JP4952020B2 - Glossy decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative sheet which has an embossed surface and to which high gloss is given by embossing. <P>SOLUTION: (1) The decorative sheet has a surface 60&deg; gloss value of 35-50, and is made by a manufacturing method including a process 1 for preparing a copper substrate having an uneven pattern, a process 2 for laminating a chromium layer at least 30 &mu;m in thickness on the uneven pattern of the copper substrate, a process 3 for sandblasting the chromium layer to make the surface roughness Rz of the chromium layer 3-5 &mu;m, and a process 4 for further laminating the chromium layer on the sandblasted surface so that the final surface roughness Rz of the chromium layer is 2-4 &mu;m. The surface of the decorative sheet is embossed by an embossing plate having a surface roughness Rz of 2-4 &mu;m, and is to be laminated on an object material. <P>COPYRIGHT: (C)2008,JPO&amp;INPIT

Description

  The present invention relates to a glossy decorative sheet provided with an effective pattern as a surface decoration material for building materials such as furniture and joinery, and a decorative board on which a glossy decorative sheet is laminated.

  The wooden decorative sheet is used by sticking to the surface of the wooden board for the purpose of protecting the surface of the wooden board, decoration, and the like. And the decorative board obtained by this is used for various building materials, furniture, etc.

  As such a decorative sheet and decorative plate, for example, a transparent acrylic resin sheet is laminated on a transparent base sheet, and the rear surface can be seen through at least one sheet surface of the transparent base sheet or the transparent acrylic resin sheet. A decorative sheet provided with a wood grain pattern layer, wherein the transparent base sheet contains high-density polyethylene or isotactic polypropylene, rubber and an inorganic filler. A wooden decorative board (Patent Document 1) to which the decorative sheet is attached is known. These decorative sheets are embossed to give the surface a concavo-convex pattern.

  The embossing of these decorative sheets is mainly performed by an embossed plate subjected to glass bead blasting. That is, an embossed plate in which a blast pattern is formed by spraying a projection material onto the surface of the embossing cylinder by a glass bead blasting method is used. In glass bead blasting, generally spherical glass particles having a Mohs hardness of about 5 are used as the projection material.

However, the embossed plate cannot provide sufficient gloss to the decorative sheet, and there is room for further improvement in terms of gloss imparting by embossing. That is, conventionally, in order to obtain high gloss, embossing is not performed or it is limited to embossing of a flat design. However, it is desired that high gloss can be realized even when a complicated pattern is applied by embossing.
JP-A-11-240113

  Accordingly, the main object of the present invention is to provide a decorative sheet having an embossed front surface and having a high gloss imparted by embossing.

  The present inventor has found that the above object can be achieved when embossing is carried out by using an embossed plate produced by a specific method as a result of intensive research in view of the problems of the prior art. The invention has been completed.

That is, this invention relates to the manufacturing method of the following embossing plate and embossing plate .

1. The first chromium layer with a thickness of 30μm or more on the uneven pattern side of the copper substrate table surface roughness Rz of 3~5μm having a concave convex pattern, the surface roughness Rz on the first layer of chromium 2~4μm Embossed plate with two chrome layers stacked in order .
2. Item 2. The embossed plate according to Item 1, wherein the second chromium layer has a thickness of 15 to 30 µm.
3. A first chrome layer having a thickness of 30 μm or more and a surface roughness Rz of 3 to 5 μm on the concavo-convex pattern side of a copper substrate having a concavo-convex pattern, and a second chrome having a surface roughness Rz of 2 to 4 μm on the first chrome layer A method for producing an embossed plate in which layers are laminated in order,
-Step 1 of preparing a copper base material having an uneven pattern,
A step 2 of laminating a first chromium layer having a thickness of 30 μm or more on the concavo-convex pattern of the copper substrate;
A step 3 of sandblasting the first chromium layer so that the surface roughness Rz of the first chromium layer is 3 to 5 μm; and
Step 4 of further laminating a second chromium layer so that the surface roughness Rz of the chromium layer is finally 2 to 4 μm with respect to the sandblast surface,
The manufacturing method of an embossing plate which has these processes in order.
4). Item 4. The method for producing an embossed plate according to Item 3, wherein the second chromium layer has a thickness of 15 to 30 µm.
5. Item 5. The method for producing an embossed plate according to Item 3 or 4, wherein the sandblasting is performed using a projection material, and the projection material is inorganic particles having a Mohs hardness of 6 to 9.
6). Item 6. The method for producing an embossed plate according to Item 5, wherein the projection material is further inorganic particles having a particle diameter of 1 to 100 µm.
7). Item 7. The method for producing an embossed plate according to Item 5 or 6, wherein the projection material is further inorganic particles selected from iron, silicon carbide, alumina, chromium oxide and iron oxide.

Below, a method for manufacturing the embossing and embossing plate of the present invention.

1. The decorative sheet of the present invention is a decorative sheet for use by being laminated on an adherend,
(1) The sheet has a front surface 60 ° gloss value of 35-50,
(2) The front surface of the sheet is embossed by an embossing plate having a surface roughness Rz of 2 to 4 μm, which is obtained by a production method having the following steps in order.
-Step 1 of preparing a copper base material having an uneven pattern,
-Step 2 of laminating a chromium layer with a thickness of 30 μm or more on the copper substrate uneven pattern,
Step 3 of sandblasting the chromium layer so that the surface roughness Rz of the chromium layer is 3 to 5 μm, and finally the surface roughness Rz of the chromium layer is 2 to 4 μm with respect to the sandblasting surface. Step 4 of further laminating a chromium layer as described above.

  The decorative sheet of the present invention has a large 60 ° gloss value of 35 to 50 on the front surface. Such glossy characteristics are achieved by using an embossed plate produced by the production method having the steps 1 to 4 described above. Further, since the decorative sheet of the present invention is embossed, after the decorative sheet is laminated with the adherend, foreign matter inevitably sandwiched between the decorative sheet and the adherend, surface irregularities of the adherend (so-called Substrate duck), unevenness (so-called adhesive duck) due to uneven application of the adhesive between the decorative sheet and the adherend, and the like are inconspicuous. Such a characteristic is easily obtained particularly when the embossed pattern is a wood grain conduit pattern.

≪Embossed version≫
The embossed plate is an embossed plate having a surface roughness Rz of 2 to 4 μm, and is obtained by a production method having the following steps in order.
(A) Step 1 of preparing a copper substrate having an uneven pattern,
(B) Step 2 of laminating a chromium layer having a thickness of 30 μm or more on the concave-convex pattern of the copper base material,
(C) Step 3 of sandblasting the chromium layer so that the surface roughness Rz of the chromium layer is 3 to 5 μm, and (D) The surface roughness Rz of the chromium layer is finally 2 with respect to the sandblasting surface. Step 4 of further laminating a chromium layer so as to be ˜4 μm.

Process 1
In step 1, a copper substrate having a concavo-convex pattern is prepared. Here, the concavo-convex pattern is a pattern to be applied to the front surface of the decorative sheet by embossing. Examples of the concavo-convex pattern include directional patterns such as a wood grain conduit pattern, a float pattern (a concavo-convex pattern of raised annual rings), a hairline, and a satin texture, and a desired pattern can be appropriately selected from these patterns. . Among these, the wood grain conduit pattern is suitable as an uneven pattern imparted to the front surface of the woody decorative sheet.

  The method for imparting the concavo-convex pattern to the copper base material is not limited. For example, a concavo-convex pattern can be imparted to the copper base material by a known corrosion method or the like. An example of the uneven | corrugated pattern provision process is shown. First, after creating a pattern of a predetermined concavo-convex pattern (wood conduit pattern, float pattern, etc.) on a computer screen, an endless file is created so that the image of the pattern is endless with the circumference of the cylinder of the embossed plate. To create an endless file, software for generating an endless pattern may be designed, and the file joint portion may be corrected with commercially available retouching software. The concavo-convex pattern data of the endless file is directly output and baked on a copper base material (embossed cylinder) coated with a resist photosensitive solution using a laser stream plate making apparatus. In this case, the width feed function of the laser stream plate making apparatus can be used in the cylinder width direction. Subsequently, a desired embossed concavo-convex pattern can be imparted to the copper base material by performing development, corrosion, and resist peeling of the cylinder. In addition, the surface roughness of the uneven | corrugated pattern provided to a copper base material is not limited, and conventionally, it may be the same as the case where an uneven | corrugated pattern is provided to a copper base material (embossing cylinder). In addition, it is preferable that the Mohs hardness of a copper base material is about 3 (about 2-4).

Process 2
In step 2, a chromium layer having a thickness of 30 μm or more is laminated on the concavo-convex pattern of the copper base material. The chromium layer can be easily applied by plating, for example. In addition, it is preferable that the Mohs hardness of a chromium layer is about 7 (about 6-8).

  The laminated thickness of the chromium layer may be 30 μm or more, and preferably about 30 to 50 μm. The laminated thickness may be a thickness that does not damage the chromium layer by the sandblasting process in step 3.

Process 3
In step 3, the chromium layer is sandblasted so that the surface roughness Rz of the chromium layer is 3 to 5 μm. Here, Rz is Rz of the surface on which the blast pattern is formed, and is not the surface roughness in consideration of unevenness such as a wood grain conduit pattern. In addition, Rz in this specification is the ten-point average roughness prescribed | regulated to JISB0601, and is the value measured on measurement length 4mm and cut-off value 0.8mm conditions.

  As the projection material used for the sandblasting treatment, inorganic particles such as iron, silicon carbide, alumina, chromium oxide, iron oxide and the like having a particle diameter of about 1 to 100 μm can be used. The shape of the inorganic particles is not limited, but is generally indefinite. It is preferable that the inorganic particles have a Mohs hardness of about 7 (about 6 to 9). The sandblast treatment can be performed by spraying the inorganic particles as a projection material, for example, from the tip of the nozzle to the surface of the chromium layer by the force of compressed air.

Process 4
In step 4, a chromium layer is further laminated on the sandblast surface so that the surface roughness Rz of the chromium layer is finally 2 to 4 μm. The laminated thickness of the chromium layer is not limited, but is about 15 to 30 μm. The chromium layer can be easily applied by plating, for example.

  In Step 4, since it is meaningful to laminate the chromium layer, Rz of the chromium layer obtained in Step 4 is set to be lower than that of the sandblast surface obtained in Step 3.

  The embossed plate obtained through the above steps 1 to 4 has a specific sandblast pattern resulting from the sandblasting process in addition to the uneven pattern (embossed uneven pattern such as a wood grain conduit pattern) to be applied to the decorative sheet. When the outermost surface of the decorative sheet is embossed using such an embossed plate, a sandblast pattern is provided in addition to the embossed uneven pattern as shown in FIG. And by providing such a sandblast pattern, the front surface of the decorative sheet becomes highly glossy (60 ° gloss value is 35 to 50).

≪Composition of makeup sheet≫
The configuration of the decorative sheet of the present invention is not limited, and the configuration of a known decorative sheet can also be adopted. In particular, in the present invention, a decorative sheet having at least a surface protective layer made of an ionizing radiation curable resin is preferable as the outermost surface layer. That is, since the surface protective layer is made of an ionizing radiation curable resin, more excellent scratch resistance and the like can be exhibited.

  When the preferable aspect of a decorative sheet is given, the decorative sheet which has at least a base material sheet, a pattern layer, a transparent resin layer, and a surface protective layer in order with respect to a to-be-adhered material is mentioned, for example. Hereinafter, each of these layers will be described.

The base material sheet and the transparent resin layer The base material sheet and the transparent resin layer can be made of a material (resin) used in a known decorative sheet, except that the latter is transparent.

  As a resin used for forming these layers, for example, a thermoplastic resin can be suitably used. Specifically, soft, semi-rigid or rigid polyvinyl chloride, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene / acrylic acid ester copolymer Polymers, ionomers, acrylic esters, methacrylic esters and the like can be mentioned. In the present invention, a polyolefin resin such as polypropylene is particularly preferable as the transparent resin layer.

  These layers may be colored as necessary. In this case, it can color by mix | blending a coloring material (a pigment or dye) with the above thermoplastic resins. Examples of the colorant include inorganic pigments such as titanium white, zinc white, petal, vermilion, ultramarine, cobalt blue, titanium yellow, and carbon black, isoindolinone, Hansa yellow A, quinacridone, permanent red 4R, phthalocyanine blue, and indus. Examples include organic pigments (including dyes) such as Ren Blue RS and Anine Phosphorus Black, metal pigments such as aluminum and brass, pearlescent pigments made of foil powder such as titanium dioxide-coated mica and basic lead carbonate, etc. It is done. These can be used alone or in combination of two or more. Further, the addition amount of the colorant may be appropriately set according to the desired color tone.

  In addition, these layers include a filler, a foaming agent, a flame retardant, a lubricant, an antistatic agent, an antioxidant, an ultraviolet absorber, a light stabilizer, a radical scavenger, and a soft component (for example, rubber) as necessary. Various additives such as these may be contained.

  A flame retardant is added in order to provide flame resistance. For example, chlorinated paraffin, tricresyl phosphate, chlorinated oil, tetrabromophthalic anhydride, tetrabromobisphenol A, dibromopropyl phosphate, tri (2,3-dibromopropyl) phosphate, antimony oxide, hydrous alumina, barium borate, etc. It can be used suitably.

  Antioxidants are added to suppress or prevent oxidative degradation. For example, alkylphenols, amines, quinones and the like are suitable.

  The ultraviolet absorber absorbs ultraviolet rays in a wavelength range of 280 to 450 nm that causes deterioration of the resin (particularly polyolefin resin). Examples thereof include benzophenone-based, salicylate-based, benzotriazole-based, and acrylonitrile-based ultraviolet absorbers. For example, an organic compound having an OH group in the molecule can be used. Specifically, 2- (2′-hydroxy-3 ′, 5′-di-tert-butylphenyl) -5-chlorobenzotriazole, 2- (2′-hydroxy-3′-tert-butyl-5 ′) -Methylphenyl) -5-chlorobenzotriazole, 2- (2'-hydroxy-3'-tert-amyl-5'-isobutylphenyl) -5-chlorobenzotriazole, 2- (2'-hydroxy-3'- 2′-hydroxyphenyl-5-5 such as isobutyl-5′-methylphenyl) -5-chlorobenzotriazole, 2- (2′-hydroxy-3′-isobutyl-5′-propylphenyl) -5-chlorobenzotriazole Chlorobenzotriazole ultraviolet absorbers, 2- (2′-hydroxy-3 ′, 5′-di-tert-butylphenyl) benzotriazo Benzotriazole-based UV absorbers such as 2'-hydroxyphenylbenzotriazole-based UV absorbers such as 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, 2,2'-dihydroxy-4- Methoxybenzophenone, 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, 2,2 ′, 4,4′-tetrahydroxy-4,4′-tetrahydroxybenzophenone UV absorbers, 2,4-dihydroxy Examples include benzophenone ultraviolet absorbers such as 2-hydroxybenzophenone ultraviolet absorbers such as benzophenone, and salicylic acid ester ultraviolet absorbers such as phenyl salicylate and 4-tert-butylphenyl salicylate. In addition, a reactive ultraviolet absorber in which an acryloyl group or a methacryloyl group is introduced into the benzotriazole skeleton can also be used. Of these, benzotriazole-based ultraviolet absorbers are particularly preferred in consideration of absorption wavelength and colorability problems.

  The radical scavenger is added to prevent discoloration due to sunlight, cracks, whitening, strength deterioration, and the like and improve weather resistance. As the radical scavenger, in addition to bis- (2,2,6,6-tetramethyl-4-piperidinyl) sebacate, for example, a hindered amine radical scavenger such as a compound disclosed in JP-B-4-82625, Piperidyl radical scavengers and the like are used.

  The method for forming these layers is not limited, for example, a method in which a preformed sheet or film is laminated on an adjacent layer, or a resin composition containing the resin is applied onto an adjacent layer by melt extrusion. Any of a method and a method of laminating together with adjacent layers can be employed. In the present invention, it is particularly preferable to form a layer by melt extrusion, and it is particularly desirable to form a polyolefin resin by melt extrusion. Specifically, it can be suitably formed by forming an adhesive layer on the pattern layer in advance, and applying a melt-extruded polypropylene thermoplastic elastomer onto the adhesive layer. The melt extrusion method may be carried out according to a known method using a T die or the like, for example.

  The thickness of these layers can be appropriately set depending on the use of the final product, the method of use, and the like, but generally it is preferably in the range of 50 to 250 μm. In particular, the transparent resin layer is preferably about 20 to 200 μm.

  Corona discharge treatment can also be performed on the front surface (front surface) and / or the back surface of the base sheet, if necessary, in order to enhance the adhesion with the adjacent layers. The method and conditions for the corona discharge treatment may follow a known method.

  Moreover, a primer layer can also be formed on the front surface (front surface) and / or the back surface of the base sheet. As a material for forming the primer layer, for example, polyester resins, polyurethane resins, acrylic resins, polycarbonate resins, vinyl chloride / vinyl acetate copolymers, polyvinyl butyral resins, nitrocellulose resins, alkyl titanates, Compounds such as ethyleneimine can also be used. In particular, the primer layer is preferably a two-component curable urethane resin. It is preferable to use fatty acid isocyanate (aliphatic isocyanate) such as hexamethylene diisocyanate (HMDI) as the isocyanate and acrylic polyol as the polyol, because more excellent weather resistance and adhesion can be obtained.

  The primer layer can be formed according to a known printing method, coating method or the like using these as they are or in a state dissolved or dispersed in a solvent.

Picture layer The picture layer (printing layer) can represent characters, symbols, drawings, etc. in addition to the patterns of natural materials such as wood grain and joints.

  The pattern layer can be formed using an ink containing a colorant and a resin binder. As the binder, for example, chlorinated polyolefin such as chlorinated polyethylene and chlorinated polypropylene, polyester resin, urethane resin, acrylic resin, vinyl chloride / vinyl acetate copolymer, cellulose resin, and the like can be used. Or 2 or more types can be used. As the colorant, a known one or a commercially available product can be used. Specifically, the aforementioned colorant can be used.

  The pattern layer can be suitably formed by a known printing method such as gravure printing, offset printing, silk screen printing, or transfer printing from a transfer sheet. For example, printing may be performed using an ink colored by adding a pigment (or dye) so that the pattern layer has a wood grain base color.

Adhesive Layer In the decorative sheet of the present invention, an adhesive layer is preferably interposed between the picture layer and the transparent resin layer.

  The adhesive used in the adhesive layer can be appropriately selected from known or commercially available adhesives according to the components constituting the pattern layer or the transparent resin layer. Examples thereof include thermosetting resins such as polyester resins, polyurethane resins, and epoxy resins, in addition to polyolefin resins such as polyethylene and polypropylene.

  Among these, in this invention, a urethane type resin adhesive is preferable at the point that heat resistance etc. can be improved more. Examples of the urethane resin adhesive include a two-component curable urethane resin having a polyol as a main component and an isocyanate as a crosslinking agent (curing agent).

  The polyol has two or more hydroxyl groups in the molecule. For example, polyethylene glycol, polypropylene glycol, acrylic polyol, polyester polyol, polyether polyol, polycarbonate polyol and the like are used.

  Moreover, as said isocyanate, the polyvalent isocyanate which has a 2 or more isocyanate group in a molecule | numerator is used. For example, aromatic isocyanates such as 2,4-tolylene diisocyanate, xylene diisocyanate, 4,4-diphenylmethane diisocyanate, aliphatics such as hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, hydrogenated diphenylmethane diisocyanate (or Alicyclic) isocyanates are used. Further, adducts or multimers of the above various isocyanates can also be used. Examples thereof include adducts of tolylene diisocyanate and trimers of tolylene diisocyanate.

  If necessary, the adhesion surface can be subjected to known easy adhesion treatment such as corona discharge treatment, plasma treatment, degreasing treatment, and surface roughening treatment.

  What is necessary is just to implement as an adhesion | attachment method according to a well-known method according to the kind etc. of adhesive agent to be used. For example, using a polyolefin resin such as polyethylene or polypropylene, a method of coating on a pattern layer by melt extrusion (extrusion coating method), a thermosetting resin such as a polyester resin, a polyurethane resin, or an epoxy resin, isocyanate, Apply an adhesive such as a crosslinking agent such as amine, a polymerization initiator such as methyl ethyl ketone peroxide, hydroperoxide, azabisisobutyronitrile, a polymerization accelerator such as cobalt naphthenate, dimethylaniline, etc. A dry laminating method can be employed. In the present invention, an adhesive capable of thermocompression bonding is used, and the pattern layer and the transparent resin layer can be laminated by thermocompression bonding.

  In the present invention, a known easy adhesion treatment such as a corona discharge treatment, a plasma treatment, a degreasing treatment, a surface roughening treatment or the like can be applied to the adhesion surface as necessary.

  The thickness of the adhesive layer varies depending on the surface protective layer, the type of adhesive used, and the like, but is usually about 0.1 to 30 μm.

Surface protective layer In the present invention, the surface protective layer is provided as the outermost surface layer. The surface protective layer may be colored as long as it is transparent. Moreover, it may be translucent as long as the pattern layer is visible. By forming the surface protective layer, the surface of the decorative sheet can be easily damaged and the scratch resistance can be improved.

  In the present invention, an ionizing radiation curable resin is used as the surface protective layer. By using an ionizing radiation curable resin, more excellent scratch resistance, weather resistance and the like can be obtained.

  A well-known thing or a commercial item can be used for ionizing radiation curable resin. Specifically, a composition containing at least one of a prepolymer, an oligomer and a monomer having a polymerizable unsaturated bond or an epoxy group in the molecule is used.

  Examples of the prepolymer or oligomer include unsaturated polyesters such as a condensate of unsaturated dicarboxylic acid and polyhydric alcohol. For example, there are methacrylates such as polyester methacrylate, polyether methacrylate, polyol methacrylate, melamine methacrylate, urethane acrylates, acrylates such as polyester acrylate, polyether acrylate, urethane acrylate, polyol acrylate, melamine acrylate, etc. .

  Monomers include styrene monomers such as styrene and α-methylstyrene, acrylic acid such as methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butoxyethyl acrylate, butyl acrylate, and phenyl acrylate. Examples include esters, methacrylic acid esters such as methyl methacrylate, ethyl methacrylate, propyl methacrylate, ethoxymethyl methacrylate, phenyl methacrylate, and lauryl methacrylate.

  As substituted amino alcohol esters of unsaturated acids, acrylic acid-2- (N, N-diethylamino) ethyl, methacrylic acid-2- (N, N-diethylamino) ethyl, acrylic acid-2- (N, N- Dibenzylamino) methyl, acrylic acid-2- (N, N-diethylamino) propyl, and the like.

  In addition, unsaturated carboxylic acid amides such as acrylamide and methacrylamide, ethylene glycol diacrylate, propylene glycol diacrylate, neobenzyl glycol diacrylate, 1,6-hexanediol diacrylate, ethyl carbitol acrylate, diethylene glycol diacrylate, A compound such as triethylene glycol diacrylate, a multifunctional product such as dipropylene glycol diacrylate, ethylene glycol acrylate, diethylene glycol dimethacrylate, or polyethylene glycol diacrylate, and / or having two or more thiol groups in the molecule Polythiol compounds such as trimethylolpropane trithioglycolate, trimethylolpropane trithiopropiolate, There are data pentaerythritol tetra thioglycolic like. Examples of the acrylate monomer having three or more functional groups include trimethylolpropane triacrylate, pentaerythritol hexaacrylate, dipentaerythritol hexamethacrylate, and the like.

  The formation method of the surface protection layer by the ionizing radiation curable resin may be in accordance with a known method. For example, a composition (coating material) containing an ionizing radiation curable resin is prepared, and a coating film is formed using this composition. The coating film may be crosslinked and cured by electron beam irradiation under use conditions (175 keV and 5 Mrad (50 kGy)). When using an ionizing radiation curable resin, it is desirable to previously provide a primer layer (particularly a primer layer made of urethane resin) on the transparent resin layer as a base.

The outermost surface (for example, surface protective layer) of the embossed decorative sheet is embossed with the embossed plate used in the present invention.

  For embossing, for example, after the decorative sheet is heated and softened on a heating drum, it is further heated to 160 to 180 ° C. with an infrared radiation heater, and pressed and shaped with an embossed plate provided with a concavo-convex pattern of a desired shape. , Cooled and fixed. In this invention, as long as the said embossing plate is used as an embossing plate, the embossing machine which installs an embossing plate is not limited. For example, in a known single wafer or rotary embossing machine, an embossing plate replaced with the embossing plate can be used.

2. Decorative plate The decorative sheet of the present invention can be made into a decorative plate by being laminated with an adherend.

Adhering material The adhering material to which the decorative sheet of the present invention is applied is not limited, and the same materials as known decorative sheets can be used. For example, a wood material, a metal, ceramics, plastics, glass, etc. are mentioned. In particular, the decorative sheet of the present invention can be suitably used for a wood material. Specifically, wood materials include veneer, wood veneer, wood plywood, particle board, medium density fiberboard (MDF) made from various materials such as cedar, firewood, firewood, pine, lawan, teak, and melapie. ) And the like.

Lamination on adherend The decorative sheet of the present invention is laminated on various adherends and used as a decorative board. Specifically, in the base sheet, a pattern layer or the like is sequentially laminated on the front surface (front surface), and an adherend is laminated on the back surface.

  The lamination method is not limited. For example, a method of sticking a decorative sheet to an adherend with an adhesive or the like can be employed. What is necessary is just to select an adhesive agent suitably from well-known adhesive agents according to the kind etc. of to-be-adhered material. Examples thereof include polyvinyl acetate, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, ethylene / acrylic acid copolymer, ionomer, butadiene / acrylonitrile rubber, neoprene rubber, natural rubber and the like.

  The decorative board manufactured in this way is, for example, interior decoration materials for buildings such as walls, ceilings and floors, surface decorative boards for furniture such as window frames, doors and handrails, furniture or light electrical appliances, cabinets such as OA equipment. It can be preferably used for a surface decorative board or the like.

  The decorative sheet of the present invention has a large 60 ° gloss value of 35 to 50 on the front surface. Such glossy characteristics are achieved by using an embossed plate produced by the production method having the steps 1 to 4 described above. Further, since the decorative sheet of the present invention is embossed, after the decorative sheet is laminated with the adherend, foreign matter inevitably sandwiched between the decorative sheet and the adherend, surface irregularities of the adherend (so-called Substrate duck), unevenness (so-called adhesive duck) due to uneven application of the adhesive between the decorative sheet and the adherend, and the like are inconspicuous. Such a characteristic is easily obtained particularly when the embossed pattern is a wood grain conduit pattern.

It is a figure which shows the structure of the decorative sheet produced in the Example. It is the microscope observation image A (magnification: 450 times) of the sandblast pattern formed on the surface of the embossing plate produced in Example 1. It is the microscope observation image B (magnification: 450 times) of the glass bead blast pattern formed in the surface of the embossing plate produced in the comparative example 1. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base material sheet 2 Picture layer 3 Transparent resin layer 4 Surface protective layer

  Examples and comparative examples are shown below to explain the present invention more clearly. However, the present invention is not limited to the examples.

Examples 1 to 3 and Comparative Example 1
A decorative sheet having the configuration shown in FIG. 1 was produced. A polypropylene resin film (thickness: 60 μm) was prepared as the base sheet 1 colored with the coloring material. After performing corona discharge treatment on the front and back surfaces, a primer layer using a urethane resin as a binder was formed on the surface by gravure printing. Next, the pattern layer 2 (thickness 2 μm) was formed by gravure printing using an ink having a urethane-based resin as a binder. On the other hand, a primer layer (not shown) using urethane resin as a binder was formed on the back surface by gravure printing.

  Next, a coating solution made of a two-component curable urethane resin was applied on the pattern layer to form an adhesive layer (thickness 3 μm). On top of that, a transparent thermoplastic resin layer 3 (thickness 80 μm) was formed by melt extrusion coating a polypropylene thermoplastic elastomer with a T-die. A two-component curable urethane resin was applied on the transparent resin layer to form a primer layer (thickness: 2 μm).

  Next, after forming a coating film with a gravure coat of urethane acrylate ionizing radiation curable resin, surface protection is achieved by irradiating an electron beam under the conditions of 175 keV and 5 Mrad (50 kGy) to crosslink and cure the coating film. Layer 4 (thickness 15 μm) was formed.

  Finally, the surface protective layer side was heated with an infrared non-contact heater to soften the surface protective layer and the transparent resin layer, and then immediately embossed by heat pressure from the surface of the surface protective layer. Thereby, a decorative sheet having an embossed pattern (wood grain conduit pattern) and a blast pattern on the surface resin layer was obtained.

  The embossed plate was produced by the following method using a commercially available embossed cylinder (copper-plated product).

<Example 1>
After the chrome plating (30 μm) was laminated on the copper plating on which the grain conduit irregularities were formed, the surface roughness Rz of the chrome plating was adjusted to 4 μm by sand blasting. Next, chrome plating was again laminated on the surface to make the surface roughness Rz 3 μm. Thus, an embossed plate (sandblasted product) was produced. FIG. 2 shows a microscopic observation image (450 times) of the sandblast pattern of the embossed plate.

  The Mohs hardness of the copper plating was about 3, and the Mohs hardness of the chrome plating was about 7. As the projection material (inorganic particles) used for the sandblast treatment, amorphous alumina particles having a Mohs hardness of about 9 were used. The plating hardness and the type of projection material are the same for Example 2 and later unless otherwise specified.

<Example 2>
After the chrome plating (30 μm) was laminated on the copper plating with the grain conduit irregularities, the surface roughness Rz of the chrome plating was adjusted to 5 μm by sand blasting. Next, chrome plating was again laminated on the surface to make the surface roughness Rz 4 μm. Thus, an embossed plate (sandblasted product) was produced.

<Example 3>
After the chrome plating (30 μm) was laminated on the copper plating having the grain conduit irregularities, the surface roughness Rz of the chrome plating was adjusted to 3 μm by sandblasting. Next, chrome plating was again laminated on the surface to make the surface roughness Rz 2 μm. Thus, an embossed plate (sandblasted product) was produced.

<Comparative Example 1>
The surface roughness Rz of the copper plating was adjusted to 4 μm by glass bead blasting with respect to the copper plating on which the grain conduit irregularities were formed. Next, chromium plating was laminated on the surface to make the surface roughness Rz 3.6 μm. In this way, an embossed plate (glass bead blasted product) was produced. The microscope observation image (450 times) of the glass bead blast pattern of the embossed plate is shown in FIG.

  In addition, as a projection material used for the glass bead blasting treatment, spherical glass beads having a Mohs hardness of about 5 were used.

Test example 1
The physical properties of the embossed plates prepared in Examples and Comparative Examples and the physical properties of the decorative sheet after embossing were examined. The results are shown in Table 1. The measurement method was as follows.
(1) Embossed plate surface roughness: Rz
The surface roughness (Rz: 10-point average roughness) of the embossed plate was measured according to JIS B 0601 with a measurement length of 4 mm and a cut-off value of 0.8 mm. In addition, Rz is Rz of the surface in which the blast pattern is formed, and is not the surface roughness which considered the unevenness | corrugation of the wood grain conduit pattern.
(2) Embossed surface shape It was judged whether the blast pattern of the embossed plate was similar to FIG. 2 (A) or FIG. 3 (B). In addition, Example 1 is A and Comparative Example 1 is B.
(3) 60 ° gloss value of the front surface of the decorative sheet The 60 ° gloss value of the front surface of the decorative sheet was measured based on the 60 ° specular gloss measurement method defined in JIS Z 8761.

  Table 1 shows that the gloss value of the front surface of the decorative sheet can be effectively improved by using the embossed plate in the present invention. It can be seen that even if the surface roughness of the embossed plate is the same, the gloss value that can be given to the decorative sheet varies depending on the difference in the blasting treatment.

Claims (7)

The first chromium layer with a thickness of 30μm or more on the uneven pattern side of the copper substrate table surface roughness Rz of 3~5μm having a concave convex pattern, the surface roughness Rz on the first layer of chromium 2~4μm Embossed plate with two chrome layers stacked in order . The embossed plate according to claim 1, wherein the second chromium layer has a thickness of 15 to 30 µm. The uneven first chromium layer pattern surface roughness Rz in a thickness of 30μm or more side 3 to 5 [mu] m, the second chromium surface roughness Rz in the first chromium layer is 2~4μm copper substrate having an uneven pattern A method for producing an embossed plate in which layers are laminated in order ,
· Step 1 of preparing a copper substrate having an uneven pattern,
• For uneven pattern of the copper base, laminating the first chromium layer thickness of at least 30μm step 2,
- As the surface roughness Rz of the first chromium layer is 3 to 5 [mu] m, the surface roughness of the first chromium layer step sandblasting 3, and relative-the sandblasting surface, finally the chromium layer Step 4 of further laminating the second chromium layer so that Rz is 2 to 4 μm ,
The manufacturing method of an embossing plate which has these processes in order . The manufacturing method of the embossing plate of Claim 3 whose thickness of the said 2nd chromium layer is 15-30 micrometers. The method for producing an embossed plate according to claim 3 or 4, wherein the sandblasting is performed using a projection material, and the projection material is inorganic particles having a Mohs hardness of 6 to 9. The method for producing an embossed plate according to claim 5, wherein the projection material is further inorganic particles having a particle diameter of 1 to 100 μm. The method for producing an embossed plate according to claim 5 or 6, wherein the projection material is further inorganic particles selected from iron, silicon carbide, alumina, chromium oxide and iron oxide.

Images