WO2006075836A1

WO2006075836A1 - Manufaturing method of sheet with surface decorative layer

Info

Publication number: WO2006075836A1
Application number: PCT/KR2005/003264
Authority: WO
Inventors: Woo Jin Jang
Original assignee: Woo Jin Jang
Priority date: 2005-01-13
Filing date: 2005-10-04
Publication date: 2006-07-20

Abstract

Disclosed herein is a method of manufacturing a sheet having a decorative surface layer, in which a transparent coating layer is formed on a base sheet having a decorative surface layer formed of glittering materials and/or corn spangles, thereby enabling easy secondary processing and protecting the decorative surface layer from the external environment, and in which a glittering layer is directly formed on a hot melt layer without the use of a base sheet, the transparent coating layer then being formed on the glittering layer, thus increasing product functionality.

Description

MANUFACTURING METHOD OF SHEET WITH SURFACE

DECORATIVE LAYER

Technical Field

[1] The present invention relates, generally, to a method of manufacturing a sheet having a decorative surface layer, and more particularly, to a method of manufacturing a sheet having a decorative surface layer, in which a transparent coating layer is formed on a base sheet having a decorative surface layer formed of glittering material and/or corn spangles, thereby making secondary processing easy and protecting the decorative surface layer from the external environment, and in which a glittering layer is directly formed on a hot melt layer without the use of a base sheet, the transparent coating layer then being formed on the glittering layer, thus increasing product functionality.

[2]

Background Art

[3] Sheets that are conventionally manufactured to have decorative surface layers including decorative materials, such as glittering materials, attached to surfaces thereof are presently commercially available. Under illumination or natural light, the glittering material attached to the sheet glitters due to the irregular reflection of light, thus providing a visual effect. The sheet is thus variously applied to accessories, etc.

[4] With reference to FIG. 1, there is shown a conventional sheet having a decorative surface layer, manufactured by applying an adhesive on a base sheet 10 to form an adhesive layer 20, and applying a glittering material on the adhesive layer 20 using a glittering material feeder to form a glittering layer 30, which is then dried.

[5] However, the sheet having a decorative surface layer thus manufactured suffers because the glittering layer 30 externally protrudes, thus the glittering material attached to the surface of the sheet may easily become detached by external friction or moisture, therefore resulting in non-uniform products and decreased reliability of products. In addition, properties, including flexibility, viscosity, strength, etc., become poor, and thus punchability is deteriorated. Hence, it is difficult to conduct secondary processing. As well, in the case where the sheet is used as accessories for clothes, shoes, etc., the glittering material may become detached from the sheet due to frequent washing, and thus the sheet does not function well as an accessory.

[6] Further, the conventional sheet having a decorative surface layer has a structure in which the glittering material is attached to the base sheet via an adhesive layer. When such a conventional sheet is cut into predetermined shapes of numbers, characters or patterns, as shown in FIG. 16, and is then attached to bags or clothes, a feeling of the glittering sheet being separated from the clothes due to the presence of the thick base sheet is created, degrading the external beauty thereof. Moreover, since the base sheet commonly used for the decorative sheet is not stretchable, the decorative sheet suffers from a hard and stiff feeling when attached to clothes.

[7]

Disclosure of Invention Technical Problem

[8] Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and an object of the present invention is to provide a sheet having a decorative surface layer, which is advantageous because it is highly reliable thanks to economical and efficient processes forming, on a base sheet, a layer of glittering material, spangles or a combination thereof, with or without the use of an adhesive layer, and forming a transparent coating layer containing a specific urethane elastomer.

[9] Another object of the present invention is to provide a method of manufacturing a sheet having a decorative surface layer, which is highly reliable thanks to economical and efficient processes using glittering material or spangles.

[10] A further object of the present invention is to provide a method of manufacturing a sheet having a decorative surface layer that creates an integrated feeling when the sheet is attached to bags or clothes by omitting a film layer from the sheet.

[H]

Technical Solution

[12] In order to achieve the above objects, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising (a) forming an adhesive layer on a surface of a base sheet; (b) applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; and (c) applying transparent resin paint on the glittering layer, to form a transparent coating layer, the transparent resin paint comprising (i) 60-80 wt% of a urethane elastomer resulting from a reaction between polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[13] Further, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising (a) applying hemispherical corn spangles, each of which has a hot melt material attached to a flat surface thereof, on a first base sheet; (b) passing the first base sheet having the spangles applied thereon between a heat roller and a support roller, and passing adhesive paper or a second base sheet fed via a feed roller between the heat roller and the support roller, so that the hemispherical corn spangles applied on the first base sheet are attached to the adhesive paper or the second base sheet, and the inverted hemispherical corn spangles applied on the first base sheet are attached to the first base sheet; and (c) applying transparent resin paint on the first base sheet or the second base sheet having the spangles attached thereto, to form a transparent coating layer, the transparent resin paint comprising (i) 60-80 wt% of a urethane elastomer resulting from a reaction between polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[14] Further, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising (a) forming an adhesive layer on a surface of a first base sheet; (b) applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; (c) applying hemispherical corn spangles, each of which has a hot melt material attached to a flat surface thereof, on the first base sheet having the glittering layer formed thereon; (d) passing the first base sheet having the corn spangles applied thereon between a heat roller and a support roller, and passing adhesive paper or a second base sheet fed via a feed roller between the heat roller and the support roller, so that the hemispherical corn spangles applied on the first base sheet are attached to the adhesive paper or the second base sheet, and the inverted hemispherical corn spangles applied on the first base sheet are attached to the first base sheet; and (e) applying transparent resin paint on the first base sheet or the second base sheet having the spangles attached thereto, to form a transparent coating layer, the transparent resin paint comprising (i) 60-80 wt% of a urethane elastomer resulting from a reaction between polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[15] Further, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising applying a hot melt material on an assistant film, and then drying the applied hot melt material, to form a hot melt layer; applying an adhesive on the hot melt layer, to form an adhesive layer; applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and laminating a transparent film on the transparent coating layer and removing the assistant film from the hot melt layer.

[16] Further, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising applying a hot melt material on an assistant film, to form a hot melt layer; directly applying a glittering material on the hot melt layer, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and laminating a transparent film on the transparent coating layer and removing the assistant film from the hot melt layer.

[17] Further, the present invention provides a method of manufacturing a sheet having a decorative surface layer, comprising applying a hot melt material on an assistant film, to form a hot melt layer; applying a glittering material on the hot melt layer, to form a glittering layer; and laminating a transparent film on the glittering layer and removing the assistant film from the hot melt layer.

[18] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following preferred embodiments taken in conjunction with the accompanying drawings.

[19]

Advantageous Effects

[20] The present invention provides a method of manufacturing a sheet having a decorative surface layer, which is advantageous because a transparent coating layer having a specific urethane elastomer is additionally formed on the decorative surface layer, and thus the decorative surface layer is protected from the external environment, such as external friction or moisture, to improve the external appearance and reliability of products. Also, the sheet, which has excellent physical properties, including flexibility, viscosity, strength, etc., is easily subjected to secondary processing and has superior washfastness. In the case of manufacturing the sheet having spangles, punchability is superior, and thus the secondarily processed sheet, as well as the sheet itself, is expected to be widely applied in various fields. Further, products having the same structure can be simultaneously manufactured through a single process, or the spangles can be recovered from paper to reuse them while manufacturing a product, if necessary. Thereby, it is possible to provide economical and efficient processes.

[21] In addition, the method of the present invention is advantageous because a glittering layer can be directly formed on the hot melt layer without the use of a base sheet. When the sheet is cut and attached to bags or clothes, the glittering material is directly attached to bags or clothes due to the absence of the base sheet, thus providing an integrated feeling. The external appearance is thus improved. Also, since the glittering layer is directly formed on the hot melt layer, the sheet itself is stretchable. When a user wears clothes to which the sheet of the present invention is attached, the user feels pleasant, rather than uncomfortable.

[22] Brief Description of the Drawings

[23] FIG. 1 is a sectional view showing the structure of a conventional sheet having a decorative surface layer; [24] FIG. 2 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a first embodiment of the present invention; [25] FIG. 3 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a second embodiment of the present invention; [26] FIGS. 4 to 7 are views schematically showing a process of manufacturing the sheet having a decorative surface layer, according to the second embodiment of the present invention; [27] FIG. 8 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a third embodiment of the present invention; [28] FIG. 9 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a fourth embodiment of the present invention; [29] FIG. 10 is views sequentially showing a process of manufacturing the sheet having a decorative surface layer, according to the fourth embodiment of the present invention; [30] FIG. 11 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a fifth embodiment of the present invention; [31] FIG. 12 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a sixth embodiment of the present invention; [32] FIG. 13 is a sectional view showing the structure of a sheet having a decorative surface layer, according to a seventh embodiment of the present invention; [33] FIGS. 14 and 15 are sectional views showing the structure of a sheet having a decorative surface layer, according to an eighth embodiment of the present invention; and

[34] FIG. 16 is an exemplary view showing the use of the sheet attached to clothes.

[35]

Best Mode for Carrying Out the Invention [36] According to an aspect of the present invention, a method of manufacturing a sheet having a decorative surface layer is provided, in which a layer of glittering material, spangles or a combination thereof is formed on a base sheet, with or without the use of an adhesive layer, and a transparent coating layer containing a specific urethane elastomer is formed through economical and efficient processes, thereby obtaining a desired sheet having a decorative surface layer, which is highly reliable and has an excellent external appearance and physical properties, including flexibility, viscosity, strength, etc. Hereinafter, preferred embodiments of the present invention are described.

[37] [First Embodiment]

[38] According to the manufacturing method of the present embodiment, a sheet having a decorative surface layer is manufactured to have a base sheet 10, an adhesive layer 20, a glittering layer 30 and a transparent coating layer 50, which are sequentially laminated, as shown in FIG. 2.

[39] First, an adhesive is applied on a sheet 10, using a typical process known in the art, to form an adhesive layer 20. Subsequently, a glittering material is applied on the adhesive layer 20 using a glittering material feeder and is then dried, to form a glitterin g layer 30.

[40] Although the base sheet 10 used in the present invention is not particularly limited, various materials, including general fabric, such as cotton, synthetic resin films, etc., may be used. In addition, the glittering material used in the glittering layer 30 is not particularly limited, but a polyester film is preferably used, in which the polyester sheet may be color printed and then cut into small particles for use.

[41] Then, transparent resin paint containing a urethane elastomer is applied on the glittering layer 30 at 100~130°C for 10-15 sec using a rolling process, to form a transparent coating layer 50, thereby completing a desired sheet having a decorative surface layer.

[42] The composition of the transparent resin paint comprises 60-80 wt% of a urethane elastomer, resulting from a reaction between polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, 0.1-1 wt% of a dispersant, and 0.1-1 wt% of a leveling agent, with the balance of a solvent.

[43] The urethane elastomer, which is a material having the same properties as soft urethane rubber, exhibits excellent elasticity and enables easy secondary processing. In addition, when a pigment, such as glittering material, is added to the resin paint, the urethane elastomer functions as a medium for conferring attachability to the material surface and simultaneously manifests flexibility and strength required for protection of the inner glittering layer, even upon frequent washing.

[44] In particular, in the present invention, when the urethane elastomer, as the reaction product between polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, is used, the specific properties as mentioned above can be realized.

[45] The urethane elastomer is contained in the transparent resin in an amount of 60-80 wt%. If the urethane elastomer is used in an amount less than 60 wt%, the properties required of the upper coating layer of the glittering sheet cannot be obtained. On the other hand, if the above amount exceeds 80 wt%, processability and handling properties are degraded. [46] The dispersant is an additive used to easily disperse the pigment, and the leveling agent is a paint surface controller, each of which is used in an amount of 0.1-1.0 wt%, suitable for the exhibition of required properties.

[47] The solvent is selected from the group consisting of aromatic hydrocarbon solvents having moderate boiling points, solvents having low boiling points and minimal offensive odors, such as alcohols, and mixtures thereof, but is not limited thereto.

[48] In addition, a pigment and a dulling agent, such as silica, may be further included, if necessary.

[49] The thickness of the transparent coating layer 50 formed by applying the transparent resin paint preferably ranges from 50 to 300 D, but is not limited thereto.

[50] The sheet thus manufactured is advantageous because the transparent coating layer

50 having superior attachability and elasticity is formed on the glittering layer 30, whereby the glittering material attached to the surface of the sheet is prevented from being easily detached by external friction or moisture, thus increasing the reliability of products. As well, physical properties, including flexibility, viscosity, strength, etc., are excellent, and thus secondary processing becomes easy and washfastness increases.

[51] [Second Embodiment]

[52] According to the manufacturing method of the present embodiment, a sheet having a decorative surface layer is manufactured to have a base sheet 10, a spangle layer 40, and a transparent coating layer 50, which are sequentially laminated, as shown in FIG. 3.

[53] Below, a process of manufacturing the above sheet is described with reference to

FIG. 4.

[54] While a first base sheet 7 is conveyed through a conveying roller 3, hemispherical corn spangles S, each of which has a hot melt material attached to a flat surface thereof, are applied on the first base sheet 7 using a spangle feeder 5. Thereby, the corn spangles are optionally applied in the hemispherical shapes and inverted hemispherical shapes on the first base sheet 7, as shown in this drawing. Although the first base sheet is not particularly limited, the base sheet used in the first embodiment may be applied.

[55] Then, adhesive paper 6 is fed via a feed roller 1.

[56] Thereby, while the first base sheet 7 and the adhesive paper 6 are conveyed and fed through the conveying roller 3 and the feed roller 1, respectively, they 6 and 7 are passed between a heat roller 2 and a support roller 4 to be laminated. When the adhesive paper 6 and the base sheet 7 are heated and compressed by the heat roller and the support roller, the hot melt material attached to the flat surface of the spangle S melts and the spangles are then attached to the adhesive paper 6 and the base sheet 7. As shown in FIG. 5, the inverted hemispherical corn spangles S are attached to the base sheet, whereas the hemispherical corn spangles S are attached to the adhesive paper 6.

[57] After the adhesive paper 6 and the base sheet 7 are removed from the heat roller 2 and the support roller 4, the base sheet 7 is wound using a bobbin (not shown) according to a typical process known to those skilled in fiber arts. Meanwhile, the spangles attached to the adhesive paper 6 are separately recovered to be reused.

[58] The base sheet 7 having the spangles S attached thereto is coated with transparent resin paint as mentioned in the first embodiment to form a transparent coating layer, to complete the sheet having the decorative surface layer of the present invention. The detailed description thereof is omitted.

[59] In FIG. 4, C designates a cushion film wound on the heat roller. When the adhesive paper 6 having the corn spangles attached thereto is passed between the heat roller 2 and the support roller 3, since the corn spangles may be flattened by crushing, the cushion film C functions to confer cushioning capability to the heat roller so that the corn spangles are not crushed and maintain their original state, thereby keeping briliantly glittering effects.

[60] In addition to the feeding of the adhesive paper through the feed roller as described above, a process of feeding a second base sheet 6-1 is described below.

[61] As shown in FIG. 6, while a first base sheet 7 and a second base sheet 6-1 are conveyed and fed through a conveying roller 3 and a feed roller 1, respectively, they 6-1 and 7 are passed between a heat roller 2 and a support roller 4 to be laminated. As shown in FIG. 7, the inverted hemispherical corn spangles S are attached to the first base sheet, whereas the hemispherical corn spangles S are attached to the second base sheet 6-1.

[62] The present embodiment, including the embodiment using the adhesive paper, is advantageous because two corn spangle-attached sheets having the same structure are manufactured at one time through a single process. In addition, since the second base sheet 6- 1 has a cushioning capability, the heat roller 2 need not be additionally wound with the cushion film C.

[63] In this way, each of two base sheets 6-1 and 7, having the corn spangles attached thereto, is coated with transparent resin paint to form a transparent coating layer, as in the first embodiment. Thereby, the corn spangles attached to the surface of the sheet may be prevented from being easily detached by external friction or moisture. As well, the base sheet, in which physical properties, including flexibility, viscosity, strength, etc., are excellent, can be provided.

[64] [Third Embodiment]

[65] According to the manufacturing method of the present embodiment, a sheet having a decorative surface layer is manufactured to have a base sheet 10, an adhesive layer 20, a glittering layer 30, a spangle layer 40 and a transparent coating layer 50, which are sequentially laminated, as shown in FIG. 8.

[66] The method of manufacturing the sheet according to the present embodiment is conducted as follows, based on those described in the first and second embodiments.

[67] First, an adhesive layer 20 and a glittering layer 30 are formed on a base sheet 10, as described in the first embodiment.

[68] Thereafter, when a first base sheet 7, having the glittering layer 30 formed thereon, is conveyed through a conveying roller 3, corn spangles are applied in the hemispherical shapes and inverted hemispherical shapes on the first base sheet using a spangle feeder 5, after which the first base sheet is passed between a heat roller 2 and a support roller 4. At this time, adhesive paper 6 or a second base sheet 6- 1 is separately fed via a feed roller 6 and passed between the heat roller 2 and the support roller 4 to be laminated on the first base sheet. Thereby, the hemispherical corn spangles are attached to the adhesive paper 6 or the second base sheet 6-1, whereas the inverted hemispherical corn spangles are attached to the first base sheet 7. On each of the first base sheet 7 and the second base sheet 6-1 having the spangles attached thereto, a transparent coating layer 50 is layered, to complete the sheet having the decorative surface layer.

[69] According to another aspect of the present invention, disclosed hereinbelow is a method of manufacturing a sheet having a decorative surface layer, which creates an integrated feeling when the sheet is attached to bags or clothes because a film layer is omitted therefrom, preferred embodiments thereof being specifically explained.

[70] [Fourth Embodiment]

[71] In this embodiment, a sheet having a decorative surface layer has a structure consisting of a hot melt layer 120, an adhesive layer 130, a glittering layer 140, a transparent coating layer 150 and a transparent film 160, which are sequentially laminated, as shown in FIG. 9.

[72] Referring to FIG. 10, the process of manufacturing the sheet is illustrated. First, a hot melt material is applied to a uniform thickness on an assistant film 110 and is then dried, to form a hot melt layer 120. Using a process typically known in the art, an adhesive is applied on the hot melt layer 120 to form an adhesive layer 130, after which a glittering material is applied on the adhesive layer 130 using a glittering material feeder and is then dried, to form a glittering layer 140.

[73] As such, although the hot melt material is not particularly limited, polyester or polyurethane is mainly used. The glittering material used in the glittering layer 140 is not particularly limited, but preferably includes, for example, a polyester film, which is color printed and then cut into small particles for use.

[74] On the glittering layer 140, transparent resin paint is applied to form a transparent coating layer, as described in the first embodiment, and thus the detailed description thereof is omitted.

[75] Subsequently, a transparent film 160 having adhesive strength is laminated on the transparent coating layer 150. The assistant film 110 provided at the lower surface of the hot melt layer 120 is removed from the hot melt layer, thereby completing the sheet having the decorative surface layer of the present invention.

[76] Thanks to the lamination of the transparent film 160, a process of cutting the sheet obtained using the above-mentioned manufacturing method into predetermined shapes of figures, characters, numbers, etc., can be easily conducted. In addition, the reason why the transparent film 160 having adhesive strength is used for lamination is that the transparent film is not laminated on the transparent coating layer through a compression process but is laminated in a simple adhesion manner so as not to crush the glittering layer 140. Hence, when the glittering layer is touched, it feels like sand granules.

[77] Further, in order to attach the sheet thus manufactured to shoes, bags, or clothes, the sheet is cut into desired shapes of figures, characters, etc., using an additional cutter, the laminated transparent film 160 is removed, and the hot melt layer 120 tightly contacts clothes, etc., and is then attached thereto using heat from an ultrasonic fusion machine known in the art.

[78] Since the sheet having a decorative surface layer thus manufactured includes the glittering layer directly formed on the hot melt layer without the use of a base sheet, the sheet itself is stretchable. Thus, in the case where such a sheet is cut into desired shapes of figures, characters or numbers and is then attached to bags or clothes, the hot melt layer 120 is immediately melted and attached to bags or clothes. Therefore, the sheet provides not a feeling of being separated from the the bags or clothes but a feeling of being integrated therewith, and an external appearance can be made more beautiful.

[79] In the sheet of the present invention, the transparent coating layer having excellent attachability and elasticity is formed on the glittering layer, whereby the glittering material attached to the surface is prevented from being easily detached by external friction or moisture, thus increasing the reliability of products. As well, physical properties, including flexibility, viscosity, strength, etc., are excellent, therefore enabling easy secondary processing and increasing washfastness.

[80] In addition, with the goal of easily performing the cutting process, when the transparent film is laminated, a simple adhesion process is adopted, instead of a conventional compression process, thus the glittering layer is not crushed. When the glittering layer is touched, a pleasant feeling like that of sand granules may be experienced.

[81] [Fifth Embodiment] [82] In this embodiment, a sheet having a decorative surface layer has a structure consisting of a hot melt layer 120, a glittering layer 140, a transparent coating layer 150, and a transparent film 160, which are sequentially laminated, as shown in FIG. 11.

[83] The sheet of the present embodiment is manufactured to have the same structure in the same manner as in the fourth embodiment, with the exception that a hot melt layer 120 is applied on an assistant film 110, and a glittering material is directly applied without the use of an adhesive before the hot melt layer 120 is dried, so that a glittering layer 140 is formed while the hot melt layer 120 is dried, and thus, a detailed description thereof is omitted, with reference to the fourth embodiment.

[84] [Sixth Embodiment]

[85] In this embodiment, a sheet having a decorative surface layer has a structure consisting of a hot melt layer 120, a glittering layer 140, and a transparent film 160, which are sequentially laminated, as shown in FIG. 12.

[86] Such a sheet is manufactured in the same manner as in the process of manufacturing a sheet shown in FIG. 10, with the exception that the step of forming a transparent coating layer 150 is omitted, and thus a detailed description thereof is omitted.

[87] Since the sheet thus manufactured has no transparent coating layer, the glittering material may not be prevented from becoming detached by friction or moisture, compared to the other embodiments as mentioned above. However, the glittering layer is not formed on the base sheet but is directly formed on the hot melt layer. Hence, when the resultant sheet is attached to bags or clothes, it has an integrated feeling, thus making the external appearance thereof more beautiful.

[88] [Seventh Embodiment]

[89] In this embodiment, a sheet having a decorative surface layer has a structure consisting of a hot melt layer 120, an adhesive layer 130, a glittering layer 140, and a transparent film 160, which are sequentially laminated, as shown in FIG. 13. This sheet is manufactured in the same manner, without the step of forming a transparent coating layer 150, as in the sixth embodiment, and thus a detailed description thereof is omitted.

[90] [Eighth Embodiment]

[91] According to the method of manufacturing a sheet having a decorative surface layer of the present embodiment, a double-sided adhesive sheet or a single-sided adhesive sheet is used, instead of using a hot melt layer.

[92] That is, the sheet having a decorative surface layer as shown in FIG. 14 is manufactured by directly applying a glittering material on a common double-sided adhesive sheet 170-1 having release paper 172 attached to a lower surface thereof to form a glittering layer 140, applying transparent resin paint on the glittering layer to form a transparent coating layer 150, and laminating an adhesive transparent film 160 on the transparent coating layer. The double-sided adhesive sheet is commercially available from 3M Company. The description of the transparent resin paint refers to the above embodiments.

[93] In order to attach the sheet having a decorative surface layer thus manufactured to shoes, bags or clothes, such a sheet is cut into desired shapes of figures or characters using an additionally provided cutter, the laminated transparent film 160 is removed and then the release paper 172 is released, after which the sheet is directly attached to clothes, etc.

[94] In addition, a sheet having a decorative surface layer as shown in FIG. 15 is manufactured by applying an adhesive on a single-sided adhesive sheet 170-2 having release paper 172 attached to a lower surface thereof to form an adhesive layer 130, applying a glittering material on the adhesive layer 130 and then drying it to form a glittering layer 140, applying transparent resin paint on the glittering layer to form a transparent coating layer 150, and laminating an adhesive transparent film 160 on the transparent coating layer. The single-sided adhesive sheet is commercially available from 3M Company, and the description of the transparent resin paint refers to the above embodiments.

[95] To attach the sheet having the decorative surface layer thus manufactured to shoes, bags or clothes, the sheet is cut into desired shapes of figures or characters using an additionally provided cutter, as shown in FIG. 16, the laminated transparent film 160 is removed and then the release paper 172 is released, after which the sheet is directly attached to clothes, etc.

[96]

Industrial Applicability

[97] As described hereinbefore, a sheet having a decorative surface layer according to the present invention can be efficiently applied to bags, clothes, shoes, hair pins, hair bands, headgear, waist belts, fashion accessories, decorative sheets, patches for clothes, etc.

Claims

[1] A method of manufacturing a sheet having a decorative surface layer, comprising:

(a) forming an adhesive layer on a surface of a base sheet;

(b) applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; and

(c) applying transparent resin paint on the glittering layer, to form a transparent coating layer, in which the transparent resin paint comprises (i) 60-80 wt% of a urethane elastomer as a reaction product of polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[2] A method of manufacturing a sheet having a decorative surface layer, comprising:

(a) applying hemispherical corn spangles, each of which has a hot melt material attached to a flat surface thereof, on a first base sheet;

(b) passing the first base sheet having the spangles applied thereon between a hea t roller and a support roller, and passing adhesive paper or a second base sheet fed via a feed roller between the heat roller and the support roller, so that the hemispherical corn spangles applied on the first base sheet are attached to the adhesive paper or the second base sheet, and the inverted hemispherical corn spangles applied on the first base sheet are attached to the first base sheet; and

(c) applying transparent resin paint on the first base sheet or the second base sheet having the spangles attached thereto, to form a transparent coating layer, in which the transparent resin paint comprises (i) 60-80 wt% of a urethane elastomer as a reaction product of polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[3] The method according to claim 2, wherein the heat roller includes a cushion film wound thereon to exhibit cushioning capability.

[4] A method of manufacturing a sheet having a decorative surface layer, comprising:

(a) forming an adhesive layer on a surface of a first base sheet;

(b) applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; (c) applying hemispherical corn spangles, each of which has a hot melt material attached to a flat surface thereof, on the first base sheet having the glittering layer formed thereon;

(d) passing the first base sheet having the corn spangles applied thereon between a heat roller and a support roller, and passing adhesive paper or a second base sheet fed via a feed roller between the heat roller and the support roller, so that the hemispherical corn spangles applied on the first base sheet are attached to the adhesive paper or the second base sheet, and the inverted hemispherical corn spangles applied on the first base sheet are attached to the first base sheet; and

(e) applying transparent resin paint on the first base sheet or the second base sheet having the spangles attached thereto, to form a transparent coating layer, in which the transparent resin paint comprises (i) 60-80 wt% of a urethane elastomer as a reaction product of polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols.

[5] The method according to claim 4, wherein the heat roller includes a cushion film wound thereon to exhibit cushioning capability. [6] A method of manufacturing a sheet having a decorative surface layer, comprising: applying a hot melt material on an assistant film, and then drying the applied hot melt material, to form a hot melt layer; applying an adhesive on the hot melt layer, to form an adhesive layer; applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and simultaneously laminating a transparent film on the transparent coating layer and removing the assistant film from the hot melt layer. [7] The method according to claim 6, wherein the transparent resin paint comprises

(i) 60-80 wt% of a urethane elastomer as a reaction product of polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols. [8] A method of manufacturing a sheet having a decorative surface layer, comprising: applying a hot melt material on an assistant film, to form a hot melt layer; directly applying a glittering material on the hot melt layer so that the glittering material adheres while the hot melt layer is dried, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and simultaneously laminating a transparent film on the transparent coating layer and removing the assistant film from the hot melt layer. [9] The method according to claim 8, wherein the transparent resin paint comprises

(i) 60-80 wt% of a urethane elastomer as a reaction product of polyester polyol having an acid value of 1.0-2.0 and polyisocyanate having at least two free isocyanate groups, (ii) 0.1-1 wt% of a dispersant, (iii) 0.1-1 wt% of a leveling agent, and (iv) a balance of at least one solvent selected from among aromatic hydrocarbons and alcohols. [10] A method of manufacturing a sheet having a decorative surface layer, comprising: applying a hot melt material on an assistant film, to form a hot melt layer; directly applying a glittering material on the hot melt layer so that the glittering material adheres while the hot melt layer is dried, to form a glittering layer; and simultaneously laminating a transparent film on the glittering layer and removing the assistant film from the hot melt layer. [11] A method of manufacturing a sheet having a decorative surface layer, comprising: directly applying a glittering material on a double- sided adhesive sheet having release paper attached to one surface of the sheet, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and laminating an adhesive transparent film on the transparent coating layer. [12] A method of manufacturing a sheet having a decorative surface layer, comprising: applying an adhesive on a single-sided adhesive sheet having release paper attached to one surface of the sheet, to form an adhesive layer; applying a glittering material on the adhesive layer, and then drying the applied glittering material, to form a glittering layer; applying transparent resin paint on the glittering layer, to form a transparent coating layer; and laminating an adhesive transparent film on the transparent coating layer. [13] A sheet having a decorative surface layer, manufactured using the method of any one of claims 1, 2, 4, 6, 8, and 10 to 12 for application to bags, clothes, shoes, hair pins, hair bands, headgear, waist belts, fashion accessories, decorative sheets, and patches for clothes.