JP7009742B2 - Manufacturing method of decorative sheet, decorative sheet, and decorative board - Google Patents

Description

The present invention relates to a method for manufacturing a decorative sheet, a decorative sheet, and a decorative board, and in particular, a method for manufacturing a decorative sheet using a cylindrical printing plate in which a plurality of cells corresponding to a pattern or the like are formed on a printed surface. Regarding decorative sheets and decorative boards.

For example, in gravure printing, a cylindrical printing plate is used, and a large number of minute recesses called cells are formed on the surface of the printing plate according to a pattern or the like, and liquid ink is supplied to the surface of the printing plate. After that, the ink on the surface other than the cell is scraped off, and only the ink in the cell is transferred to a printed object such as paper or a plastic film, so that the pattern is printed (for example, Patent Document 1). ..

Products that use this gravure printing method include decorative paper for knockdown furniture RTA (Ready to Assembly furniture), titanium paper for melamine decorative board, kitchen materials, steel plate laminating sheets, building interior materials, exterior materials, and aluminum. Decorative sheets as surface decorative members for building materials and home appliances, such as sheets for wrapping on base materials, are known. In recent years, the surface has a gloss difference and the illusion of human eyes is used. , A decorative sheet that visually gives a three-dimensional effect has been developed (for example, Patent Document 2).

Japanese Unexamined Patent Publication No. 4-350654 Japanese Unexamined Patent Publication No. 2000-43223

By the way, in the decorative sheet produced by the printing plate provided with the cell, there is room for improvement in the raised design of the unevenness of the outermost surface layer formed on the outermost surface.
The present invention has been made by paying attention to the above points, and an object of the present invention is to provide a method for manufacturing a decorative sheet, a decorative sheet, and a decorative board, which can improve the raised design of the outermost surface layer. And.

In order to solve the problem, in the method for producing a decorative sheet according to one aspect of the present invention, a printing layer and a first surface protective layer are formed in this order on a base sheet and formed on a printing surface of a cylindrical printing plate. The first step of supplying ink to the plurality of cells and transferring the ink in the plurality of cells of the printing plate onto the first surface protective layer to form the first layer.
After the first step, ink is supplied to a plurality of cells formed on the printing surface of the cylindrical printing plate, and the ink in the plurality of cells of the printing plate is transferred onto the first layer to form the second layer. Including a second step of forming a second surface protective layer composed of a first layer and a second layer by forming the ink.
The plurality of cells of the printing plate used in the first step are formed by laser engraving.

Further, the decorative sheet according to one aspect of the present invention has a printed layer formed on a base sheet, a first surface protective layer formed on the printed layer, and a first surface protective layer formed on the first surface protective layer. With 2 surface protection layers
The thickness of the second surface protective layer is 3% or more and 2300% or less of the thickness of the first surface protective layer.
Further, the decorative board according to one aspect of the present invention has a printed layer formed on a base sheet, a first surface protective layer formed on the printed layer, and a first surface protective layer formed on the first surface protective layer. A decorative sheet having two surface protective layers and having a thickness of the second surface protective layer of 3% or more and 2300% or less of the thickness of the first surface protective layer is attached to the substrate.

According to one aspect of the present invention, it is possible to provide a method for producing a decorative sheet, a decorative sheet, and a decorative board, which can improve the raised design of the outermost surface layer.

It is a figure which shows the structure in one Embodiment of a decorative sheet. It is a figure which shows the structure of the printing plate used in one Embodiment of the manufacturing method of a decorative sheet, (a) is a sectional view, (b) is a partial plan view of (a). It is sectional drawing which shows the depth of the cell formed in the printing plate of FIG. It is sectional drawing explaining the manufacturing method of the printing plate used in one Embodiment of the manufacturing method of a decorative sheet. FIG. 3 is a plan view showing another shape of a cell formed on a printing plate used in another embodiment of a method for manufacturing a decorative sheet.

Next, an embodiment of the present invention will be described with reference to the drawings. In the description of the drawings below, the same or similar parts are designated by the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between the thickness and the plane dimensions, the ratio of the thickness of each layer, etc. are different from the actual ones. Therefore, the specific thickness and dimensions should be determined in consideration of the following explanation. In addition, it goes without saying that the drawings include parts having different dimensional relationships and ratios from each other.

Further, the embodiments shown below exemplify devices and methods for embodying the technical idea of the present invention, and the technical idea of the present invention describes the material, shape, structure, and arrangement of components. Etc. are not specified as the following. The technical idea of the present invention may be modified in various ways within the technical scope specified by the claims described in the claims.

(Cosmetic sheet)
<Structure>
FIG. 1 is an example of a decorative sheet 15 manufactured according to an embodiment of a method for manufacturing a decorative sheet, which will be described later.
As shown in FIG. 1, the decorative sheet 15 is formed by laminating a printing layer 17, a first surface protective layer 18, and a second surface protective layer 19 on one surface of a base sheet 16 in this order. .. In such a configuration, the second surface protection layer 19 functions as the outermost surface layer.
The base sheet 16 is made of a resin film, and as the resin film, for example, a colored polypropylene resin is used.
The print layer 17 has a dot pattern of a predetermined pattern printed on the base sheet 16.

The first surface protective layer 18 is formed by applying a transparent or translucent resin containing medium as a main component on the print layer 17.
Further, the second surface protective layer 19 is partially formed on the first surface protective layer 18 and covers a part of the first surface protective layer 18 (for example, a portion of the print layer 17 facing the printing ink). It is a layer. This makes it possible to visually represent the wood grain conduit. The second surface protective layer 19 may be formed, for example, in an area of 0.1% or more on the first surface protective layer 18, and the thickness of the second surface protective layer 19 is the thickness of the first surface protective layer 18. It is 3% or more and 2300% or less. These "thicknesses" are dimensions along the direction in which the base sheet 16, the printing layer 17, the first surface protective layer 18, and the second surface protective layer 19 are laminated.

Further, the second surface protective layer 19 is formed by laminating the first layer 19A and the second layer 19B from the first surface protective layer 18 side. The second surface protection layer 19 constitutes the "outermost surface layer". The second surface protective layer 19 may be laminated with three or more layers.
Further, the shape of the second surface protective layer 19 may be a regular shape including at least a non-circular shape, or may be an irregular pattern shape. Further, the shape may be synchronized with the pattern of the print layer 17, whereby the pattern can be made to look realistic.

(Veneer)
<Structure>
Further, the decorative board of the present embodiment is formed by attaching the decorative sheet 15 to a substrate (not shown). The substrate is a plate-shaped member made of metal or wood. As the metal system, for example, aluminum, steel, stainless steel, and a composite panel can be used. The composite panel includes, for example, a resin layer as a core material and a metal plate (aluminum, galvalume, stainless steel, etc.) attached to both sides of the resin layer. Further, as the wood type, MDF (medium density fiberboard), plywood, and particle board can be used.

(Manufacturing method of decorative sheet)
Next, an embodiment of a method for manufacturing the decorative sheet 15 will be described.
In the method for producing the decorative sheet 15 of the present embodiment, the first surface protective layer 18 is formed on the printed layer 17 formed on one surface of the base sheet 16, and the first surface protective layer 18 is formed on the first surface protective layer 18. A first step and a second step for forming the second surface protective layer 19 are included.
First, ink is supplied to the printing surface of the printing plate 1 to fill the inside of a large number of cells 6 with ink.
Next, the ink on the printing surface other than the cell 6 is scraped off.
Next, the first surface protective layer 18 is laminated on the print layer 17 by applying a transparent resin containing medium as a main component on the upper part of the print layer 17 laminated on the base sheet 16.
After that, the first step and the second step for forming the second surface protective layer 19 on the first surface protective layer 18 are performed.

[First step]
In the first step, ink is supplied to a plurality of cells formed on the printing surface of a cylindrical printing plate (not shown), and the ink in the plurality of cells of the printing plate is applied to the first surface protective layer 18. This is a step of transferring onto the top to form the first layer 19A as the "first edition". This first step is preferably screenless printing.

[Second step]
In the second step, as in the first step, ink is supplied to a plurality of cells formed on the printing surface of the cylindrical printing plate, and the ink in the plurality of cells of the printing plate is applied to the first layer 19A. This is a step of transferring to the top to form the second layer 19B as the "second edition". The second surface protective layer 19 is formed by these first steps and the second steps.
Here, in the present embodiment, the plurality of cells of the printing plate used in the first step are formed by laser engraving.

<Printed version>
2 to 4 are views on the printing plate 1 used for the decorative sheet of the present embodiment.
[Constitution]
As shown in FIGS. 2A and 2B, the printing plate 1 has a cylindrical shape, and is provided on, for example, a nickel-plated layer 3 provided on the surface of an iron cylinder 2 and an upper portion of the nickel-plated layer 3. It has a copper-plated layer 4 and a plurality of cells 6 formed on the surface of the copper-plated layer 4. The plurality of cells 6 include, for example, a plurality of cells 6, 6, 6, ... With different sizes of openings. A large number of the plurality of cells 6, 6, 6, ... Are formed at positions corresponding to the pattern to be printed on the object to be printed.

As shown in FIG. 2B, the cell 6 has a shape having, for example, a quadrangular opening 6a and a flat bottom surface 6b, and the diagonal length d of the opening 6a is set to, for example, 30 to 200 μm. Has been done. Here, the diagonal line refers to the maximum diagonal dimension of the opening.
Here, the planar shapes of the openings 6a of the plurality of cells 6 may be the same shape or may include different shapes as long as they are not circular (including an elliptical shape). Further, the sizes of the openings may be the same or different.
Further, the depth h of each of these cells 6 (see FIG. 2A) is set to 60 μm or more and 90 μm or less, and is preferably 60 μm or 90 μm. The aspect ratio of the diagonal length d and the depth h of the opening 6a of the cell 6 may be set within a predetermined range.

[Production method]
Next, the manufacturing method of the printing plate 1 shown in FIG. 2 will be described with reference to FIGS. 4A to 4I.
First, the iron cylindrical cylinder 2 shown in FIG. 4A is held in the holding device 50 so as to be rotatable in the axial direction thereof. Then, the surface 2a in the circumferential direction of the cylinder 2 is nickel-plated, and as shown in FIG. 4B, the nickel-plated layer 3 is formed on the surface 2a of the cylinder 2. The thickness of the nickel-plated layer 3 is, for example, about 7 μm.
Next, as shown in FIG. 4C, the copper plating layer 4 is formed on the nickel plating layer 3. The thickness of the copper-plated layer 4 is, for example, about 200 to 300 μm.

Next, as shown in FIG. 4D, a sensitive material layer 5 that reacts with the laser beam is formed on the copper-plated layer 4. The sensitive material layer 5 is made of a sensitive material that reacts with a laser beam, and is not particularly limited as long as it exhibits a function as a resist, and is made of, for example, carbon. The sensitive material layer 5 is formed by applying a liquid material dispersed in, for example, a dispersion medium onto the copper-plated layer 4 and drying it.
Next, as shown in FIG. 4 (e), the YAG laser device 8 irradiates the sensitive material layer 5 with a laser beam to perform laser engraving to form a desired pattern 5A. The YAG laser device 8 is movably installed, for example, in the R1 and R2 directions on a plane equidistant from the sensitive material layer 5 in FIG. 4 (e) and in the L direction orthogonal to the R1 and R2 directions. Will be done.

In laser irradiation by the YAG laser device 8, for example, "cylinder rotation speed", "beam number", "beam feed pitch (μm)", and "beam irradiation interval" are set according to the desired pattern to be formed. Set. Here, the "cylinder rotation speed" is preferably, for example, 600 to 1000 rpm, more preferably 800 rpm. Further, examples of the "number of beams" include a 1-beam method, a 2-beam method, and a 4-beam method. Further, the “beam feed pitch” refers to the pitch at which the YAG laser device 8 is moved along the axial direction of the cylinder. Further, as the "beam irradiation interval", a "spiral type", an "intermittent type", or the like is selected. These conditions are appropriately combined and set in consideration of accuracy and efficiency according to the desired pattern to be formed.

A plurality of cells 6 are formed by laser engraving by a YAG laser device 8 so that each opening 6a has a non-circular shape (including a non-elliptical shape) and each depth h is 60 μm or more and 90 μm or less. .. The depth h is preferably 60 μm or 90 μm. That is, the openings 6a of the plurality of cells 6 have a non-circular shape (including a non-elliptical shape), so that at least one corner portion is provided on the peripheral edge (opening peripheral edge) of the opening 6a. Form a shape.

Next, as shown in FIG. 4 (f), the copper plating layer 4 is corroded by applying the etching solution 9 using the sensitive material layer 5 patterned according to the desired cell shape by laser drawing as a mask. A cell 6 having a desired shape is formed on the copper-plated layer 4 (see FIG. 4 (g)). This "cell 6 having a desired shape" is a cell 6 having an opening shape as shown in FIG. 2 (b).
Next, as shown in FIG. 4 (h), the sensitive material layer 5 is removed to expose the plurality of cells 6 formed on the copper-plated layer 4.
Next, the wear resistance is enhanced by providing the chrome-plated layer 10 on the surface 4a of the copper-plated layer 4 in FIG. 4 (h) (see FIG. 4 (i)). It is preferable that the chrome-plated layer 10 is provided, but the surface of the copper-plated layer 4 (including the chrome-plated layer 10) functions as a printing surface.
In this way, by performing the steps of FIGS. 4A to 4I, the printing plate 1 in which the plurality of cells 6 are formed is produced.

As another embodiment, as shown in FIG. 5, the shape of the openings 6a of the plurality of cells 6, 6, 6, ... Formed on the surface of the copper plating layer 4 is not a quadrangle but a hexagon. May be good. Even in such an embodiment, the diagonal dimension d of the opening 6a is preferably 30 to 200 μm.
Further, the shape of the plurality of cells 6 formed on the surface of the copper plating layer 4 may be only a circular shape, but as described above, the ink transferability is better when the non-circular shape is included, and the openings have different non-circular shapes. The cell 6 having a portion may be formed on the copper plating layer 4.

Next, examples of the present invention will be described.
(Example 1)
<Making the first printing plate>
First, a nickel-plated layer, a copper-plated layer, and a sensitive material layer were sequentially formed on the circumferential surface of an iron cylindrical cylinder. The thickness of the nickel-plated layer was 7 μm, the thickness of the copper-plated layer was 150 μm, and the thickness of the sensitive material layer was 6 μm.

Next, while moving the YAG laser device on a plane at substantially equal intervals from the sensitive material layer, laser engraving was performed by irradiating a laser beam from the YAG laser device toward the sensitive material layer. The sensitive material layer was patterned with a plurality of cells having only a square shape with diagonal dimensions of 30 to 200 μm.
The patterning of the sensitive material layer by laser was performed under the following conditions.
・ Cylinder rotation speed: 600 rpm
・ Number of beams: 2 beams ・ Beam feed pitch: 4 μm
・ Beam irradiation interval: intermittent type

Next, the copper-plated layer is corroded by applying an etching solution (ferrous chloride) using a sensitive material layer patterned according to the desired cell shape as a mask by laser drawing, and the copper-plated layer is desired. A plurality of cells having the shape of (1) were formed. At this time, the depth of each cell was adjusted to 31 μm.
Next, a chrome-plated layer was formed on the surface of the copper-plated layer to prepare a first printing plate of a screenless plate.

<Making the second printing plate>
In the production of the first printing plate described above, the second printing plate was produced in the same manner as the production of the first printing plate, except that the shapes of the openings of the cells formed on the copper plating layer were all circular.

<Making the third printing plate>
First, a nickel-plated layer and a copper-plated layer were sequentially formed on the circumferential surface of an iron cylindrical cylinder. The thickness of the nickel-plated layer was 7 μm, and the thickness of the copper-plated layer was 250 μm.
Next, while rotating the cylinder, helio printing was performed on the copper-plated layer with a diamond blade at a line number of 60 L / cm, and the depth was 55 μm and the diagonal dimension was 30 to 200 μm. The cell was formed on the copper-plated layer to prepare a third printing plate.

<Making a decorative sheet>
Next, the decorative sheet of this example was prepared. Specifically, first, the print layer 17 is formed on one surface of the base sheet 16.
Next, ink was supplied to the printing surface of the first printing plate to fill the inside of a large number of cells with ink.
Next, the ink on the printed surface other than the cell was scraped off.
Next, the first surface protective layer was laminated on the print layer by applying a transparent resin containing medium as a main component on the upper part of the print layer.
Next, as the first plate, the ink filled in the cell is transferred onto the first surface protective layer by rotating the cylinder and moving the first surface protective layer to the printed surface using the first printing plate. The first step was performed.
Next, as the second plate, the first printing plate is used again to transfer the ink filled in the cell by rotating the cylinder and moving the layer formed in the first step to the printing surface. As a result, a second surface protective layer was formed to obtain a decorative sheet of Example 1.

(Example 2)
A decorative sheet of Example 2 was obtained in the same manner as in Example 1 except that the second printing plate was used for the first plate of Example 1.
(Example 3)
A decorative sheet of Example 3 was obtained in the same manner as in Example 1 except that the third printing plate was used for the second plate of Example 1.
(Comparative Example 1)
A decorative sheet of Comparative Example 1 was obtained in the same manner as in Example 1 except that the third printing plate was used for the first plate in Example 1 and the second printing plate was used for the second plate.
(Comparative Example 2)
A decorative sheet of Comparative Example 2 was obtained in the same manner as in Example 1 except that the third printing plate was used as the first plate in Example 1 and the second plate was not performed.
(Comparative Example 3)
A decorative sheet of Comparative Example 3 was obtained in the same manner as in Example 1 except that the second edition was not performed in Example 1.
(evaluation)
The decorative sheets of Examples 1 to 3 and Comparative Examples 1 to 3 obtained as described above were evaluated for ink transfer property and raised design property.

<Ink transferability>
For the decorative sheets of Examples 1 to 3 and Comparative Examples 1 to 3, the net shape of the printed matter was confirmed with a microscope, the one with a sharp net shape was "◎", the lowest level that could be actually used was "○", and the net. Those whose shape is out of shape are designated as "x". The evaluation results are shown in Table 1.

<Exciting design>
The decorative sheets of Examples 1 to 3 and Comparative Examples 1 to 3 were evaluated by 10 people with a feeling of touch. That is, the one that feels closer to the surface of the wooden board is "◎", the one that feels closer to the surface of the wooden board is "○", and the smooth surface like plate glass is "x". The evaluation results are shown in Table 1.

As shown in Table 1, the decorative sheets of Examples 1 to 3 produced by using the laser engraved printing plate as the first plate and then using the laser engraving or helio engraved printing plate as the second plate. It was found that the heaping design was better than that of the decorative sheets of Comparative Examples 1 to 3.
Further, it was found that the decorative sheets produced by the printing plates of Examples 1 and 3 having cells having non-circular openings formed on the printed surface have good ink transferability in addition to raised design. rice field.

As described above, according to the present invention, the printing plate used for the first plate is a printing plate in which cells are formed by laser engraving. A veneer can be provided. Further, by making the opening of the cell non-circular, it is possible to improve the transferability of the ink from the cell to the object to be printed.

1 Printing plate 2 Cylinder (cylindrical body)
3 Nickel plating layer 4 Copper plating layer 5 Sensitive layer 6 Cell 6a Opening 6b Bottom surface 6c Unevenness 8 YAG laser device 9 Etching liquid 10 Chrome plating layer 15 Decorative sheet 16 Base sheet 17 Printing layer 18 First surface protective layer 19 First 2 Surface protective layer

Claims (8)

A printing layer and a first surface protective layer are formed on the base sheet in this order, ink is supplied to a plurality of cells formed on the printing surface of the cylindrical printing plate, and the ink is supplied to the plurality of cells of the printing plate. The first step of transferring the ink of the above onto the first surface protective layer to form the first layer, and
After the first step, ink is supplied to a plurality of cells formed on the printing surface of a cylindrical printing plate, and the ink in the plurality of cells of the printing plate is transferred onto the first layer to form a second layer. Including a second step of forming a second surface protective layer composed of a first layer and a second layer by forming the ink.
The plurality of cells of the printing plate used in the first step are formed by laser engraving.
The plurality of cells of the printing plate used in the first step have a circular opening, a rectangular opening, or a hexagonal opening.
The plurality of cells of the printing plate used in the second step are formed by laser engraving.
The plurality of cells of the printing plate used in the second step have a circular opening, a square opening, or a hexagonal opening.
The length of the diagonal line of the opening is set within the range of 30 μm or more and 200 μm or less.
The depth of the cell at the opening is set within the range of 60 μm or more and 90 μm or less .
A method for manufacturing a decorative sheet, wherein at least a part of the side surface of the second surface protective layer is an inclined surface . The method for manufacturing a decorative sheet according to claim 1, wherein the first step is screenless printing. The method for producing a decorative sheet according to claim 1 or 2 , wherein the printing plate used in the first step and the printing plate used in the second step are the same printing plate. The method for producing a decorative sheet according to any one of claims 1 to 3 , wherein the depth of the cell in the opening is 60 μm or 90 μm. The print layer formed on the base sheet, the first surface protective layer formed on the printed layer, and the second surface protective layer formed on the first surface protective layer are provided.
The thickness of the second surface protective layer is 3% or more and 2300% or less of the thickness of the first surface protective layer.
The second surface protective layer includes a first layer located on the side of the first surface protective layer and a second layer formed on the first layer.
The shape of the first layer is circular, quadrangular, or hexagonal in plan view.
The length of the diagonal line of the first layer is in the range of 30 μm or more and 200 μm or less in a plan view.
The thickness of the first layer is in the range of 60 μm or more and 90 μm or less .
The shape of the second layer is circular, quadrangular, or hexagonal in plan view.
The length of the diagonal line of the second layer is within the range of 30 μm or more and 200 μm or less in a plan view.
A decorative sheet characterized in that at least a part of the side surface of the second surface protective layer is an inclined surface . The decorative sheet according to claim 5 , wherein the thickness of the first layer is 60 μm or 90 μm. The decorative sheet according to claim 5 or 6 , wherein the first layer and the second layer have the same shape. A decorative board according to any one of claims 5 to 7 , wherein the decorative sheet is attached to a substrate.

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