JP7142508B2 - Decorative sheet and decorative metal plate using the sheet - Google Patents

Description

TECHNICAL FIELD The present invention relates to a decorative sheet imparted with a design by embossing. It also relates to a decorative metal plate laminated with the decorative sheet.

2. Description of the Related Art Conventionally, a decorative sheet having a mirror surface portion and an embossed portion has been used as a surface decoration material for interiors such as walls and ceilings of buildings, unit baths, system kitchens, furniture, cabinets, and the like. The decorative sheet is imparted with a design due to the difference in glossiness between the mirror surface portion and the embossed portion.
The decorative sheet 1 shown in FIG. 12 has a mirror surface portion 2 and an embossed portion 3 on its surface. The handle of the floats (Fig. 12(A)). As shown in FIGS. 12(B) and 12(C), many conventional decorative sheets 1 have embossed portions 3 formed from a plurality of convex portions 3b.

Patent Literature 1 is an invention relating to a mirror-embossed decorative sheet with inconspicuous scratches and a mirror-embossed plate used for the production thereof. In Patent Document 1, by setting the area of the embossed portion (embossed portion) to 20 to 50% and the area of the mirror surface portion to 50 to 80%, dust and scratches on the decorative sheet are prevented while maintaining the mirror surface of the sheet. conspicuous.
Patent document 2 is an invention relating to a decorative metal sheet, and discloses a decorative sheet to which a design is imparted by embossing (embossing). The decorative sheet is characterized in that fine projections formed by embossing have flat upper surfaces. Since the upper surface of the convex portion is flat, even if the convex portion is scratched with a fingernail or the like, the glossiness does not change significantly, and scratches are hardly noticeable.

Japanese Patent Application Laid-Open No. 2006-212909 JP 2010-42575 A

An embossed decorative sheet usually feels uneven due to embossing when the surface is stroked by hand. However, in recent years, there has been a demand for a decorative sheet that is smooth to the touch, despite the fact that the embossed portion imparts design. An object of the present invention is to provide such a sheet. In other words, it is an object to provide a decorative sheet in which the embossed portion can be confirmed visually but cannot be confirmed tactilely.
Hereinafter, the state in which the embossed portion can be visually confirmed easily is expressed as "good pattern appearance", and the state in which it is difficult to visually confirm is expressed as "poor pattern appearance".

A general embossing roll is produced by providing a mirror-finished roll, such as a roll-shaped iron core plated with copper, with fine concave portions by machine engraving, etching, or the like. Since the recessed portions of the embossing roll are reversed and transferred to the decorative sheet, the embossed portions of the general decorative sheet become convex portions and protrude from the mirror surface portion.
The present inventors have found that if the embossed part protrudes from the mirror surface part, it is easy to feel unevenness when touched with a hand. It has been found that if the width is sufficiently narrow, it is difficult to feel unevenness when touched with a hand. Therefore, the embossed portion is formed by a narrow concave portion. However, since the embossed portion has only monotonous streak-like concave portions, it is difficult to stand up, so a convex portion is formed in the concave portion.

That is, according to the present invention, as means for solving the above problems, there is provided a decorative sheet comprising a mirror surface portion and an embossed portion, wherein the embossed portion comprises a recess having a width of 0.1 to 15 mm and a plurality of Provided is a decorative sheet comprising convex portions, wherein the upper surface of each convex portion does not exceed the surface of the mirror surface portion.
Also provided is the decorative sheet, wherein the difference between the upper surface of the convex portion and the surface of the mirror surface portion is 0 to 10 μm.
Further, the decorative sheet is provided, wherein the difference between the upper surface of the convex portion and the surface of the mirror surface portion is more than 0 μm and 10 μm or less.

Further, there is provided the decorative sheet characterized in that the projections are substantially streak-shaped, and the distance between adjacent projections is 70 to 1000 μm.
Further, the decorative sheet is provided, wherein the projections are substantially lattice-shaped, and the length of one side of the lattice is 150 to 1000 μm.
Further, the decorative sheet is provided, wherein the projections are projecting, and the distance between adjacent projections is 30 to 1000 μm.
Further, the decorative sheet is provided, wherein the area of the mirror surface portion exceeds 50% of the area of the entire film.
Further, there is provided a decorative metal plate, which is characterized by bonding the decorative sheet to a metal plate.

Since the decorative sheet of the present invention has narrow recesses in the embossed portion, it gives a smooth feel without feeling unevenness when touched with a hand. In addition, since a plurality of protrusions are provided in the recess, the pattern is good and the embossed portion can be easily visually confirmed. In particular, when the difference between the upper surface of the convex portion and the surface (flatness) of the mirror surface portion is 0 to 10 μm, more preferably more than 0 μm and 10 μm or less, the pattern stands out well.

Further, when the intervals between the convex portions are wide, specifically, when the following (1) to (3) are satisfied, the decorative sheet is less likely to be contaminated.
(1) When the projections are substantially streak-shaped, the distance between the adjacent projections is 70 to 1000 μm.
(2) When the projections are substantially lattice-shaped, the length of one side of the lattice is 150 to 1000 μm.
(3) The projections are projecting, and the distance between adjacent projections is 30 to 1000 μm.

1 is a schematic plan view (A) of the decorative sheet of the present invention, its aa' cross-sectional view (B), and bb' cross-sectional view (C). 1 is a schematic plan view of a decorative sheet of the present invention; FIG. 1 is a schematic plan view of a decorative sheet of the present invention; FIG. The surface shape of the decorative sheet of Example 1 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 2 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 3 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 4 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 5 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 6 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. The surface shape of the decorative sheet of Example 7 was image-processed so that the color at the high position was light and the color at the low position was dark. The surface shape of the decorative sheet of Comparative Example 1 was image-processed so that the higher positions were lighter in color and the lower positions were darker in color. 1A and 1B are a schematic plan view (A) and a partially enlarged view (B) of a conventional decorative sheet, and a sectional view (C) taken along the line aa' of the partially enlarged view.

The present invention will be described in detail below. In each drawing, the same reference numerals represent the same or equivalent components. Moreover, the present invention is not limited to the following forms, and can take various forms.

[Decorative sheet]
(resin composition)
The decorative sheet of the present invention is made of a thermoplastic resin. The thermoplastic resin is not particularly limited, and conventionally known materials can be appropriately selected and used. Specifically, polyvinyl chloride, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyamide, polyethylene, polypropylene, polycarbonate, polyethylene naphthalate, ethylene/vinyl acetate copolymer, ethylene/acrylic acid copolymer, ethylene - Acrylic acid ester copolymers, ionomers, acrylic acid esters, methacrylic acid esters, and the like can be mentioned. Among them, polytrimethylene terephthalate and polybutylene terephthalate have a high crystallization speed, so by using these resins, the shape of the embossing roll can be accurately transferred to the decorative sheet. The decorative sheet of the present invention can be formed by using the above-described resins or copolymers thereof singly or in combination of two or more.

Moreover, the decorative sheet of the present invention may be colored. In this case, a colorant (pigment or dye) can be added to the thermoplastic resin to color it. Examples of colorants that can be used include inorganic pigments such as titanium dioxide, carbon black and iron oxide, organic pigments such as phthalocyanine blue, and various dyes. One or more of these can be selected from publicly known or commercially available products. Also, the amount of the coloring agent to be added may be appropriately set according to the desired color tone and the like.
The decorative sheet of the present invention may be a single-layer sheet, or may be a multi-layer sheet. If the decorative sheet has a three-layer structure and only the middle layer is colored, it is possible to avoid the problem of mold deposits adhering to the extruder when the decorative sheet is formed into a film.

Further, decorative sheets contain various additives such as fillers, matting agents, foaming agents, flame retardants, lubricants, antistatic agents, antioxidants, ultraviolet absorbers, light stabilizers, etc., as required. It's okay if it is.
The thickness of the decorative sheet can be appropriately set according to the application of the final product, the method of use, etc., but is generally preferably 20 to 300 μm, particularly preferably 70 to 150 μm.

FIG. 1 is a plan view (A), an aa' sectional view (B), and a bb' sectional view (C) showing an embodiment of the decorative sheet of the present invention. A decorative sheet 1 of the present invention comprises a mirror surface portion 2 and an embossed portion 3 . The area ratio (%) of the mirror surface portion 2 and the embossed portion 3 is not particularly limited, but it is preferable that the mirror surface portion: embossed portion = 50 to 95:50 to 5, particularly 70 to 90:10 to 30. Preferably. If the area ratio of the mirror surface portion is less than 50%, it is difficult to impart the desired design to the decorative sheet.

(mirror surface)
The mirror surface part 2 is smooth and has excellent glossiness, and gives the decorative sheet a dignified feeling and a high-class feeling. The mirror surface portion 2 preferably has an arithmetic mean roughness Ra (JIS B0601 2013) of 0.5 μm or less. If the arithmetic mean roughness of the mirror surface portion 2 exceeds 0.5 μm, the mirror surface property of the portion is lost, and the desired design property cannot be imparted to the decorative sheet. The arithmetic mean roughness Ra is preferably 0.3 μm or less, particularly preferably 0.1 μm or less. Although the lower limit of the arithmetic mean roughness Ra is not particularly limited, it is preferably 0.01 μm or more. When the arithmetic mean roughness Ra of the mirror surface portion 2 is less than 0.01 μm, when the mirror surface portion 2 is scratched, the scratches are conspicuous.

(Embossed part)
The embossed portion 3 is composed of a concave portion 3a recessed from the mirror surface portion 2 and a plurality of convex portions 3b formed in the concave portion 3a.
In the decorative sheet of the present invention, the width d (concave) of the concave portion 3a is 0.1 to 15 mm. When the width d (concave) is less than 0.1 mm, it becomes difficult to form the convex portion 3b in the concave portion 3a, and the embossed portion has poor standing. If the width d (concave) exceeds 15 mm, the surface of the decorative sheet tends to feel uneven when stroked with a hand. The width d (concave) may not be constant within the decorative sheet, and may vary within the range of 0.1 to 15 mm.

Further, the decorative sheet of the present invention has a plurality of protrusions 3b within the recesses 3a, but the upper surfaces of the protrusions 3b do not exceed the surface (tsura) of the mirror surface portion 2. As shown in FIG. If the upper surface of the convex portion 3b exceeds the surface of the mirror surface portion 2, there is a possibility that unevenness may be felt when the cosmetic sheet is stroked.
The difference α between the upper surface of the convex portion 3b and the surface of the mirror surface portion 2 is preferably 0 or more, particularly more than 0 μm, and more preferably 10 μm or less, particularly 5 μm. When the difference α exceeds 10 μm, it becomes difficult for the convex portions 3b to reflect light, and the embossed portion has a poor standing pattern. Moreover, when the difference α is 0 to 5 μm, the convex portions 3b contribute to giving the film a smooth feel. Therefore, when the width d (concave) of the concave portion exceeds 10 mm, the difference α between the upper surface of the convex portion 3b and the surface of the mirror surface 2 is preferably 0 to 5 μm. When the difference α is not 0 μm (the upper surface of the convex portion 3b does not match the surface of the mirror surface portion 2), the mirror surface portion 2 and the convex portion 3b reflect light differently, so the decorative sheet 1 is excellent in design.

In addition, when the upper surface of the protrusion 3b is not flat, the "upper surface" of the protrusion 3b corresponds to the "upper end". Further, when the surface of the mirror surface portion 2 is not flat (smoothly undulating), "does not exceed the surface of the mirror surface portion 2" corresponds to "does not exceed the line segment connecting the edges 2a and 2a' of the mirror surface portion". . Moreover, even if the convex portion 3b slightly exceeds the surface of the mirror surface portion 2, it is included in the scope of the present invention as long as it cannot be perceived as a tactile sensation.

The distance from the surface of the mirror surface portion 2 to the bottom surface of the concave portion 3a is also not particularly limited, but is preferably 10 to 30 μm, particularly preferably 10 to 20 μm. If the distance is less than 10 μm, the convex portion 3b becomes shallow, the appearance of the concave portion 3a and the convex portion 3b are similar, and the standing pattern is deteriorated. Further, when the distance exceeds 30 μm, stain resistance deteriorates.

Further, the decorative sheet of the present invention, whether shown in the drawings or others, is excellent in stain resistance if the distance between the adjacent projections is 150 μm, especially 300 μm or more. However, as will be described later, depending on the pattern, even if the distance between the adjacent protrusions is less than 150 μm, the contamination resistance may be excellent. In consideration of standing pattern, the distance between the convex portions is preferably 1000 μm or less, particularly preferably 500 μm or less.
In addition, when the intervals between the convex portions in the embossed portion are not constant, it is preferable that 70% or more of the convex portions appearing in the effective range as the decorative sheet are within the above range, and the intervals between all the convex portions in the effective range are within the above range. is desired.

In the decorative sheet shown in FIG. 1, the protrusions 3b are streaks extending in the width direction of the recesses 3a. The distance d1 (protrusion) formed between the adjacent protrusions of the protrusions 3b is preferably 70 to 1000 μm, particularly preferably 220 to 500 μm. If the interval d1 (convex) is less than 220 μm, especially less than 70 μm, dirt tends to clog between the convex portions 3b. If the interval d1 (protrusion) between the streak-like protrusions 3b exceeds 500 μm, especially 1000 μm, the light-reflecting surface of the embossed portion 3 becomes narrow, resulting in poor pattern standing.
As shown in FIG. 1, the streak-like protrusions 3b may extend in the width direction of the recesses 3a, or may extend substantially parallel to the recesses 3a and form a certain angle with the recesses 3a. may be In any case, the interval d1 (convex) is preferably 70 to 1000 μm.

The decorative sheet 1 shown in FIG. 2 has a lattice-like protrusion 3b. Each side d2 (convex)-1 and d2 (convex)-2 of the lattice is preferably 150 to 1000 μm, particularly preferably 300 to 500 μm. If the lattice intervals d2 (convex)-1 and d2 (convex)-2 are less than 300 μm, especially less than 150 μm, dirt tends to clog the convex portions 3b. Further, if the lattice intervals d2 (convex)-1 and d2 (convex)-2 exceed 500 μm, especially 1000 μm, the pattern of the embossed portion becomes poor.
The embossed portions 3 are formed in a plurality in the decorative sheet as shown in FIG. It's okay to be there.

The decorative sheet shown in FIG. 3 has projections 3b. The distances d3 (convex)-1 and d3 (convex)-2 between the convex portion 3b and the adjacent convex portion are both preferably 30 to 1000 μm, particularly 100 μm, in consideration of stain resistance and patterning. It is preferably ˜500 μm.
When the decorative sheet 1 has a plurality of embossed portions 3, each embossed portion should not be substantially parallel if the widths d (concave)-1 and d (concave)-2 are both 0.1 to 15 mm. For example, they may be arranged in a cross shape as shown in FIG.

[Manufacturing of decorative sheet]
The method for producing the decorative sheet of the present invention is not particularly limited, but for example, a T-die-cast embossing method can be employed. Specifically, first, a resin composition for a decorative sheet is put into an extruder, melted and supplied to a T-die, and then the molten resin composition is allowed to flow down from the T-die to form an embossing roll that also serves as a casting roll. A method of applying embossing at the same time as taking it off with a roll can be adopted.

[Decorative metal plate]
The decorative metal sheet of the present invention is obtained by laminating the decorative sheet described above on the surface of the metal sheet. As the metal plate, those conventionally used for decorative metal plates can be used without particular limitation. A nickel-based alloy plate, a titanium-based alloy plate, a magnesium-based alloy plate, or the like can be used. The method of bonding the decorative sheet to the metal plate is not particularly limited, but bonding using a thermosetting adhesive is common. Also, a so-called thermal lamination method can be employed in which the metal plates are heated in advance and laminated without loosening the adhesive.
Alternatively, a backer material may be laminated between the decorative sheet and the metal plate with an adhesive interposed therebetween by a dry lamination method.

EXAMPLES Next, the present invention will be described in detail with reference to Examples, but the present invention is not limited to these. The evaluation method in the present invention is as follows.
[Smoothness]
Rub the surface of the cosmetic sheet with your hand. When unevenness was felt, it was evaluated as ×, and when it was not felt, it was evaluated as ○.
[Stain resistance]
First, a dyeing solution containing carbon black is dripped onto the surface of the decorative sheet and spread over the surface of the decorative sheet. Next, the dye solution on the surface of the decorative sheet is wiped off with a cloth containing a cleaning component. If 50% or more of the embossed part of the decorative sheet was stained black, △ if the area of 10% or more and less than 50% of the embossed part was stained black, and less than 10% of the area where the dyeing solution remained was evaluated as ○.

[Example 1]
Using polybutylene terephthalate, a decorative sheet of 100 μm was produced by the T-die-cast embossing method. The embossed portion consists of recesses with a width of 0.5 to 0.8 mm and a plurality of protrusions formed between the recesses. , and the interval formed between adjacent convex portions (corresponding to d1 (convex) in FIG. 1) was set to 225 μm. The difference (α) between the upper surface of the convex portion and the surface of the mirror surface portion was set to 0 μm.
[Example 2]
A decorative sheet was produced in the same manner as in Example 1, except that the interval formed between adjacent convex portions (corresponding to d1 (convex) in FIG. 1) was set to 75 μm.

[Examples 3 to 5]
Using polybutylene terephthalate, a decorative sheet of 100 μm was produced by the T-die-cast embossing method. The projections were formed in a lattice shape as shown in FIG. The width of the recesses and the length of one side of the lattice (corresponding to d2 (convex)-1 and d2 (convex)-2 in FIG. 2) are as shown in Table 1.
[Examples 6 and 7]
Using polybutylene terephthalate, a decorative sheet of 100 μm was produced by the T-die-cast embossing method. The projections were formed in the shape of projections as shown in FIG. Table 1 shows the widths of the recesses and the intervals formed between the adjacent protrusions (corresponding to d3 (protrusion)-1 and d3 (protrusion)-2 in FIG. 3).

[Comparative Example 1]
A decorative sheet without concave portions as shown in FIG. 12 was manufactured. A decorative sheet was produced in the same manner as in Example 1, except that the embossed portion was formed from a plurality of projections. The interval between each convex portion was 35 μm.

The smoothness and stain resistance of the decorative sheets of Examples 1 to 7 and Comparative Example 1 were evaluated. The results are also shown in Table 1. In the decorative sheets of Examples 1 to 7, the embossed portions consisted of concave portions with a width of 0.1 to 15 mm and a plurality of convex portions in the concave portions, and no unevenness was felt when touched by hand. In the decorative sheet of Comparative Example 1, the embossed portion was formed of convex portions that protruded from the mirror surface portion, and the unevenness was felt when touched by hand. Further, the decorative sheets of Examples 1, 3 and 6 had sufficiently wide protrusions and excellent stain resistance.

FIG. 4 shows the surface shape of the decorative sheet of Example 1, which was image-processed so that the higher position is lighter in color and the lower position is darker in color. Similarly, the image-processed surface shapes of Example 2 to Comparative Example 1 are shown in FIGS. 5 to 11. FIG.
In addition, when comparing Examples 1 to 7, when the distance between the adjacent protrusions is constant, the protrusion-like protrusions are the most excellent in stain resistance, followed by the streak-like protrusions, and the grid-like protrusions. is assumed to be the most susceptible to contamination. It is presumed that this is due to the ease with which the dye that has entered the recesses is scraped out.

1 decorative sheet 2 mirror surface portions 2a, 2a' edge of mirror surface portion 3 embossed portion 3a concave portion 3b convex portion

Claims (3)

A decorative sheet comprising a mirror surface portion and an embossed portion,
The area of the mirror surface portion exceeds 50% of the area of the entire sheet,
The embossed portion consists of a concave portion formed in a stripe shape with a width of 0.1 to 0.8 mm and a plurality of convex portions in the concave portion,
The upper surface of the convex portion does not exceed the surface of the mirror surface portion,
The decorative sheet, wherein the projections are substantially streak-shaped, substantially grid-shaped, or projected in the width direction of the recesses. 2. The decorative sheet according to claim 1, wherein the convex portion corresponds to any one of the following a) to c) .
a) The protrusions are substantially streak-shaped extending in the width direction of the recesses, and the distance between adjacent protrusions is 75 to 225 μm.
b) the projections are substantially lattice-shaped, and the length of one side of the lattice is 110 to 325 μm;
c) the projections are projection-shaped, and the distance between adjacent projections is 35 to 110 μm; A decorative metal plate comprising a metal plate laminated with the decorative sheet according to claim 1 or 2.

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