PL241117B1

PL241117B1 - Decorative sheet and a decorative panel containing it

Info

Publication number: PL241117B1
Application number: PL416529A
Authority: PL
Inventors: Naoki Tokumoto; Shin Oota; Jun Mizutani
Original assignee: Toppan Cosmo Inc
Priority date: 2015-05-01
Filing date: 2016-03-17
Publication date: 2022-08-01
Also published as: PL416529A1; JP2016210046A; JP6094621B2; DE102016104984A1

Abstract

Arkusz dekoracyjny obejmuje warstwy podłoża papierowego pierwszą i drugą, warstwę żywicy termoplastycznej umieszczoną między warstwami podłoża papierowego pierwszą i drugą i sklejającą warstwy podłoża papierowego pierwszą i druga, i warstwę, nadrukowanego wzoru wytworzoną na pierwszej warstwie podłoża papierowego. Arkusz dekoracyjny ma wiele określających, wytłoczenie części obniżonych wytworzonych na tej stronie powierzchni, na której tworzy się, warstwę nadrukowanego wzoru arkusza dekoracyjnego, a głębokość wielu określających wytłoczenie części obniżonych wynosi 15% lub więcej w odniesieniu do grubości całkowitej arkusza dekoracyjnego przed wytłaczaniem. Panel dekoracyjny obejmuje taki arkusz dekoracyjny laminowany na jednej z powierzchni podłoża.The decorative sheet comprises first and second layers of a paper substrate, a thermoplastic resin layer interposed between the first and second layers of the paper substrate and a gluing first and second layers of the paper substrate, and a printed pattern layer formed on the first layer of the paper substrate. The decorative sheet has a plurality of embossing defining portions produced on the side of the surface on which the printed decorative sheet pattern is formed, and the embossing depth of the recess portions is 15% or more of the total thickness of the decorative sheet prior to embossing. The decorative panel comprises such a decorative sheet laminated to one of the surfaces of the substrate.

Description

PL 241 117 B1

Description of the invention

FIELD OF THE INVENTION

The present invention relates to decorative sheets and decorative panels comprising a decorative sheet, in particular a decorative sheet that is provided with pattern printing and raised and lowered surfaces, and is used for general interior materials, surface decoration of assembly furniture, and the like, and a decorative panel containing such a decorative sheet.

BACKGROUND OF THE INVENTION

Decorative sheets with a pattern and durability improved by laminating a transparent film on a thermoplastic resin with print thereon, extruding a thermoplastic resin, or the like, have been practically and widely used.

On the other hand, papers with a preprint thereon are sometimes used as decorative sheets or decorative papers. For such a case, a method is known in which a paper substrate is printed, impregnated with a thermoplastic resin, and heat and pressure applied to it using a press to obtain a decorative panel. According to this method, the thermoplastic resin present on the surface of the decorative panel makes it possible to produce a decorative panel (or decorative sheet) with high surface hardness and high abrasion resistance.

Patent Document 1 (Japanese Unexamined Patent Application Publication No. H8-132582) discloses an example of such a decorative sheet that uses paper for a substrate. The decorative sheet described in Patent Document 1 is provided with an embossing layer composed of a thermoplastic resin sandwiched between two sheets of tissue (paper substrate) so that the two tissues are laminated to each other.

SUMMARY

However, in the decorative sheet described in Patent Document 1, two sheets of tissue are glued together by embossing a layer of a thermoplastic resin coating. Such tacking increased the tensile strength of these paper substrates and was likely to prevent tearing of the paper, but the improvement of the décor sheet pattern by deeper embossing was not sufficient, thus leaving a need for further pattern improvement.

Thus, the present invention relates to a decorative sheet with a further improved pattern and a decorative panel comprising such a decorative sheet.

To solve the above problem, the decorative sheet of the present invention comprises first and second paper substrate layers, a thermoplastic resin layer interposed between the first and second paper substrate layers and a gluing first and second paper substrate layer, and a pattern layer formed on the first paper substrate layer. The decorative sheet has a plurality of depressed portions defining the embossing on that side of the surface on which the pattern layer of the decorative sheet is formed, and the maximum depth of the plurality of depressed portions defining the embossing is 15% or more with respect to the total thickness of the decorative sheet prior to embossing, the maximum depth of the plurality of defining embossing of the depressed portions is 70 µm or more.

In this decorative sheet, the maximum depth of the plurality of relief defining portions is 15% or more with respect to the total thickness of the decorative sheet prior to embossing. For this reason, much more raised and lowered configurations are provided on the surface side of the decorative sheet, and thus the pattern can be improved further.

The decorative sheet of the present invention comprises first and second paper substrate layers, a thermoplastic resin layer interposed between the first and second layers of the paper substrate and a bonding first and second paper substrate layers, and a pattern layer formed on the first paper substrate layer, the plurality of relief defining portions forming on the surface side on which the decorative sheet pattern layer is formed, and the maximum depth of the plurality of depressed portions defining the embossing is 70 µm or more.

In the above decor sheet, the maximum depth of the plurality of depressed portions defining the embossing will be 70 µm or more. For this reason, there are many more raised and lowered configurations on the surface side of the decorative sheet, and thus the pattern can be improved further.

PL241 117 B1

In the above decorative sheet, preferably the thickness of the paper material used for the first and second layers of the paper substrate will be 15 Pm or greater and less than 60 Pm. When the thickness of the paper material is 60 µm or more, it may be difficult to apply suitable embossing to the decorative sheet and hardly any decorative sheet is obtained with a significantly improved pattern. Conversely, when the thickness of the paper material is less than 15 µm, tearing of the paper material or the like can easily occur when embossing is applied.

In the above decorative sheet, preferably the thickness of the thermoplastic resin layer will be 20 µm or greater and 70 µm or less, and it will be thicker than the paper material used for the second layer of the paper substrate. Thus, when the thermoplastic resin layer has a thickness of 20 µm or more, depressed defining portions are more reliably formed in the decorative sheet during the application of embossing, and so the pattern can be improved. Additionally, such a thickness may prevent the extruded configuration from returning to its pre-extrusion configuration, even when the decorative sheet is laminated or similarly treated.

In the above decor sheet, preferably the thickness of the paper material used for the first layer of the paper substrate placed on the surface side of the decoration sheet will be thicker than the thickness of the paper material used for the second layer of the paper substrate. In this case, easy printing is possible (improved printability).

In the above decorative sheet, preferably a plurality of depressed portions will be formed on the back of the surface side of the decorative sheet which is the side opposite the surface side towards the laminate. In this case, the adhesive enters the recessed portions when the decorative sheet is, for example, adhered to the substrate, whereby the adhesion of the decorative sheet can be improved. Accordingly, the amount of glue used can also be reduced. The recessed portions provided on the back side of the surface can also reduce the wrinkles that arise when the decorative sheets are laminated together.

In the above decorative sheet, the plurality of the depressed portions may be formed at positions viewed in the direction of the laminate different from the positions at which the depressed portion defining embossing is formed.

It may also be understood that the present invention relates to a decorative panel comprising a decorative sheet formed by any of the above and a substrate, wherein the decorative sheet is laminated to the surface of the substrate. According to this decorative panel, as in the decorative sheet, the effects as described above can also be achieved.

According to the present invention, a decorative sheet with a further improved pattern and a decorative panel comprising such a decorative sheet can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view showing a section through the structure of a decorative sheet according to the present invention;

FIG. 2 is a cross-sectional view showing the different thicknesses of the decorative sheet according to the present invention; and

FIG. 3 is a diagram of an extrusion apparatus.

DETAILED DESCRIPTION

Next, the decorative sheet and decorative panel according to the present invention will be described in detail with reference to the drawings. In the description, the same elements or elements having the same function may be designated with the same symbol, and repeated description thereof is omitted.

FIG. 1 is a schematic cross-sectional view showing a cross-section through the structure of a decorative sheet according to the present invention. As illustrated in FIG. 1, the decorative sheet 10 is configured with a first layer of paper substrate 1, a second layer of paper substrate 2, a thermoplastic resin layer 3, and a pattern printing layer (pattern layer) 4. The first and second paper substrate layers 1, 2 are adhered and secured to each other. by a layer of thermoplastic resin 3 sandwiched therebetween. The decorative sheet 10 has an embossed surface 10a and a plurality of embossed recess parts 5 are formed on the surface 10a. Each of the embossing deflection portions 5 is formed, for example, in a groove-like shape extending in the longitudinal direction in a wood-like pattern. The decorative sheet 10 also has a plurality of recessed portions 6 formed on the rear face 10b. Each of the recessed portions 6, as in the emboss-defining recessed portions 5, is formed, for example, in a similar shape.

PL 241 117 B1 into the groove extending in the longitudinal direction. It is preferred that the recessed portions 6 on the rear side of surface 10b are formed at positions viewed in the direction of the laminate different from the positions in which a defining embossing of the recessed portions 5 is formed on the side of surface 10a, but may also be formed in positions viewed in the direction of the laminate, the same as the positions where the defining embossing is created on the depressed part 5.

The decorative sheet 10 containing such a laminate is heated to a predetermined temperature and passes through an embossing unit composed of an embossing roll and a rear rubber roll, whereby the raised and lowered configurations are suitable on both surfaces 10a, 10b thereof. In the decorative sheet 10, the laminate may be rendered ductile upon heating. The laminate may also increase the tensile strength due to the presence of the thermoplastic resin layer 3. Accordingly, the extrudability of the laminate is increased.

Examples of the first and second paper substrate layers 1, 2 include various paper materials containing 50% or more cellulose fibers. It is preferred, for example, that the paper material constituting the first and second paper substrate layers 1, 2 has a thickness of 15 µm or greater and less than 60 µm, and more preferably the thickness is 25 µm or greater and 35 µm or less. When the paper material used for the first and second paper substrate layers 1, 2 is thinner than 15 µm, the strength is unsuitable for printing further processing. In contrast, when the paper material has a thickness of 60 µm or more, the embossability is poor, possibly making embossing difficult, or deep embossing may be difficult.

Further, as to the thicknesses of the paper materials constituting the first and second paper substrate layers 1, 2, each of the thicknesses of the paper materials used for the first and second paper substrate layers 1, 2 may be the same. Alternatively, the paper material used for the first layer of the paper substrate 1 may be thicker than the paper material used for the second layer of the paper substrate 2, in other words, the paper material for the second layer of the paper substrate 2 may be thinner than the paper material for the first layer of the paper substrate 1, or also vice versa. However, when the paper material for the second layer of the paper substrate 2 is thinner, the paper material on the embossed side of the surface 10a can be prevented from tearing or the like. Further, when the paper material for the second layer of the paper substrate 2 is thinner, the overall thickness of the entire decorative sheet 10 can also be made thinner. For this reason, it is preferable that the thickness of the paper material for the second layer of the paper substrate 2 is thinner than the thickness of the paper material for the first layer of the paper substrate 1. It should be noted that the paper material constituting the first layer of the paper substrate 1 is thicker than the paper material constituting the second layer of the paper substrate. 2 allows easy printing (good printability) of the first layer of paper substrate 1.

The thermoplastic resin layer 3 is laminated between the first and second paper substrate layers 1, 2, and adheres the first and second paper substrate layers 1, 2 to each other. The thermoplastic resin layer 3 also deforms when extrusion is applied and serves to hold and consolidate such a deformed configuration. The thickness of the thermoplastic resin layer 3 is not limited, but is preferably, for example, 20 μm or greater and 70 μm or less, and more preferably 35 μm or greater and 55 μm or less, and much more preferably 45 μm or greater and 55 μm or less. It is also preferred that the thickness of the thermoplastic resin layer 3 is thicker than the paper materials constituting the first and second paper substrate layers 1, 2. It is particularly preferred that the thermoplastic resin layer 3 is thicker than the paper material constituting the second paper substrate layer 2, in other words, such that the paper material for the second paper substrate layer 2 is thinner than the thermoplastic resin layer 3. Such a thermoplastic resin layer 3 is provided by forming a thermoplastic resin layer using, for example, an extruder, and laminating the first and second paper substrate layers 1,2 thereon.

It is preferred that the thermoplastic resin layer 3 is composed of a thermoplastic resin having a melting point of, for example, 100 ° C or higher and 200 ° C or less, and composed of any of, for example, polyvinyl chloride, poly ( vinylidene fluoride), nylon 12, polyamide, polyvinyl alcohol, polystyrene, styrene-acrylonitrile copolymers, styrene-butadiene-acrylonitrile copolymers, high-density polyethylene, medium-density polyethylene, low-density polyethylene, polypropylene, ethylene-acetate copolymers vinyl, polyacetal, polymethyl methacrylate), modified acrylic, polycarbonate, polyacetal, nitrocellulose, cellulose propionate, ethyl cellulose, cellulose acetate, and polyurethane.

PL241 117 B1

When the melting point of the resin constituting the thermoplastic resin layer 3 is in the range of 100 ° C or higher and 200 ° C or less, no degradation of the paper quality is caused, and embossing can be performed without degradation in productivity, such as in line speed. The thermoplastic resin constituting the thermoplastic resin layer 3 may be suitably selected in view of the melting point, but in view of the resin's cost and fluidity, it is preferable to use, for example, high density polyethylene, medium density polyethylene, and low density polyethylene.

The printed pattern layer 4 imparts a pattern or the like to the decorative sheet 10, and is formed by, for example, an ink. Examples of the pattern include a wood-like pattern. A known printing method and printing apparatus can be used as the printing method for producing such a pattern printing layer. The printing method is not particularly limited, but from an efficiency perspective, for example, a gravure printing method can be used.

The ink constituting the printed pattern 4 layer is not particularly limited, and it may be any water-based or solvent-based ink. Paint can be conveniently selected while considering compatibility with apparatus or performance required by decorative sheets and decorative panels. For dyes included in the printing ink for the décor sheet and décor panel, it is generally preferable to use a pigment dye while considering lightfastness.

A clear resin coating layer (not shown in the FIGURES) may further be provided on the printed pattern layer 4. The provided clear resin coating layer controls the gloss of the surface 10a of the decorative sheet 10 and allows the fabrication of a preferred pattern. In addition, the provided coating layer also enables the physical properties of the decorative sheet 10 surface, such as abrasion resistance, to be improved. The coating layer may also provide a partial gloss difference, such as in the vascular portion of a wood-like finish. Thus, it is also possible to visually create the rise and fall phenomena and combine them with the raised and lowered configuration created by embossing to express a high quality pattern.

Known coating equipment may be used to provide the coating layer, or else gravure printing equipment may be used. The clear resin constituting the coating layer is not particularly limited, but, for example, for gloss control, those resins in which silica is dispersed in a two-component curable urethane resin can be used.

In the following, a method of extruding a laminate comprising first and second paper substrate layers 1, 2 glued together by a thermoplastic resin layer 3 is described with reference to FIG. 2 and FIG. 3. It should be noted that the description of the method of gluing the paper materials constituting the first and second paper substrate layers 1, 2 by the thermoplastic resin layer 3 is omitted as conventional methods can be used.

First, as illustrated in FIG. 2 (a), a laminate 100 is formed configured with a second paper substrate layer 2, a thermoplastic resin layer 3, a first paper substrate layer 1, and a printed pattern layer 4 laminated in that order. The overall thickness D of the laminate 100 may be, for example, 60 µm to 160 µm, and preferably 80 µm to 120 µm. It should be noted that when a laminate 100 is formed, the thickness of the paper materials and the like constituting the first and second paper substrate layers 1, 2 is rather reduced as heat and pressure are applied to the laminate.

In turn, as illustrated in FIG. 3, extrusion is applied to the obtained laminate 100, using extrusion equipment 20. Extrusion equipment 20 is equipped with a main heating drum 21, an infraheater 22, a bar heater 23, an embossing roller 24 , rear rubber roller 25, and pickup roller 26.

The main heating drum 21 is cylindrical in shape and can rotate about a centreline line. The laminate 100 fed to the extrusion apparatus 20 first travels around the outer periphery of the main heat drum 21. The infrared heater 22 is a heater for heating the laminate 100 wound around the main heat drum 21. The infrared heater 22 is positioned close to the main heat drum 21 along a portion of the outer circuit. main heating drum 21. The laminate 100 moves further as the main heating drum 21 rotates and is heated by the infrared heater 22.

The longitudinal heater 23 is a heater for further heating the laminate 100 as it is transported away from the main heating drum 21. The longitudinal heater 23 is positioned along the area where

The laminate 100 moves from the main heat drum 21 to the embossing roll 24 and the rear rubber roll 25.

Embossing roll 24 and rear rubber roll 25 form an embossing unit and work together to emboss the laminate 100. Embossing roll 24 and rear rubber roll 25 are positioned downstream of main heat drum 21. Embossing roll 24 and rear rubber roll 25 are each positioned in a process line. cylindrical in shape and capable of pivoting about a respective centreline line. The embossing roll 24 and the rear rubber roll 25 contact each other at the outer periphery and emboss the laminate 100 as the laminate 100 passes therebetween. Details of the construction of embossing roll 24 and rear rubber roll 25 are described later.

The take-up roll 26 is positioned downstream of the embossing roll 24 and the rear rubber roll 25 and receives the laminate 100 (i.e., embossed decorative sheet 10) which has passed through the embossing roll 24 and the rear rubber roll 25 from the embossing apparatus 20.

As described above, embossing apparatus 20 used herein has, for example, devices for heating the laminate 100. The heated laminate 100 is then inserted between an embossing unit including an embossing roll 24 that has raised and lowered configurations on its surface, and a rear rubber roll. 25, and embossed as illustrated in FIG. 2 (b). When the laminate 100 is heated, the thermoplastic resin layer 3 softens and the surface 100a is easily embossed. Additionally, by positioning the thermoplastic resin layer 3 between the paper materials constituting the first and second paper substrate layers 1, 2, the tensile strength of the heated laminate 100 is increased, whereby an anti-tearing effect etc. of the laminate 100 can be obtained.

An extrusion having a depth of 15 µm or more is used to carry out embossing. This is because when the D1 (height difference) defining the embossing of the depressed portions 5 in the finished decorative sheet or decorative panel is 15 Pm or more, the embossing creates a raised and depressed effect as a pattern and so effectively appeals to visual perception.

Further, it is preferred, but not limited to, that the rear rubber roll used in this embodiment especially has a hardness of 50 or greater and 90 or less, and it is more preferred that the rear rubber roll has a hardness of 50 or greater. and 70 ° or less. The hardness is measured according to, for example, ISO 7619. In this embodiment, it is preferred to use a rear rubber roller with a hardness of 50 °. It should be noted that when a rear rubber roll having a hardness of more than 95 [deg.] Is used, the embossed pattern may be bad. It should be noted that the hardness of the rear rubber roll 25 can also be measured according to JIS K 6301 A or JIS K 6253, and the hardness measured according to these is equivalent to the hardness measured according to ISO 7619.

Embossing can be carried out using embossing equipment equipped with the ingredients described above to give a decorative sheet laminate with a raised and lowered surface, whereby a decorative sheet 10 can be obtained. rubber rollers. For this reason, when the embossing defining portions 5 are formed on the surface of the side 100a of the laminate 100 by the embossing roll after the laminate enters the rear rubber roll and the embossing roll, alternate recessed portions 6 having a predetermined depth are simultaneously formed on the rear side of the surface 100b. It should be noted that in the above manufacturing method, embossed lowered portions 5 and depressed portions 6 on surface 100a and rear surface 100b are formed on the laminate 100 substantially simultaneously, needless to say, embossing apparatus may be used for each of the surfaces 100a respectively and rear face 100b to separately provide defining embossing depressed portions 5 and depressed portions 6.

Next, the relationship between the overall thickness D of the decorative sheet 10 (laminate 100) before embossing and the depth D1 defining the embossing of the depressed portions 5 on the face 10a side (also referred to as maximum depth) will be described.

The decorative sheet 10 of this embodiment uses the embossing method described above, and hence a deeper embossing can be formed in the decorative sheet 10 than conventional embossing. Thus, in the decorative sheet 10 according to the present embodiment, the embossing depth D1 of the depressed portions 5 is 15% or more with respect to the total thickness D of the decorative sheet 10 before embossing. More preferably depth D1

The embossing portion 5 will be greater than 10% and 200% or less with respect to the total thickness D of the decorative sheet 10 prior to embossing. Defining the embossing of the recessed portions 5 constituting the recessed portions so deep (grooves) allows the decorative sheet 10 to have, for example, a more natural wood-like finish pattern. It should be noted that the depth D1 defining the embossing of the depressed portions 5 is specifically 70 µm or more. As the depth D1 defining the embossing of the depressed portions 5 becomes deeper, the pattern of the decorative sheet 10 can be improved, the feel and texture of the decorative sheet 10 can also be improved, and furthermore, the adhesive strength of the first and second paper substrate layers 1, 2 with the thermoplastic resin layer 3 can be improved. improve. The depth D1 defining the embossing of the recess 5 is preferably 200 µm or less, in which case a decorative sheet 10 with excellent moisture resistance can be provided.

It should be noted that the decorative sheet 10 is also provided with a plurality of grooved recessed portions 6 on the side of the rear face 10b, i.e. the side where the decorative sheet 10 is adhered to the substrate, or the like. For this reason, the adhesion strength to the substrate or the like can be easily increased. Moreover, the recessed portions 6 provided on the rear face side can also reduce the wrinkles that arise when the decorative sheets are laminated together.

Further, when the thermoplastic resin is reheated during extrusion, the correlated peel strength can be increased between the thermoplastic resin layer 3 and the paper material constituting the first paper substrate layer 1 or the second paper substrate layer 2. The peel strength (correlated peel strength) can be 1.8 N / 25 mm or more, more preferably 2.3 N / 2.5 mm or more, in the case, for example, where a decorative sheet 25 mm wide is secured to a 3 mm thick MDF substrate using a double-sided adhesive tape (Sekisui Chemical Co., Ltd., double-sided tape # 5760), then peeled off using a tensile strength tester (Orientec Co., Ltd., RTM-100) with an elastic loading rate of 200mm / min at 180 °.

It should be noted that such a decorative sheet 10, for example, can also be used as a decorative material by laminating to one of the surfaces of the substrate with an adhesive. Examples of the backing used for the decorative material include medium density fiberboard (MDF), plywood, and particle board, and inorganic supports such as gypsum board and metal board.

EXAMPLES

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the present invention is not limited to only these examples.

Example 1. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) Mixed paper (Tentok Paper Co., Ltd., TP23) having a basis weight of ²³ g / m2 (33 μm thickness) was provided as the first paper substrate, and a pattern was printed thereon using cellulose nitrate ink (Toyo Ink Co ., Ltd., PCNT Ink) and urethane ink (Toyo Ink Co., Ltd., PCRNT Ink). In turn, a transparent surface protection coating in which an isocyanate curing agent was added to a base resin containing an acrylic polyol as the main component was applied to the printed surface in an amount of 7 g / m ² dry weight to give a paper substrate for the decorative sheet.

(2) The paper substrate printed with the pattern as described above was cured at 60 ° C for 48 hours to allow the curing reaction to take place in the surface protective layer. In turn, molten high-density polyethylene at a heating temperature of 300 ° C was extruded at 2 to 20 g / 10 min in the form of a sheet between the unprinted side of the paper substrate and the mixed paper (Oji Paper Co., Ltd., FIXW23) having a basis weight of 23 g / m ² (thickness 30 µm), which was to constitute the second paper substrate, was pressed, and immediately cooled. This procedure produced a laminate comprising first and second layers of paper substrate on the front and back polyethylene layers, respectively. The thickness of the polyethylene layer was 50 µm and the total thickness D of the laminate was 101 µm.

(3) The surface temperature of the printed pattern of the obtained laminate was heated to 130 ° C, which is close to the melting point of polyethylene. A heated laminate was introduced between an embossing roll produced by the etching system and having a maximum depth of 150 μm and a rubber rear roller having a hardness of HS 50 ° (hardness spring),

When measured using a durometer according to JIS K6301: 1975, to give raised and lowered configurations both on the surface and on the back surface of the laminate, which was then immediately cooled. This procedure produced a decorative sheet with a raised and lowered configuration. The depth D1 defining the embossing of the depressed portions on the surface side of the obtained decorative sheet had a height difference of a maximum of 10 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 99%, thus confirming a satisfactory pattern for the decorative sheet. Also extrusion was easy to apply. The difference in height (depth) of the depth of embossing D1 was measured at the maximum height (Rmax) using a surface texture and integrated contour measuring instrument (Tokyo Seimitsu Co., Ltd., SURFCOM 120A).

(4) An ethylene-vinyl acetate emulsion single-component adhesive was applied with a coating weight of 55 g / m ² on a medium density fiber (MDF) substrate having a thickness of 2.5 mm and the obtained decorative sheet having the configuration the elevated and the lowered were laminated to an MDF substrate using a laminating roll, the surface of which was heated to a temperature of 100 ° C. This procedure produced a decorative panel having a raised and lowered configuration. On the obtained decorative panel, the embossing depressed portions had a maximum depth of 59 µm, and a decorative panel having a satisfactory raised and lowered pattern could be produced.

Example 2. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was prepared using the same ingredients and procedure as in Example 1 except that 52 µm thick blend paper (Tentok Paper Co., Ltd., HP45) was used as the first paper substrate. The overall thickness D of this laminate was 117 µm.

(3) The thus produced laminate was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 70 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 60%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

(4) The decorative panel was produced using the same ingredients and procedure as in Example 1. As a result, it was possible to produce a decorative panel having a satisfactory raised and lowered pattern.

Example 3. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was prepared using the same ingredients and procedure as in Example 2 except that 55 µm thick blended paper (Tentok Paper Co., Ltd., HPS45) was used as the second paper substrate. The overall thickness D of this laminate was 140 µm.

(3) The thus produced laminate was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 21 μm, and the depth ratio D1 with respect to the total thickness D before embossing was 15%, thus a non-problematic pattern for the decorative sheet was confirmed. Also extrusion was easy to apply.

Example 4. A decorative sheet was prepared using the following ingredients and procedure.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1 except that the thickness of the high density polyethylene used for the thermoplastic resin layer was 18 µm. The overall thickness D of this laminate was 72 µm.

(3) The laminate thus produced was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the embossed portions of the obtained decorative sheet had a height difference of at most 72 μm, and the depth ratio D1 with respect to the total thickness D before embossing was 100%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

(4) However, the decorative panel was not produced because the thickness of the thermoplastic resin layer was small.

PL241 117 B1

Example 5. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1 except that the thickness of the high density polyethylene used for the thermoplastic resin layer was 90 µm. The overall thickness D of this laminate was 136 µm.

(3) The thus produced laminate was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of not more than 140 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 103%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

Example 6 Using the following ingredients and procedure, a decorative sheet was prepared, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1 except that the thickness of the high density polyethylene used as the thermoplastic resin layer was 105 Pm. The overall thickness D of this laminate was 150 µm.

(3) The laminate thus produced was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 148 μm, and the depth ratio D1 with respect to the total thickness D before embossing was 99%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

Example 7. A decorative sheet was prepared using the following ingredients and procedure.

(1) (2) A laminate was prepared using the same ingredients and procedure as in Example 1, except that 50 µm mixed paper was used as the first paper substrate. The overall thickness D of this laminate was 116 µm.

(3) The thus-produced laminate was extruded by the same procedure as in Example 1. The hardness of the rubber roller used for embossing, however, was HS 80 °. The embossing depth D1 of the embossed portions of the obtained decorative sheet had a height difference of a maximum of 17 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 15%, thus confirming a non-problematic pattern for the decorative sheet. Also extrusion was easy to apply.

(4) However, a decorative panel was not manufactured using this sheet.

Example 8 Using the following ingredients and procedure, a decorative sheet was prepared, and a decorative panel was prepared using this sheet.

(1) (2) The laminate was produced using the same ingredients and procedure as in Example 1, except that low density polyethylene was used as the thermoplastic resin. The overall thickness D of this laminate was 101 µm.

(3) The thus-produced laminate was extruded by the same procedure as in Example 7. More specifically, the hardness of the embossing rear rubber roll was HS 80 °. The embossing depth D1 of the embossed portions of the obtained decorative sheet had a height difference of a maximum of 29 µm and the ratio of the depth D1 to the total thickness D before embossing was 28%, thus confirming a non-problematic pattern for the decorative sheet. Also extrusion was easy to apply.

Example 9. A decorative sheet was prepared using the following ingredients and procedure.

(3) The laminate thus produced was extruded by the same procedure as in Example 1. However, the hardness of the trailing rubber roll used for extrusion was HS 90 °. The embossing depth D1 of the resulting decorative sheet had a height difference of a maximum of 21 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 21%, thus confirming a non-problematic pattern for the decorative sheet. Also extrusion was easy to apply.

(4) However, a decorative panel was not manufactured using this sheet.

Example 10. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(3) The thus-produced laminate was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing was however HS 70 °. The depth D1 defining the embossing of the recessed portions of the obtained decorative sheet had a height difference of a maximum of 45 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 44%, which confirmed a relatively satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 11. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(3) The laminate thus produced was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing was however HS 60 °. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 70 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 69%, thus confirming a satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 12. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1. The overall thickness D of this laminate was 101 µm.

(3) The laminate thus produced was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for extrusion was however HS 90 °. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 40 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 40%, thus confirming a relatively satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 13. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(3) The thus-produced laminate was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing, however, was HS 80 °. The depth D1 defining the embossing of the recessed parts of the obtained decorative sheet had a height difference of a maximum of 50 μm, and the depth ratio D1 with respect to the total thickness D

The PL241 117 B1 before embossing was 50%, thus confirming a satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 14. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(3) The thus-produced laminate was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing was however HS 70 °. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 64 µm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 63%, thus confirming a satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 15. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(3) The laminate thus produced was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing was however HS 60 °. The depth D1 defining the embossing of the recessed portions of the obtained decorative sheet had a height difference of maximum 81 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 80%, thus confirming a satisfactory pattern for the decorative sheet. Also extrusion was easy to apply.

Example 16. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was manufactured using this sheet.

(1) (2) The laminate was produced using the same ingredients and procedure as in Example 1 except that medium density polyethylene was used for the thermoplastic resin. The overall thickness D of this laminate was 101 µm.

(3) The laminate thus produced was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of at most 91 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 90%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

Example 17. Using the following ingredients and procedure, a decorative sheet was prepared, and a decorative panel was prepared using this sheet.

(1) (2) The laminate was produced using the same ingredients and procedure as in Example 1 except that low density polyethylene was used for the thermoplastic resin. The overall thickness D of this laminate was 101 µm.

(3) The laminate thus produced was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of not more than 80 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 79%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

PL 241 117 B1

Example 18. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was prepared using this sheet.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1, except that low density polyethylene was used for the thermoplastic resin, and the thickness of the low density polyethylene was 24 µm. The overall thickness D of this laminate was 77 µm.

(3) The laminate thus produced was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 65 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 84%, thus a relatively satisfactory pattern for the decorative sheet was confirmed. Also extrusion was easy to apply.

(4) However, a decorative panel was not produced using this sheet because the thickness of the thermoplastic resin layer was small.

Example 19. A decorative sheet was prepared using the following ingredients and procedure, and a decorative panel was manufactured using this sheet.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1 except that low density polyethylene was used for the thermoplastic resin and the thickness of the low density polyethylene was 66 µm. The overall thickness D of this laminate was 115 µm.

(3) The thus-produced laminate was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 63 μm, and the depth ratio D1 with respect to the total thickness D before embossing was 55%, thus a satisfactory pattern for the decorative sheet has been confirmed. Also extrusion was easy to apply.

Comparative Example 1. A decorative sheet was prepared using the following ingredients and procedure.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 1, except that 60 μm mixed paper (Tentok Paper Co., Ltd., HC60) was used as the first paper substrate and mixed paper 60 µm thick (Oji Paper Co., Ltd., HC50) was used as the second paper substrate. The overall thickness D of this laminate was 151 µm.

(3) The thus-produced laminate was extruded with the same procedure as in Example 1. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 10 μm, and the ratio of the depth D1 with respect to the total thickness D before embossing was 6%, so that a satisfactory pattern for the decorative sheet has not been confirmed. However, extrusion was easy to apply.

(4) However, a decorative panel was not manufactured using this sheet.

Comparative Example 2. A decorative sheet was prepared using the following ingredients and procedure.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 2. The overall thickness D of this laminate was 117 µm.

(3) The thus-produced laminate was extruded by the same procedure as in Example 1. The hardness of the trailing rubber roll used for embossing, however, was HS 95 °. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 12 µm and the ratio of the depth D1 with respect to the total thickness D before embossing was 10%, so that a satisfactory pattern for the decorative sheet was not confirmed. However, extrusion was easy to apply.

(4) However, a decorative panel was not manufactured using this sheet.

Comparative Example 3. A decorative sheet was prepared using the following ingredients and procedure.

(1) (2) A laminate was produced using the same ingredients and procedure as in Example 3. The overall thickness D of this laminate was 140 µm.

(3) The thus-produced laminate was extruded by the same procedure as in Comparative Example 2. More specifically, the hardness of the trailing rubber roll used for extrusion was HS 95 °. The depth D1 defining the embossing of the depressed portions of the obtained decorative sheet had a height difference of a maximum of 5 μm, and the depth ratio D1 with respect to

PL241 117 Β1 to the total thickness D before embossing was 4%, so that a satisfactory pattern for the decorative sheet was not confirmed. However, extrusion was easy to apply.

(4) However, a decorative panel was not manufactured using this sheet.

The following Table 1 summarizes Examples 1 to 19 and Comparative Examples 1 to 3 described above. Note that "Excellent", "Good", "Acceptable", or "Unacceptable" are listed under Formula in Table 1, and these denote the perfection level of the pattern in that order. "Excellent", "Good", and "Acceptable" mean meeting the requirements, while "Unacceptable" means a defect. In the Extrusion entry in Table 1 "Good" is given in the case where extrusion was easily achieved, while "Acceptable" is given in the case where extrusion was not readily obtained but was feasible. Similarly, under Lamination in Table 1, the term "Good" is given in the case where a decorative panel having a good raised and lowered pattern could be produced, while the symbol is given in the case where no decorative panel was manufactured. It should be noted that Comparative Examples 1-3 and Examples 1, 3, 7-10, 12-14, 18 and 19 are not within the claimed scope of the invention. Examples 2, 4-6, 11 and 15-17 are within the claimed scope of the invention.

Table 1

Claims

PL 241 117 B1

As can be seen in Table 1 above, decorative sheets having an embossing depth with a thickness ratio of 15% or more, more preferably 30% or more, and decorative panels comprising such decorative sheets can be obtained, whereby an improvement in the pattern is confirmed. Decorative sheets having a depth D1 defining embossment of the recessed portions of 70 µm or more have also been confirmed to have particularly high pattern quality.

List of references

1 ... First layer of paper backing, 2 ... Second layer of paper backing,

3 ... Thermoplastic resin layer, 4 ... Printed pattern layer (Pattern layer),

5 ... Defining the embossing low part, 6 ... Low part, 10 ... Decorative sheet,

10a ... Surface, 10b ... Back surface, 100 ... Laminate, 100a ... Surface, 100b ... Back surface, D ... Total thickness of the decorative sheet before embossing, D1 ... Depth defining the embossing lowered part.

Patent claims

1. A decorative sheet containing:

first and second layers of the paper substrate;

a thermoplastic resin layer interposed between the first and second layers of the paper substrate and gluing the first and second layers of the paper substrate; and a pattern layer formed on the first layer of the paper substrate, wherein a plurality of relief defining portions are formed on that side of the surface on which the pattern layer of the decorative sheet is formed, and the maximum depth of the plurality of relief defining portions is 15% or more of the total thickness the decorative sheet prior to embossing, characterized in that the maximum depth of the plurality of depressed portions defining the embossing is 70 µm or more.

2. The decorative sheet according to claim 1 The method of claim 1, wherein the thickness of the paper material used for the first and second layers of the paper substrate is 15 µm or greater and less than 60 µm.

3. The decorative sheet according to claim 1 The method of any of claims 1 to 2, characterized in that the thickness of the thermoplastic resin layer is 20 Pm or greater and 70 Pm or less and is thicker than the paper material used for the second paper substrate layer.

4. The decorative sheet according to claim 1 The method of any of claims 1 to 3, characterized in that the thickness of the paper material used for the first layer of the paper substrate placed on the surface side of the decorative sheet is thicker than the thickness of the paper material used for the second layer of the paper substrate.

5. The decorative sheet according to claim 1 A method as claimed in any one of claims 1 to 4, characterized in that a plurality of recessed portions are formed on the back of the surface side of the decorative sheet.

A decorative sheet according to claim 1. The process of claim 5, characterized in that the plurality of the depressed portions are formed at positions viewed in the direction of the laminate different from the positions in which the depressed portions define an embossing are formed.

7. Decorative panel containing:

a decorative sheet and substrate, wherein the decorative sheet is laminated to the surface of the substrate, characterized in that the decorative sheet is as defined in claim 1; 1 to 6.