JPH10324097A - Embossed decorative sheet and door formed by laminating the sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a grain pattern with a quality impression with no wiping by a method wherein an uneven surface is formed in a tracheal part embossed according to a woodgrain tracheal crosssectional pattern under the condition that the gloss of the uneven surface as just mentioned above is suppressed lower than that in the neighborhood of the tracheal part. SOLUTION: A resist pattern is formed at a tracheal part 1 by printing mapping image data outputted from an image file on a resist photosensitive layer applied onto the surface of an embossing cylinder 3 and then developing them. By peeling off the resist through etching, the tracheal part 1 is formed in an even shape according to a selected uneven pattern. The gloss of the uneven surface formed in the tracheal part embossed according to a woodgrain tracheal crosssectional pattern is suppressed to lower gloss. Thus, a realistic wood with the same quality impression as that of a decorative sheet, on which a wiping work is applied, can be reproduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet on which a conduit is embossed and a door to which the decorative sheet is attached.

[0002]

2. Description of the Related Art A decorative sheet having a texture, a high-grade appearance, and an improved design by realistically reproducing a wood grain cross section of natural wood is widely used for interior materials, furniture, cabinets of home electric appliances, and the like. These are generally embossed portions corresponding to the cross section of a wood grain conduit, and a concave portion formed by embossing is filled with a dense ink by wiping. Japanese Patent Publication No. 58-1431
2. Japanese Patent Publication No. 602985 proposes wiping. In general, controlling the gloss of the surface of the decorative sheet is performed at the finishing stage. Traditional,
In order to control the final gloss of a decorative sheet having a thermoplastic resin layer such as polyvinyl chloride or polyolefin resin on the surface, it is common to suppress the gloss by shaping with an embossed plate with fine irregularities It is a target. In this case, the uneven shape of the embossed plate surface is formed by spraying a projection material on the surface of the embossed cylinder by sandblasting or by matte chrome plating on the cylinder surface. Also, the surface of the embossing plate can be engraved by a gravure printing cylinder engraving machine to form an uneven shape and roughen the surface. Further, in the final stage of the decorative sheet processing, the gloss may be suppressed by performing an OP coating that gives a matte feel to the decorative sheet surface.

[0003]

Generally, in order to realistically reproduce the wood grain conduit cross section of natural wood, after embossing the decorative sheet surface with an embossing plate manufactured based on an image of the wood grain conduit cross section, The depth and roughness of the wood grain cross-section are reproduced by wiping by filling the embossed pipe with ink, but wiping requires a lot of ink costs and increases the number of steps, which takes time and effort. There is a problem that it leads to an increase in the delivery time and the delivery time. In addition, products that have been coated with an OP coat that gives a matte feel without wiping
Since the coating liquid does not enter the embossed conduit portion, there is a problem that the conduit portion results in a glossy and unnatural product. The present invention has been made in view of the above-mentioned problems, and a textured wood grain pattern can be obtained without wiping. Also, even if an OP coat is applied on the entire surface, the gloss is not reversed at the conduit portion and its peripheral portion. It is an object of the present invention to provide a decorative sheet which is high in cost and can reduce manufacturing costs and a door to which the decorative sheet is attached.

[0004]

Means for Solving the Problems A decorative sheet according to the present invention made in order to solve the above-mentioned problem is a decorative sheet for embossing a conduit part having a wood grain pattern. Forming a surface, the gloss of the uneven surface is suppressed to be smaller than the gloss of the periphery of the conduit portion, and the arrangement of the unevenness of the uneven surface is performed regularly or irregularly; A gradation is formed on the gloss of the surface. Further, this embossed decorative sheet is adhered to a core material to provide a door having an improved design effect.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is an example of a conduit pattern formed by a wood-grain conduit cross-sectional pattern found in natural wood. Each wood grain conduit cross-sectional pattern A is seemingly irregular but has an oblong shape extending in substantially the same direction. Therefore, the pattern model of the wood grain conduit cross-sectional pattern A is shown by an oblong shape as shown in FIG. . Also, the depth inside the conduit part is
It changes continuously in the longitudinal direction in any conduit section.

In the decorative sheet according to the present invention, the gloss of the uneven surface formed on the conduit portion embossed according to the wood grain conduit cross-sectional pattern A is suppressed to be smaller than the gloss of the peripheral portion. FIG. 3 is an explanatory diagram of an uneven pattern of an uneven surface formed in a conduit portion of a decorative sheet according to the present invention. A wide range of patterns can be used for the concavo-convex pattern. For example, FIG. 3A shows a case where the irregularities on the irregular surface are regularly arranged. The arrangement may be, for example, a halftone dot array of gravure printing shown in FIG. ) May be a halftone dot array of offset printing. FIG. 3 (b)
This is a case where irregularities on the irregular surface are irregularly arranged. For example, a pattern of a grain screen as shown in (b) may be used, or an irregular pattern created by computer graphic as shown in (b) It may be. With any of the concavo-convex patterns, the fineness of the concavities and convexities can be appropriately selected, and a concavo-convex surface having a predetermined gloss can be formed by a photoetching method described later. FIG. 3 (c)
Is a case where gradation is provided in the fineness of the uneven pattern on the uneven surface. This gradation may be a continuous change or a step change. The reason for having such a gradation is to simulate a change in the depth of the conduit portion which changes according to the longitudinal direction of the conduit caused by obliquely cutting the cylindrical grain conduit.

FIG. 4 is a state diagram in which the wood grain conduit cross-sectional pattern A and the concavo-convex pattern B are mapped. The decorative sheet according to the present invention embossed by the conduit embossing plate created based on the image mapped in this way is controlled so that the gloss of the conduit portion 1 is smaller than the gloss of the peripheral portion 2. So that the depth of the conduit feels more than the actual depth. Generally, the depth of the embossment in the conduit part 1 is 100 to 140 μm, and the amplitude of the uneven surface formed on the bottom is 20 to 30 μm.

The surface of the embossed decorative sheet according to the present invention is provided with a thermoplastic resin layer such as a polyolefin resin or polyvinyl chloride. In order to obtain the texture of natural wood, the luster of these resin surfaces is required. It is necessary to lower the level to a predetermined level, and the peripheral portion 2 of the conduit portion 1 is also embossed at the same time by the above-described conduit embossing plate, thereby forming a fine uneven shape. Generally, the surface roughness R of the embossed plate
_a (center line average roughness) increases, the gloss of the embossed decorative sheet surface decreases. When the embossing plate is roughened by sandblasting to reduce the gloss, it is effective to use a projection material having a particle size of 3 μm or more in _Ra , but the roughness of the surface becomes conspicuous, There is a problem that the finish with a high quality texture is impaired. Therefore, in the case of a wood grain pattern, there is naturally a limit in roughening the peripheral portion 2 other than the conduit portion 1. Further, instead of embossing the peripheral portion 2, an OP coat that gives a mat-like feeling may be applied to the entire surface. Whatever means is used to control the gloss, in the decorative sheet according to the present invention, if the gloss of the uneven surface of the conduit portion 1 is not less than the gloss of the peripheral portion 2 other than the conduit portion. No. The greater the difference in gloss between the two, the more the depth of the conduit is perceived to be greater than the actual depth, and the same effect as in the state filled with ink by wiping can be obtained. Further, by giving gradation to the gloss of the uneven surface of the conduit portion 1, it seems as if the depth of the conduit portion 1 has a change. Due to the visual effects described above, the decorative sheet according to the present invention can reproduce the woodgrain pattern of natural wood realistically, three-dimensionally, and with a texture even when the wiping step is cut.

Next, a method for producing an embossed decorative sheet according to the present invention will be described. First, a natural wood manuscript containing a conduit pattern as shown in FIG. 1 is photographed on a color film, and image data is inputted by a color scanner, or photographed by a digital camera, and the image data is directly outputted to CEPS. You may enter it. Next, from this image data, binary image data of the wood grain conduit cross-sectional pattern A used as a photomask pattern is created, or binary image data of the wood grain conduit cross-sectional pattern A is created directly by computer graphic technology. On the other hand, one of the uneven patterns B as shown in FIG. 3 is selected and mapped to the grain conduit cross-sectional pattern A to create an image file that is endless with the circumferential length of the emboss cylinder.

FIG. 5 is an explanatory view of a method for producing an embossed decorative sheet according to the present invention. In this manufacturing, a photo-etching technique is used. First, as shown in FIG. 5A, mapping image data is output from the above-described image file using a laser stream plate making apparatus on a resist photosensitive layer applied to the surface of the metallic emboss cylinder 3. The resist pattern is formed on the conduit portion 1 by baking and developing. Next, when the first corrosion is performed and the resist is stripped, the concavo-convex shape is formed in the conduit portion 1 according to the selected concavo-convex pattern B, as shown in FIG. Next, the emboss cylinder 3 is coated again with the resist photosensitive liquid, and this time, the binary image data of the wood grain conduit cross-sectional pattern A is output and developed.
A resist pattern for masking the conduit portion 1 is formed as shown in FIG. When the second corrosion is performed in this state, FIG.
As shown in (d), portions other than the conduit portion 1 are corroded, and the convex portions 5 necessary for the conduit embossing are obtained. Next, a fine grain image is printed on the entire surface 2 of the periphery of the conduit portion 1, and after development, the third corrosion or sandblasting is performed, and finally the resist for masking the conduit portion 1 is peeled off. By applying chrome plating to the entire surface, an embossing plate 10 used in the present invention as shown in FIG. 5 (e) is obtained.

The embossing plate 1 produced by the above manufacturing method
When embossing is performed on a thermoplastic resin film 7 such as polyolefin resin or polyvinyl chloride, so-called doubling embossing for laminating on the base film 8 is performed, or simultaneous embossing is performed by T-die extrusion molding. An embossed decorative sheet 20 according to the present invention having the embossed portions 6 as shown in FIG. 5 (f) is obtained.

Further, when the embossed decorative sheet 20 produced by the above method is bonded to a core material of a door having a honeycomb structure with a strong adhesive, a door to which the embossed decorative sheet according to the present invention is bonded is obtained.

[0013]

EXAMPLE A decorative sheet according to the present invention was prototyped using an oak wood grain pattern as an original. An image file was created by mapping a gravure halftone dot of 120 lines / inch as a concavo-convex pattern B as shown in FIG. Further, an image file which was endlessly corrected according to an emboss cylinder (420 mm in the width direction and 930 mm in the circumferential direction) was created. The endless file data is output to a cylinder coated with a photosensitive solution in advance using a laser stream plate making apparatus (manufactured by Synch Laboratories), and printing is performed. Then, development, corrosion, and resist stripping are performed in this order. Reference numeral 1 was an uneven surface in which cells in the shadow portion of the gravure printing plate surface were arranged. Next, the photosensitive liquid is applied again to the cylinder, a binary image of the wood grain conduit cross-sectional pattern A is output and baked, and a second corrosion is performed using the resist layer 4 obtained by development as a mask to form the convex portion 5. Was molded. next,
The mask provided on the conduit portion 1 is left as it is,
A grain image composed of a sand pattern of 0 to 100 μm was printed on the peripheral portion 2, developed, corroded, and stripped of resist. Using this embossing plate 10,
As a result of performing doubling embossing on the vinyl chloride film, the embossing depth of the conduit portion 1 becomes 110 μm,
An uneven surface having a depth of 30 μm was further formed on the bottom. When the embossed decorative sheet 20 according to the present invention thus produced was visually observed, it was possible to reproduce a realistic wood grain pattern having a texture similar to that of a conventional decorative sheet subjected to wiping processing. Further, this embossed decorative sheet was bonded to both surfaces of a core material having a honeycomb structure using a strong adhesive, and a door was produced by bonding the embossed decorative sheet according to the present invention.

[0014]

According to the present invention, by reducing the gloss of the uneven surface of the conduit portion 1 formed by the conduit embossment to be smaller than that of the peripheral portion 2, the conduit pattern can be formed almost in the same manner as the decorative sheet which has been wiped without wiping. Can be realistically reproduced with a texture, and therefore, a reduction in manufacturing cost and a shortened delivery time can be realized.

[Brief description of the drawings]

FIG. 1 is an example of a conduit pattern constituted by a wood grain conduit cross-sectional pattern found in natural wood.

FIG. 2 is a cross-sectional pattern model of a grain conduit of a decorative sheet according to the present invention.

FIG. 3 is an explanatory view of an uneven pattern of an uneven surface formed in a conduit portion of a decorative sheet according to the present invention.

FIG. 4 is a state diagram in which a wood grain conduit cross-sectional pattern A and an uneven pattern B are mapped.

FIG. 5 is an explanatory diagram of a method for producing an embossed decorative sheet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Conduit part 2 Peripheral part 3 Emboss cylinder 4 Resist layer 5 Convex part 6 Emboss part 7 Thermoplastic resin film 8 Base film 10 Emboss plate used for the present invention 20 Decorative sheet according to the present invention A Wood grain conduit cross-sectional pattern B Concavo-convex pattern

Claims (5)

[Claims] 1. A decorative sheet in which a wood-grained conduit portion is embossed, wherein an embossed surface is formed on the embossed conduit portion in accordance with the wood-grained conduit cross-sectional pattern, and the gloss of the concavo-convex surface is less than the gloss around the conduit portion. Embossed decorative sheet characterized in that the amount of embossing is reduced. 2. The embossed decorative sheet according to claim 1, wherein the irregularities on the irregular surface are regularly arranged. 3. The embossed decorative sheet according to claim 1, wherein the irregularities on the irregular surface are irregularly arranged. 4. The embossed decorative sheet according to claim 1, wherein a gradation is formed on the gloss of the uneven surface. 5. A door to which an embossed decorative sheet according to claim 1, wherein the embossed decorative sheet according to claim 1 is adhered to a core material to improve a design effect.