 1 before embossing, it is accurately formed in a desired pattern and thickness in the concave and convex portion 1a. The embossing means is not limited to the above means as long as the substrate sheet 1 can be shaped into an uneven shape after the printing layer 2 is formed. The concavo-convex pattern is formed in a range of more than 5 μm in height difference and 50 μm or less . Lever beyond the difference in height 5 [mu] m, deep very carving, to crisp stereoscopic effect is obtained, it is also possible height difference is shaped into fine irregularities such as fine line pattern as long 50μm or less.
[0014]
The metal thin film layer 3 is a layer for expressing metallic luster, and is provided on the surface having the printed layer 2 of the base sheet 1 after embossing. It is formed by a vacuum deposition method, a sputtering method, an ion plating method, a plating method, or the like. In this case, a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, or zinc, or an alloy or compound thereof is used depending on the metallic luster color to be expressed. The film thickness of the metal thin film layer 3 is generally 0.005 μm to 0.5 μm.
[0015]
As the printing layer 2, a pattern layer 2a for decoration can be formed (see FIGS. 2, 3, and 4). Examples of the material of the pattern layer 2a include resins such as polyvinyl resins, polyamide resins, polyester resins, polyacrylic resins, polyurethane resins, polyvinyl acetal resins, polyester urethane resins, cellulose ester resins, and alkyd resins. In addition, it is preferable to use a pigment or dye containing an appropriate color as a colorant. In addition, the pattern layer 2a includes translucent coloring and light shielding coloring. In the case of providing a multicolored pattern or a pattern having gradation expression, an offset printing method or a gravure printing method is particularly suitable as a method for forming the pattern layer 2a. The dry film thickness of the pattern layer 2a is generally 0.5 μm to 30 μm.
[0016]
As the printing layer 2, an anchor layer 2b that improves the adhesion of the metal thin film layer 3 can be formed (see FIGS. 5, 6, and 7). As the material of the anchor layer 2b, a two-component cured urethane resin, a thermosetting urethane resin, a melamine resin, a cellulose ester resin, a chlorine-containing rubber resin, a chlorine-containing vinyl resin, a polyacrylic resin, an epoxy resin, A vinyl-based copolymer resin resin may be used. The dry film thickness of the anchor layer 2b is generally 0.5 μm to 10 μm.
[0017]
As the printing layer 2, a release layer 2c can be formed (see FIGS. 8, 9, and 10). When the decorative sheet is inserted into the injection mold and the molten resin is injected from the back side and then the base sheet 1 is peeled off, the release layer 2c is formed on the entire surface of the base sheet 1. Thereby, the peelability of the base material sheet 1 can be improved. The release layer 2c is released together with the base sheet 1 when the base sheet 1 is peeled (see FIG. 11). As the material of the release layer 2c, melamine resin release agent, silicone resin release agent, fluororesin release agent, cellulose derivative release agent, urea resin release agent, polyolefin resin release agent Paraffin type release agents and composite release agents thereof may be used. The dry film thickness of the release layer 2c is generally 0.2 μm to 10 μm.
[0018]
As the printing layer 2, a release layer 2d can be formed (see FIGS. 12, 13, and 14). When the release layer is inserted into the injection mold and the molten resin is injected from the back side and then the base sheet 1 is peeled off, the release layer is applied to the entire surface of the base sheet 1 or the release layer 2c. By forming the release layer 2d, the peelability from the base sheet 1 or the release layer 2c can be improved. Note that the release layer 2d remains on the molded product side and becomes the outermost surface when the base sheet 1 is peeled (see FIG. 15). Examples of the material for the release layer 2d include polyacrylic resins, polyester resins, polyvinyl chloride resins, cellulose resins, rubber resins, polyurethane resins, polyvinyl acetate resins, and vinyl chloride-vinyl acetate. A copolymer such as a polymer resin or an ethylene-vinyl acetate copolymer resin may be used. When the peeling layer 2d is required to have hardness, a photo-curing resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. The release layer 2d can also be colored. The dry film thickness of the release layer 2d is generally 0.5 μm to 30 μm.
[0019]
As the printing layer 2, a solvent-soluble resin layer 2e can be formed in a portion where the metal thin film layer 3 is not required (see FIGS. 16 and 17). After the metal thin film layer 3 is applied over the entire surface (see FIG. 18), solvent cleaning is performed to remove an unnecessary metal vapor deposition film together with the solvent-soluble resin layer 2e (see FIG. 19). A solvent often used in this case is water or an aqueous solution. As a material for the solvent-soluble resin layer 2e, a water-soluble urethane resin, a water-soluble acrylic resin, a polyvinyl alcohol resin, a water-soluble polyester resin, or the like may be used. The dry film thickness of the solvent-soluble resin layer 2e is generally 0.5 μm to 20 μm.
[0020]
In the present invention, a coat layer can be formed on the print layer 2 together with the print layer 2. The coating layer is formed by a coating method such as a reverse coating method, a roll coating method, a comma coating method, or a spray coating method, and can be formed with a solid surface by filling the concave portion 1a of the concavo-convex pattern. There is no such problem. Therefore, the coat layer may be formed before embossing, or may be formed after embossing or after formation of metal thin film layer 3. As the coat layer, a solid pattern layer can be formed. Moreover, an anchor layer can be formed as a coat layer. The same material as each layer as the printed layer 2 can be used for the pattern layer and the anchor layer as the coat layer.
[0021]
Furthermore, this invention can form one or two or more convex printing layers only with the convex part 1b of the uneven | corrugated pattern on the base material sheet 1 with the printing layer 2. FIG. This convex printed layer may be formed before embossing, or may be formed after embossing or after formation of metal thin film layer 3. As the convex printing layer, the convex solvent-soluble resin layer 7 can be formed (see FIG. 20). After the metal thin film layer 3 is applied over the entire surface, solvent cleaning is performed to remove an unnecessary metal vapor deposition film together with the convex solvent-soluble resin layer 7 (see FIG. 21). Moreover, the convex pattern layer 8 can be formed as a convex printing layer (refer FIG. 22). The same material as the solvent-soluble resin layer 2e and the pattern layer 2a as the printing layer 2 can be used for the convex-part solvent-soluble resin layer 7 and the convex-part pattern layer 8, respectively. As a printing method for the convex printing layer, a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, or the like can be used.
[0022]
Moreover, this invention can form the contact bonding layer for adhesion | attachment with a molded article in the surface opposite to the surface which has the uneven | corrugated pattern of the base material sheet 1, or a surface which has an uneven | corrugated pattern. The formation of this adhesive layer is limited to after the formation of the metal thin film layer 3 when it is provided on the surface having the concavo-convex pattern of the substrate sheet 1, but before embossing when it is provided on the surface opposite to the surface having the concavo-convex pattern. Or before the formation of the metal thin film layer 3. As the material of the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molded product to be decorated is appropriately selected and used. For example, when the material of the molded product is an acrylic resin, an acrylic resin or the like may be used. Also, if the material of the molded product is polyphenylene oxide / polystyrene resin, polycarbonate resin, styrene copolymer resin, polystyrene blend resin, acrylic resin, polystyrene resin, polyamide resin that has an affinity for these resins It is recommended to use resin. As a method for forming the adhesive layer, a normal printing method such as an offset printing method, a gravure printing method, a screen printing method, or a coating method such as a reverse coating method, a roll coating method, a comma coating method, or a spray coating method may be used. it can. Further, an adhesive sheet may be attached as the adhesive layer. The dry film thickness of the adhesive layer is generally 0.5 μm to 30 μm.
[0023]
【Example】
Example 1
The decorative sheet used for the wood grain interior panel of the automobile was manufactured as follows.
[0024]
A gravure printing method uses a 2 μm-thick micro-pipe first pattern layer using a 100 μm-thick acrylic resin sheet as a base sheet and acrylic resin-based ink containing black pigment (containing 10% carbon black) on one side. A second pattern layer having a conduit pattern of 1.5 μm in thickness using an acrylic resin-based ink containing a brown pigment (containing 5% iron oxide) was formed thereon by a gravure printing method. Furthermore, an anchor layer having a thickness of 10 μm was formed on the entire surface by gravure printing using a vinyl chloride resin-based ink containing a yellow pigment (containing 1% benzidine yellow) having no occlusion.
[0025]
Next, the surface provided with the printed layer of the base sheet is shaped into an uneven shape by heating and pressing through the sheet so that the surface provided with the printed layer between the embossing roll and the rubber roll is on the embossing roll side. In addition, a concavo-convex pattern with a height difference of 7 μm that expresses the three-dimensional effect of the fine grained micropipe was provided. In addition, the recessed part of the uneven | corrugated pattern on a base material sheet and said printing layer are designed to overlap.
[0026]
Next, a decorative sheet was obtained by providing a metal thin film layer made of aluminum having a thickness of 0.05 μm on the entire surface of the base sheet provided with a printed layer by a vacuum deposition method.
[0027]
In the decorative sheet having a concavo-convex pattern obtained in this way, the desired printed layer is accurately formed in the concavo-convex recesses on the base sheet, and the metal thin film layer is not cracked or transparent. Met. After that, the decorative sheet is set in a movable mold for injection molding, vacuum molded, and after closing the mold, acrylonitrile butadiene styrene resin containing talc is injected toward the concavo-convex pattern surface to obtain acrylonitrile butadiene styrene resin. Can be solidified to form a resin molded product, and at the same time, a decorative sheet is integrally bonded to the surface thereof to obtain a wood grain interior panel of an automobile.
[0028]
Example 2
In the following manner, a decorative sheet used for the stone-like building material was manufactured.
[0029]
A 100 μm thick polypropylene sheet is used as a base sheet, and a 2 μm thick stone pattern pattern layer is formed by gravure printing on one side using a vinyl chloride resin ink containing white pigment (containing 30% iron oxide). did. An anchor layer having a thickness of 4 μm using a chlorine-containing rubber-based resin ink was formed on the entire surface by gravure printing. Furthermore, a solvent-soluble resin layer having a thickness of 2 μm using a water-soluble acrylic resin-based ink was formed on the entire surface by a gravure printing method in a portion where the metal thin film layer was not required.
[0030]
Next, the surface provided with the printed layer of the base sheet is shaped into an uneven shape by heating and pressing through the sheet so that the surface provided with the printed layer between the embossing roll and the rubber roll is on the embossing roll side. In addition, a concavo-convex pattern with a height difference of 12 μm, which expresses the three-dimensional appearance of the grain, was provided. In addition, the recessed part of the uneven | corrugated pattern on a base material sheet and said printing layer are designed to overlap.
[0031]
Next, a metal thin film layer made of aluminum having a thickness of 0.05 μm was provided on the entire surface of the base sheet on which the printed layer was provided by vacuum deposition.
[0032]
Next, after washing with water and removing the unnecessary metal deposition film together with the solvent-soluble resin layer, a black pigment (containing 10% carbon black) is seen through in the portion where the pattern layer of the stone pattern is not formed. A decorative sheet was obtained by forming a solid pattern layer of 15 μm in thickness using a urethane resin-based ink with a reverse coating method.
[0033]
In the decorative sheet having a concavo-convex pattern obtained in this way, the desired printed layer is accurately formed in the concavo-convex recesses on the base sheet, and the metal thin film layer is not cracked or transparent. Met. Thereafter, an adhesive is applied to the surface of the decorative sheet having the concavo-convex pattern, and the decorative sheet is attached to the surface of the MDF (medium density fiber board), whereby a stone-like building material can be obtained.
[0034]
【The invention's effect】
Since the method for manufacturing a decorative sheet having a concavo-convex pattern according to the present invention has the above-described configuration and operation, the following effects are exhibited.
[0035]
That is, in the method for producing a decorative sheet having a concavo-convex pattern according to the present invention, the embossing is performed before forming a printed layer at least overlapping a part or all of the concavo-convex recesses on the base sheet, Since the formation is performed after embossing, a desired printed layer can be accurately formed in the concave portion of the concavo-convex pattern which is extremely deeply carved on the base material sheet, and the metal thin film layer does not break or show through.
[Brief description of the drawings]
FIG. 1 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 2 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 3 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 4 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 5 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 6 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 7 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 8 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 9 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 10 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 11 is a view showing an example of a peeling step after the decorative sheet having a concavo-convex pattern according to the present invention is integrated with a molded product.
FIG. 12 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 13 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 14 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 15 is a view showing an example of a peeling step after the decorative sheet having a concavo-convex pattern according to the present invention is integrated with a molded product.
FIG. 16 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 17 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 18 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 19 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 20 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 21 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 22 is a diagram showing an example of a process for forming a decorative sheet having a concavo-convex pattern according to the present invention.
FIG. 23 is a diagram showing the state of printing ink in the concave portions of the concave-convex pattern formed on the base sheet.
FIG. 24 is a diagram showing the state of printing ink in the concave portions of the concave-convex pattern formed on the base sheet.
FIG. 25 is a diagram showing the state of printing ink in the concave portions of the concave-convex pattern formed on the base sheet.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Base sheet 1a Concave part 1b Convex part 2 Print layer 2a Picture layer 2b Anchor layer 2c Release layer 2d Release layer 2e Solvent-soluble resin layer 3 Metal thin film layer 4 Embossing roll 5 Rubber roll 6 Molded article 7 Convex solvent-soluble resin layer 8 Convex pattern layer 9 printing ink

Claims (1)

A decoration in which one surface of a base sheet is formed into a concavo-convex shape by embossing to have a concavo-convex pattern with a height difference of more than 5 μm and 50 μm or less, and at least a printed layer and a metal thin film layer are formed on the concavo-convex pattern surface In the method for producing a sheet for use in a sheet, the printed layer at least overlapping with a part or all of the concave and convex portions of the concavo-convex pattern on the base sheet is formed before embossing, and the metal thin film layer is formed after embossing. A method for producing a decorative sheet having a concavo-convex pattern.

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