JPH08150692A - High relief decorative sheet having irregular pattern therein - Google Patents

Abstract

PURPOSE: To provide a decorative sheet having a cubic sense and excellent deep design effect by providing an irregular pattern in an intermediate layer of the decorative sheet. CONSTITUTION: A picture pattern layer 12 is provided on a rear face of a base material film 11 as a surface. An irregular pattern layer 14 consisting of an ionizing radiation setting resin is formed on a base film 13 as an intermediate layer. Further, on a coloring thermoplastic resin film 17 to be a lower layer, a brightening resin layer 16 is formed out of a thermoplastic resin containing a brightening material such as brightening metallic powder, on which a printing layer 15 is provided, and three kinds of films are formed separately. The above- mentioned three films are laminated with heat so as to form a decorative sheet 1 wherein irregular shapes of the irregular pattern layer are formed on the printing layer 15, the brightening resin layer 16, and the coloring thermoplastic resin film 17.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement of a decorative sheet for building materials, and in particular, it is a makeup that reproduces a state close to natural wood, such as a wood grain printed pattern, and expresses a three-dimensional effect and a wood grain shine. It is about the seat.

[0002]

2. Description of the Related Art Conventionally, various methods have been proposed as means for applying a concavo-convex pattern (embossing) to a decorative surface of a decorative material. For example, a mechanical embossing method using an embossing roll or an embossing plate, A chemical embossing method using a foaming agent, a foaming inhibitor, a curing inhibitor, or the like is known. However, since such a decorative sheet has an uneven pattern formed on the surface of the thermoplastic resin sheet, the stain resistance of the surface is inferior, and foreign matter such as dust gets into the uneven pattern, and the appearance of the surface is impaired. However, there is a fear that the uneven shape may be damaged due to abrasion or abrasion.

On the other hand, in order to eliminate these drawbacks, a decorative sheet in which an uneven pattern is formed on the back surface of a base sheet has also been proposed. For example, on the back surface of a transparent polyvinyl chloride sheet, an uneven pattern made of an ultraviolet curable resin is formed,
A solid printing layer of glittering ink and a pattern layer of normal ink are formed on one surface of another colored polyvinyl chloride sheet, and both sheets are laminated with the uneven pattern surface and the pattern surface as shown in FIG. 5 and heated. Laminated by. A transparent film having one surface embossed, an intermediate transparent thermoplastic resin film having a pattern printed thereon, and a colored thermoplastic resin film having a pattern printed thereon, as shown in FIG. 6, and laminated by heating. As shown in FIG. 7 (a), a transparent thermoplastic resin film is provided on the back with a pattern layer and a glittering solid printing layer, and the colored thermoplastic resin film is heated on the glittering solid printing layer side of this film by heating. Laminate and emboss from the colored thermoplastic resin film side of this laminated film,
As shown in FIG. 7 (b), a colored thermoplastic resin film and a glittering solid printing layer on which an uneven pattern is formed. Etc.

[0004]

However, the decorative sheet having a concavo-convex pattern formed on the back surface of the base sheet has the following problems. In the case of No. 3, the unevenness in the interior and the luster of the wood grain could be expressed, but the three-dimensional effect with a deep pattern was insufficient. In the case of No. 3, the three-dimensional effect of the pattern was obtained, but the unevenness inside was insufficient, and the luster of the wood grain could not be expressed. In the case of No. 3, a feeling of wood grain was obtained, but internal unevenness and three-dimensional effect could not be sufficiently expressed. The present invention solves these problems and provides a decorative sheet excellent in design that can obtain an internal unevenness, which is not seen in a conventional embossed decorative sheet, and can express a three-dimensional pattern. To aim.

[0005]

A high-relief decorative sheet having a concavo-convex pattern inside a laminated sheet, which is a protective layer of a transparent or translucent thermoplastic resin from the surface / a pattern layer by printing / transparent or translucent A thermoplastic resin film / a concavo-convex pattern layer made of an ionizing radiation curable resin containing a vinyl chloride copolymer / a resin layer containing a glittering substance / a transparent, semi-transparent or colored thermoplastic resin film The uneven shape of the uneven pattern layer made of an ionizing radiation-curable resin containing the vinyl chloride copolymer is sequentially laminated, and the uneven shape of the resin layer containing the glittering substance and the transparent, semitransparent or colored thermoplastic resin is used. A decorative sheet characterized by being applied to a film. In addition, the decorative layer is a decorative sheet in which the resin layer containing the glittering substance is a film of a thermoplastic resin in which powders of the glittering substance are kneaded and mixed. Furthermore, the protective layer of the transparent or translucent thermoplastic resin on the outermost surface is a decorative sheet having an uneven pattern on the surface.

[0006]

According to the present invention, since a layer having a transparent uneven pattern is interposed between the pattern layer and the glitter resin layer, the reflection surfaces of the light reflected by the pattern layer and the light reflected by the glitter resin layer are provided. Since it is different, on the uneven pattern or shiny (wave pattern) of the base,
It is possible to obtain a decorative sheet in which a design (wood grain or the like) can be seen in a floating manner, has a three-dimensional effect, and has a deep design effect.

[0007]

The present invention will be described in detail below with reference to the drawings based on the embodiments. FIG. 1 is an enlarged cross-sectional view showing an example of the decorative sheet of the present invention, and FIG. 2 is an explanatory diagram when manufacturing the decorative sheet. FIG. 3 is an explanatory view when making a decorative sheet having another layer structure, and FIG. 4 is a sectional view of the decorative sheet. FIG. 5, FIG. 6, and FIG. 7 are conventional decorative sheets, and show the layer structure in the case where a concavo-convex pattern is present inside the laminated sheet. FIG. 8 is a schematic cross-sectional view showing a manufacturing process when an uneven pattern is formed on a substrate film by a drum printing method described below using an ionizing radiation curable resin. FIG. 9 is a schematic cross-sectional view showing a manufacturing process when the decorative sheet of the present invention is manufactured by a belt pressing method, and FIG. 10 is a schematic showing a manufacturing method when a decorative sheet is manufactured by a flat plate hot pressing method. FIG.

An example of making the decorative sheet of the present invention is shown below. First, as shown in FIG. 2 (a), a transparent or semitransparent thermoplastic resin film is used as the substrate film 11 on the surface, and the pattern layer 1 is printed with ordinary printing ink.
Print 2. Next, as shown in FIG. 2B, an uneven pattern made of an ionizing radiation curable resin is formed on a transparent or semitransparent thermoplastic resin film as a base material film 13 of the intermediate layer by a drum printing method described later. Form the layer 14. Further, as shown in FIG. 2 (c), solid printing is performed with a glittering ink obtained by adding a glittering substance (titanium dioxide-coated mica, fish scale foil, aluminum powder, copper powder, brass powder, etc.) to the colored thermoplastic resin film 17. Then, the glittering resin layer 16 is formed, and the printing layer 15 is further provided thereon with an ordinary ink, if necessary. The above three films are shown in FIG.
Arranged as shown in (b) and (c), this is laminated by heating with a belt press system, a flat plate press system, a doubling emboss system, or the like (hereinafter referred to as thermal lamination),
As shown in FIG. 1, the decorative sheet 1 in which the uneven shape of the uneven pattern layer 14 is given to the printed layer 15, the glitter resin layer 16 and the colored plastic film 17 is produced.

As another layer structure, a decorative sheet may be produced as follows. That is, as shown in FIG. 3A, the hard coat layer 18 is formed on the surface which becomes the surface of the transparent thermoplastic resin film. As shown in FIG. 3 (b), as the base material film 13 of the intermediate layer, a transparent or semitransparent thermoplastic resin film is formed on the uneven pattern layer 14 made of an ionizing radiation curable resin by a drum printing method.
And a pattern layer 12 is provided on the opposite side of the concavo-convex pattern layer.

Next, as shown in FIG. 3 (c), a glittering resin film 16 and a colored thermoplastic resin sheet 17 formed from a thermoplastic resin in which a glittering substance is kneaded are prepared.
Arranged as shown in (a), (b) and (c) and laminated by hot pressing or the like to produce a decorative sheet 1 as shown in FIG. On the outermost surface of the decorative sheet, an embossed pattern layer, a mirror surface layer, a mat layer, etc. may be provided in addition to the hard coat layer.

A method of forming an uneven pattern on a substrate with an ionizing radiation curable resin using a roll intaglio (hereinafter referred to as a drum printing method) will be described below. In the drum printing method, as shown in FIG. 8, an ionizing radiation curable resin liquid 23 is coated on a roll intaglio 21 engraved with a desired uneven pattern by a nozzle type coating device 24 and cured by a nip roll 25. Resin liquid 23 is filled in the concave portion 22 of the roll intaglio plate. At the same time, the intermediate layer substrate film 13 is formed on the surface of the roll intaglio plate by the ionizing radiation curable resin liquid
3, the film is irradiated with ionizing radiation from above the film using the ionizing radiation irradiation device 27 to cure the resin liquid filled in the concave portion 22 of the roll intaglio, and the cured ionized film on the base film 13. The radiation curable resin 23a is adhered. After the ionizing radiation curable resin is sufficiently cured, the base film 13 is peeled from the roll intaglio 21 by the peeling roll 26, and the uneven pattern 12 made of the cured ionizing radiation curable resin is formed on the base film 13. is there. As the uneven pattern, a wave pattern, an abstract pattern, a wood grain conduit pattern, etc. are mainly used.

Next, a method for producing a decorative sheet by heat laminating with a belt press system and a flat plate hot press system will be described. In the belt press method, a decorative sheet is manufactured using a device as shown in FIG. First, the paper feed winding 31
The winding A, the winding B, and the winding C are set in a, 31b, and 31c, respectively. The winding A is, as shown in FIG.
A pattern is printed on the substrate film 11 on the surface.
In the winding B, as shown in FIG. 2B, the concavo-convex pattern layer 14 is formed of the ionizing radiation curable resin on the base film 13 of the intermediate layer. As for winding C, as shown in FIG. 2 (c), a colored thermoplastic resin film is solid-printed with an ink to which a glittering substance is added to form a glittering resin layer, and the ink is normally printed thereon. It is provided with layers.

The above three types of films are unwound from each winding and superposed, and sent to a laminating device in which the stainless belt 33 is rotating. The three stacked films are heated by the heating roll 32 and simultaneously pressed,
The films are closely attached and integrated. The three integrated films are sandwiched by stainless belts and sent to the next step.

As shown in FIG. 9, the integrated three sheets of film are heated in a preheating section, and further heated in a heating section to be heated to 3
The thermoplastic resin film and the glitter resin layer of a sheet will be in a semi-molten state. Next, the outside of the thermoplastic resin film on the surface and the colored thermoplastic resin film on the lower surface are solidified by cooling in the cooling unit. As described above, the three films, which are solidified on the outer side and semi-molten on the inner side, are further cooled by the cooling roll 37 and simultaneously pressed to melt and adhere the three films to produce the decorative sheet 1. Then, the take-up roll 38 is used to produce the take-up roll-shaped decorative sheet 1.

Next, the flat plate hot pressing method will be described. In the flat plate hot pressing method, as shown in FIG. 10, a decorative sheet is manufactured using a pressing device. First, FIG.
As shown in (a), (b), and (c), a base film (A) on the surface on which a pattern is printed, a base film (B) as an intermediate layer on which an uneven pattern is formed by an ionizing radiation curable resin, A film (C) having a glittering resin layer and a printed layer formed on a colored thermoplastic resin sheet is shown in FIG. 10 by stacking three films in the order shown in FIGS. 2 (a), 2 (b) and 2 (c). like,
It is placed on the stainless steel plate 43 placed on the lower heating plate 41b of the press machine. The stainless steel plate 43 is placed on the three films, and the three films are further stacked and placed on the stainless steel plate, which is repeated 5 to 10 steps, and as shown in FIG. Place a stainless steel plate on the.

The films A, B, and C stacked in multiple stages as described above are moved by moving the piston 45 in the hydraulic cylinder 46 to apply pressure between the upper heating plate 41a and the lower heating plate 41b. The film is heated by the heater 42 built in the heating plate, and the A, B, and C films are heat-sealed to form one sheet. After heating and pressurizing for a certain period of time to completely heat-bond the three films, the heating is stopped to cool the laminated sheet, the pressure is released, and the laminated sheet is taken out from the pressing device to obtain a decorative sheet.

The film material and ink material used in the decorative sheet of the present invention will be described below. The transparent or semitransparent film substrate used for the substrate film for the surface and the substrate film for the intermediate layer can be used as long as it is a thermoplastic resin, and is not particularly limited; Resin, acrylic resin, etc. are mainly used. Besides, polystyrene, vinyl acetate, ethylene-vinyl acetate copolymer, ABS and the like can be used. The thickness of the resin layer may be in the range of 20 to 200 μm, but the thickness of about 50 to 150 μm is preferable in terms of design effect and handling.

The pattern layer is formed by printing using an ink made of a known resin, pigment, dye, additive or the like. The printing method is not particularly limited, and a conventional method can be used, but the gravure printing method is suitable for printing a wood grain pattern. Also in the case of solid printing with a glitter ink in combination with a grain pattern, a glitter ink prepared by adding a glitter pigment, a dye, an additive, etc. to a known resin is used. Examples of bright pigments include metal powder such as aluminum powder, copper powder, and brass powder or metal foil pieces, pigments having metallic luster such as cut pieces of metal-deposited synthetic resin film, titanium dioxide-coated mica, fish scale foil, bismuth trichloride. A pigment having pearl luster or interference luster, etc. is used.

As described above, the glittering resin layer may be formed on the colored thermoplastic resin film by solid printing using the glittering ink, but the glittering substance may be added to the thermoplastic resin such as polyvinyl chloride. May be kneaded to form a film, and this film may be attached to a colored thermoplastic resin to form a glittering resin layer.

As the ionizing radiation curable resin, known ultraviolet curable resins and electron beam curable resins are mainly used.
Examples of these resins include polyfunctional prepolymers, oligomers and / or monomers having two or more acryloyl groups, methacryloyl groups, polymerizable unsaturated groups such as acryloyloxy groups, epoxy groups, and thiol groups in the molecule. A liquid composition whose main component is a body is used. Examples of these prepolymers, oligomers or monomers include urethane acrylates, epoxy acrylates, polyester acrylates, acrylates such as silicon acrylates, urethane methacrylates, epoxy methacrylates, polyester methacrylates, and methacrylates such as silicon methacrylates. Examples include unsaturated polyester, polythiol, and polyvinylpyrrolidone. Preferably,
It is preferable to use a high cross-link density type such as acrylate, epoxy acrylate, silicon acrylate, and siloxane.

When curing with visible light or ultraviolet light, a photopolymerization initiator such as benzophenones, acetophenones and thioxanthones is added. When using ultraviolet rays such as a high-pressure mercury lamp as the ionizing radiation, it is necessary to transmit the ultraviolet rays and cure with the ultraviolet rays, and it is necessary to use a transparent resin. Ultraviolet rays or electron beams are usually used as the ionizing radiation, but other visible light rays, X-rays and the like can also be used.

The colored thermoplastic resin film is not particularly limited, but a polyvinyl chloride sheet is preferable in terms of workability. The thickness of the sheet can be used in the range of 100 to 800 μm, but is preferably about 200 to 600 μm.

A more detailed description will be given below with reference to specific examples. (Example 1) As a base film on the surface, a thickness of 50 μm
Acrylic film (HBS001 manufactured by Mitsubishi Rayon Co., Ltd.)
As shown in FIG. 2A, a wood grain pattern was printed by a gravure printing method using an acrylic resin ink to prepare a surface film (A).

Next, a transparent polyvinyl chloride sheet having a thickness of 200 μm (GR Clear-200 manufactured by Riken Vinyl Industry Co., Ltd.) was used as a base material film for the intermediate layer by the above-mentioned drum printing method and a vinyl chloride-based copolymer. A predetermined uneven pattern was formed using a UV-curable resin containing XD-808VC (manufactured by Dainichiseika Kogyo Co., Ltd.), and an intermediate sheet (B) was prepared as shown in FIG. 2 (b). Roll intaglio is made by direct etching method, depth 20μm, spacing 100
Using a plate having a μm line-shaped uneven pattern, the UV curable resin was irradiated with two 160 W high-pressure mercury lamps and cured at a line speed of 10 m / min to form an uneven pattern on the intermediate layer sheet. .

As the colored thermoplastic resin film 17, a 200 μm-thick colored polyvinyl chloride sheet (GR-200 manufactured by Riken Vinyl Industry Co., Ltd.) was used, and aluminum powder was added as a glittering metal powder to the acrylic resin. As shown in FIG. 2 (c), a glittering resin layer 16 is formed by solid printing by gravure printing with a vinyl chloride / vinyl acetate copolymer type ink, and further a printing layer 15 is formed thereon with a normal ink. Thus, the lower layer sheet (C) was produced.

As shown in FIG. 9, the three types of films and sheets produced as described above were subjected to a continuous belt press system under heating conditions of 150 to 160 ° C. and a line speed of 1.
The decorative sheet 1 was produced by hot laminating at 0 m / min. The decorative sheet produced in this manner was a decorative sheet that was rich in depth and shiny and rich in three-dimensional effect.

(Example 2) As a substrate film on the surface,
As shown in FIG. 3 (a), a hard coat layer 18 was formed on a surface of a polyvinyl chloride film having a thickness of 100 μm (GR Clear-100 manufactured by Riken Vinyl Industry Co., Ltd.) by using an ultraviolet curable resin. A film (A) was produced. Next, in the same manner as in Example 1, a concavo-convex pattern was formed on a polyvinyl chloride film having a thickness of 100 μm, and the same ink as in Example 1 was used for gravure printing on the side opposite to the concavo-convex pattern.
An intermediate sheet (B) as shown in (b) was produced. Further, as shown in FIG. 3 (c), a film is made of polyvinyl chloride resin in which aluminum powder is kneaded to have a thickness of 10
A glittering polyvinyl chloride film 16 of 0 μm was produced.
Further, a 400 μm thick colored non-plasticized polyvinyl chloride sheet 17 prepared separately was prepared. The films and sheets produced as described above are superposed in the order shown in FIGS. 3 (a), (b), and (c), and then heat-laminated by a flat plate hot press as shown in FIG. A decorative sheet was produced. This decorative sheet was also a decorative sheet with depth and a rich three-dimensional effect.

[0028]

As described above, according to the present invention,
Since a transparent uneven pattern layer is interposed between the pattern layer and the glitter resin layer, the reflection surface of the light reflected by the pattern layer and the light reflected by the glitter resin layer are different. It is possible to obtain a decorative sheet with a three-dimensional effect and a deep appearance, in which a design (wood grain, etc.) floats on the (wave pattern). In addition, the production speed is increased and the work efficiency is improved as compared with the conventional mechanical embossing method and chemical embossing method.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view showing an example of a decorative sheet of the present invention.

FIG. 2 is an explanatory diagram showing an example of producing a decorative sheet, and (a) is a diagram in which a pattern layer is provided on a base film on the surface. (B) The figure which formed the uneven | corrugated pattern on the base material film of an intermediate | middle layer. (C) The figure which provided the glittering resin layer and the printing layer in the colored thermoplastic resin film.

FIG. 3 is an explanatory view showing another example when producing a decorative sheet, and (a) is a view in which a hard coat layer is provided on a base film on the surface. (B) The figure which formed the uneven | corrugated pattern and the pattern layer on the base material film of an intermediate | middle layer. (C) The figure which showed the glittering resin film and the coloring thermoplastic resin film.

FIG. 4 is an enlarged cross-sectional view of a decorative sheet manufactured in Example 2.

FIG. 5 is a cross-sectional view showing an example of a layer structure of a conventional decorative sheet.

FIG. 6 is a cross-sectional view showing another layer structure of a conventional decorative sheet.

FIG. 7 is a cross-sectional view showing another layer structure of a conventional decorative sheet, and (a) is a view showing the layer structure of the decorative sheet before embossing. (B) The figure which embossed from the lower layer side to the decorative sheet of (a).

FIG. 8 is a schematic cross-sectional view showing a manufacturing process when an uneven pattern is formed on a film by using an ionizing radiation curable resin by a drum printing method.

FIG. 9 is a schematic cross-sectional view of a manufacturing process when manufacturing a decorative sheet by a belt press method.

FIG. 10 is a schematic cross-sectional view when manufacturing a decorative sheet by a flat-plate hot pressing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative sheet 11 Surface base film 11a Embossed surface base film 12 Picture layer 13 Intermediate layer base film 14 Concavo-convex pattern layer 15 Printing layer 16 Glittering resin layer 17 Colored thermoplastic resin film 18 Hard coat layer Reference Signs List 21 roll intaglio 22 plate recess 23 ionizing radiation curable resin liquid (before curing) 23a cured ionizing radiation curable resin 24 nozzle type coating device 25 nip roll 26 peeling roll 27 ionizing radiation irradiation device (ultraviolet irradiation device) 31a paper feed roll Take-up A 31b Feeding take-up B 31c Feeding take-up C 32 Heating roll 33 Stainless belt 34 Preheating part 35 Heating part 36 Cooling part 37 Cooling roll 38 Discharging take-up 41a Upper heating plate 41b Lower heating plate 42 Heater 43 Stainless steel plate 44 3 sheets Overlaid sheet 45 Piston 46 Hydraulic series Dah 47 fixed platen

Claims (3)

[Claims] 1. A high-relief decorative sheet having a concavo-convex pattern inside a laminated sheet, comprising a protective layer of a transparent or translucent thermoplastic resin from the surface / a pattern layer by printing /
Transparent or translucent thermoplastic resin film / irregular pattern layer made of ionizing radiation curable resin containing vinyl chloride copolymer / resin layer containing glittering substance / transparent, translucent or colored thermoplastic Resin films are sequentially laminated, and the concavo-convex shape of the concavo-convex pattern layer made of the ionizing radiation-curable resin containing the vinyl chloride copolymer is transparent, semi-transparent or colored with the resin layer containing the glittering substance. A decorative sheet characterized by being applied to a thermoplastic resin film. 2. The decorative sheet according to claim 1, wherein the resin layer containing the glittering substance is a thermoplastic resin film in which powders of the glittering substance are kneaded. 3. The decorative sheet according to claim 1, wherein the outermost transparent or translucent thermoplastic resin protective layer has an uneven pattern on its surface.