WO2016117661A1 - Method for manufacturing cosmetic sheet, cosmetic sheet, method for manufacturing cosmetic panel, and cosmetic panel - Google Patents

Abstract

Provided is a method for manufacturing a cosmetic sheet, the method comprising: a preparation step for preparing a pair of base papers containing 50 mass% or more of cellulose fibers, and having a thickness of 15 μm to less than 60 μm; a lamination step for arranging between the pair of base papers a thermoplastic resin layer having a melting point of 100-200°C and a thickness of 20-70 μm, adhering the pair of base papers together by means of the thermoplastic resin layer, and forming a laminate; and a processing step for passing the laminate between an embossing roll having a maximum depth of 15 μm or greater, and a rubber back roll having a hardness of 50° to less than 90° as measured on the basis of ISO 7619, and imparting an embossed profile to the laminate.

Description

Decorative sheet manufacturing method and decorative sheet, and decorative plate manufacturing method and decorative plate

The present invention relates to a decorative sheet manufacturing method and a decorative sheet, and a decorative plate manufacturing method and a decorative sheet. More specifically, the present invention relates to a method for manufacturing a decorative sheet, a decorative sheet, and a decorative plate that are subjected to pattern printing for surface decoration of general interior materials and assembly furniture, and the surface is provided with irregularities. The present invention relates to a method and a decorative board.

2. Description of the Related Art Conventionally, a decorative sheet in which design properties and durability are improved by laminating or embossing a transparent film on a printed thermoplastic resin film has been put into practical use and widely used.

In this case, in order to further improve the design properties, the surface of the decorative sheet is embossed to form irregularities or adjust the gloss. Embossing is carried out by passing a heated and plastic sheet between an embossed plate (embossing roll) having irregularities on the surface and a back roll (rubber back roll) made of rubber.

On the other hand, printed paper may be used as a decorative sheet or decorative paper. Furthermore, a method is also known in which a base paper is printed, impregnated with a thermosetting resin, and then subjected to heat and pressure with a press to form a decorative board. In this case, the surface hardness and the wear resistance can be improved by having the thermosetting resin on the surface thereof. In this case, it is also possible to provide irregularities on the surface of the decorative sheet or decorative plate by using a press plate having irregularities at the time of pressing.

Or, a decorative sheet obtained by printing on a relatively thin paper and applying a resin coating on its surface to enhance durability is generally known as a so-called coated paper. Coated paper is inexpensive and excellent in productivity. On the other hand, it is not easy to give unevenness to the surface of the coated paper. If an embossing roll is used to make the surface of the coated paper uneven, there is a method of passing the coated paper between the embossing roll and a rubber back roll having unevenness so as to mesh with the unevenness of the embossing roll. However, this method is not sufficient in terms of design as well as difficulty in production due to insufficient flexibility and stretchability of the base paper.

In particular, in order to give physical irregularities to a decorative sheet using a base paper having 50% or more of cellulose fibers, it is necessary to use a so-called male-female embossing unit. Another problem is that the rubber back roll having irregularities so as to mesh with the irregularities of the embossing roll is expensive.

As a countermeasure, it is possible to incorporate a large amount of thermoplastic resin into the base paper, but the paper has special specifications and is not economical.

In Patent Document 1, a proposal is made to provide an extruded layer of a thermoplastic resin between thin papers. However, the purpose was to obtain a paint-like surface finish, and was not mainly aimed at the surface unevenness effect.

JP-A-8-132582

In view of such a situation, the present invention provides a manufacturing method for manufacturing a decorative sheet having a good concavo-convex shape at low cost by using a base paper having 50% or more of cellulose fibers without using a male-female embossing unit. It is an object of the present invention to provide a decorative sheet and a decorative board.

The manufacturing method of the decorative sheet according to the present invention has a melting point of 100 ° C. between a pair of base papers and a preparation step of preparing a pair of base papers containing 50% by mass or more of cellulose fibers and having a thickness of 15 μm or more and less than 60 μm. A lamination process in which a thermoplastic resin layer having a thickness of 20 to 70 μm and a thickness of 20 μm or more and 70 μm or less is disposed, and a laminate in which a pair of base papers are bonded together by the thermoplastic resin layer, A processing step of imparting an embossed shape to the laminate by passing between an embossing roll having a depth of 15 μm or more and a rubber back roll having a hardness measured based on ISO7619 of 50 ° or more and less than 95 °; Is provided. Moreover, the manufacturing method of said decorative sheet is good also considering the hardness measured based on ISO7619 of a rubber back roll as 50 degrees or more and 65 degrees or less.

In this method for producing a decorative sheet, the measurement is based on an embossing roll having a depth of 15 μm or more and ISO7619 with respect to a laminate in which a pair of base papers containing 50% by mass or more of cellulose fibers are bonded together by a thermoplastic resin layer. Embossing is performed using a rubber back roll having a hardness of 50 ° or more and less than 95 °. In this case, since embossing is performed using a rubber back roll having a lower hardness than usual, a good embossed shape can be imparted even though the base paper contains 50% by mass or more of cellulose fibers. Further, not only the front surface but also the back surface of the laminate is provided with a concavo-convex shape, so that a better appearance can be obtained. Therefore, the manufacturing method which manufactures the decorative sheet which has a favorable uneven | corrugated shape cheaply can be provided using the base paper which has 50% or more of cellulose fibers, without using a male-female type embossing unit. Moreover, it becomes possible to show | play the effect mentioned above more suitably by making hardness measured based on ISO7619 of a rubber back roll into 50 degrees or more and 65 degrees or less.

Moreover, the method for manufacturing a decorative sheet may further include a printing step of providing a pattern printing layer on one surface of a pair of base papers. In this case, a decorative sheet with high designability can be produced.

Further, in the method for manufacturing the decorative sheet, the surface of the laminate may be subjected to ink jet printing before or after the processing step. According to inkjet printing, painting can be performed before or after embossing. Thereby, a decorative sheet with high designability can be manufactured.

Moreover, the manufacturing method of the decorative sheet according to the present invention, as another aspect, is a method for manufacturing a decorative sheet in which a base paper is printed and has an emboss on the surface. From the thickness of 15 μm containing 50% by mass or more of cellulose fibers. Design printing is performed on the surface using a base paper of less than 60 μm, and the opposite surface of the pattern printing layer is laminated with another base paper through a thermoplastic resin layer having a melting point of 100 ° C. to 200 ° C. and a thickness of 20 μm to 70 μm. The laminated body is passed between an embossing roll having a depth of 15 μm or more and a rubber back roll having a hardness (ISO7619) of 50 ° to less than 95 ° to give an embossed shape. In this case as well, a good embossed shape can be imparted as described above.

Moreover, the manufacturing method of the decorative sheet according to the present invention includes a decorative sheet preparing step of preparing a decorative sheet manufactured using the above-described decorative sheet manufacturing method, and bonding the decorative sheet to at least one surface of the substrate. A sticking step. According to the method for manufacturing a decorative sheet, the effects described above can be achieved in the same manner as the method for manufacturing a decorative sheet.

The present invention can also be understood as an invention of a decorative sheet manufactured using the above-described method for manufacturing a decorative sheet. According to this decorative sheet, the above-described effects can be achieved as in the method of manufacturing a decorative sheet.

Also, the present invention can be grasped as an invention of a decorative board having the above-described configuration of the decorative sheet. According to this decorative board, the effects described above can be achieved in the same manner as the method for manufacturing a decorative sheet.

ADVANTAGE OF THE INVENTION According to this invention, it is possible to provide the manufacturing method which manufactures the decorative sheet which has favorable uneven | corrugated shape cheaply using the base paper which has 50% or more of cellulose fibers, without using a male-female type embossing unit. It is possible to provide a decorative sheet and a decorative board.

FIG. 1 is a partial cross-sectional view of an embodiment of a decorative sheet according to the present invention. FIG. 2 is a flowchart of the manufacturing method of the decorative sheet. FIG. 3 is a schematic configuration diagram of the embossing device. FIG. 4 is a diagram schematically showing a convex portion on the surface of the embossing roll. FIG. 5 is a flowchart of a method for manufacturing a decorative board.

Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings.

FIG. 1 is a partial cross-sectional view of an embodiment of a decorative sheet according to the present invention. As illustrated in FIG. 1, a pattern printing layer 4 is provided on the base paper 1 of the decorative sheet 10. The base paper 1 is laminated with the base paper 2 via a thermoplastic resin layer 3. The laminated body is embossed on the surface to form irregularities, and constitutes a decorative sheet 10. In this invention, a laminated body is heated, and an unevenness | corrugation is provided by passing the embossing unit which consists of an embossing roll and a rubber back roll. The laminate can be provided with plasticity by being heated. Moreover, a laminated body can also increase a tensile strength by having the thermoplastic resin layer 3. FIG. Thereby, the embossing suitability of a laminated body improves.

Next, a method for manufacturing the decorative sheet 10 will be described. FIG. 2 is a flowchart of the manufacturing method of the decorative sheet. First, a pair of base papers 1 and 2 is prepared (preparation process: step S10). As the base paper 1 and the base paper 2, paper containing 50% by mass or more of cellulose fibers is used. The thickness of the base papers 1 and 2 is 15 μm or more and less than 60 μm. When the thickness of the base papers 1 and 2 is thinner than this range, the strength is not suitable for printing and post-processing. When the thickness of the base papers 1 and 2 is larger than this range, it is not suitable for embossing.

The pattern printing layer 4 is provided on the surface of the base paper 1 (printing step: step S11). As a printing method for providing the pattern printing layer 4, a known printing method / printing apparatus can be used. The method is not particularly limited. For example, from the viewpoint of productivity, a gravure printing method, a transfer method, or an inkjet method can be used.

The printing apparatus for providing the pattern printing layer 4 on the base paper 1 by the inkjet method is not particularly limited as long as it is a general inkjet printing machine. For example, as an inkjet printer, various inkjet printers such as a head-fixed printer (for example, a line method or a single pass method) or a head-movable printer (for example, a serial head method) may be used. Is possible.

Printing ink is not particularly limited. The printing ink may be a water-based ink or a solvent type ink, and is appropriately selected in consideration of compatibility with the apparatus and performance required for the decorative sheet 10 and the decorative plate. In general, the colorant contained in the ink is preferably a pigment type in consideration of light resistance.

As the ink used in the transfer method, an ink containing a resin such as an acrylic resin, a vinyl chloride resin-vinyl acetate resin copolymer, a polyester resin, a polyvinyl butyral resin, or a urethane resin can be used.

As the ink (inkjet ink) used in the inkjet method, water-based ink, solvent-based ink, UV ink, or the like can be used. In addition, it is especially preferable to use UV ink from the viewpoint of the adhesiveness of the inkjet ink with respect to the base paper 1, and the design property of the printed pattern printing layer 4. FIG. Further, as the ink-jet ink, an ink containing an active hydrogen group may be used.

It is also possible to obtain a desirable design property by providing a coating layer of a transparent resin on the pattern printing layer 4 and adjusting the gloss of the surface. The coat layer may be provided for the purpose of improving surface properties such as wear resistance. Further, the coat layer can be partially provided with a difference in gloss such as a conduit portion of wood. As a result, it is possible to visually create a feeling of unevenness and express more sophisticated design properties in combination with unevenness due to embossing.

In order to provide the coating layer, a known coating apparatus may be used, or a gravure printing apparatus may be used. The transparent resin is not particularly limited. For example, silica for gloss adjustment can be dispersed in a two-component curable urethane resin.

Then, the thermoplastic resin layer 3 is arrange | positioned between a pair of base papers 1 and 2, a pair of base papers 1 and 2 is bonded together by the said thermoplastic resin layer 3, and a laminated body is formed (lamination process: step S12). . The thermoplastic resin layer 3 is between a pair of base papers 1 and 2 and constitutes a part of the laminate. The thermoplastic resin layer 3 is formed using an extruder, and the base paper 1 and the base paper 2 can be bonded together. The thickness of the thermoplastic resin layer 3 is preferably 20 μm or more and 70 μm or less.

The melting point of the thermoplastic resin constituting the thermoplastic resin layer 3 is preferably 100 ° C. or higher and 200 ° C. or lower. By setting the melting point of the thermoplastic resin constituting the thermoplastic resin layer 3 in the range of 100 ° C. or more and 200 ° C. or less, embossing is performed without causing thermal deterioration of the paper and without impairing productivity such as line speed. Can be performed. The thermoplastic resin constituting the thermoplastic resin layer 3 can be appropriately selected in consideration of the melting point. Examples of the thermoplastic resin having a melting point of 100 ° C. or higher and 200 ° C. or lower include polyvinyl chloride, polyvinylidene fluoride, nylon 12, polyamide, polyvinyl alcohol, polystyrene, styrene / acrylonitrile copolymer, styrene / butadiene / acrylonitrile copolymer. , High density polyethylene, medium density polyethylene, low density polyethylene, polypropylene, ethylene / vinyl acetate copolymer, polyacetal, polymethyl methacrylate, modified acrylic, polycarbonate, polyacetal, nitrocellulose, cellulose propionate, ethyl cellulose, cellulose acetate, or polyurethane Etc.

As the thermoplastic resin constituting the thermoplastic resin layer 3, for example, high-density polyethylene, medium-density polyethylene, or low-density polyethylene is particularly preferably used in consideration of the resin price and fluidity at the time of melting. Can do.

The laminated body thus obtained is embossed using an embossing device (processing step: step S13). FIG. 3 is a schematic configuration diagram of the embossing device. As shown in FIG. 3, the embossing device 20 includes a main heat drum 21, an infrastructure heater 22, a bar heater 23, an embossing roll 24, a rubber back roll 25, and a take-off roll 26.

The main heat drum 21 has a cylindrical shape and can be rotated around the central axis. The laminated body 10a supplied to the embossing device 20 first wraps around the outer periphery of the main heat drum 21 and proceeds. The infrastructure heater 22 is a heater for heating the laminated body 10a wound around the main heat drum 21. The infrastructure heater 22 is disposed in the vicinity of the main heat drum 21 along a part of the outer periphery of the main heat drum 21. The laminated body 10 a is heated by the infrastructure heater 22 while proceeding toward the downstream side as the main heat drum 21 rotates.

The bar heater 23 is a heater for further heating the laminated body 10a sent from the main heat drum 21 to the downstream side. The bar heater 23 is disposed between the main heat drum 21, the embossing roll 24 and the rubber back roll 25 along the region where the laminated body 10 a travels.

The embossing roll 24 and the rubber back roll 25 constitute an embossing unit, and cooperate to emboss the laminate 10a. The embossing roll 24 and the rubber back roll 25 are disposed on the downstream side of the main heat drum 21. Each of the embossing roll 24 and the rubber back roll 25 has a cylindrical shape and can be rotated around the respective central axis. The embossing roll 24 and the rubber back roll 25 are in contact with each other, and when the laminated body 10a passes between them, the laminated body 10a is embossed. Detailed configurations of the embossing roll 24 and the rubber back roll 25 will be described later.

The take-off roll 26 is disposed on the downstream side of the embossing roll 24 and the rubber back roll 25, and embosses the laminated body 10a (that is, the embossed decorative sheet 10) that has passed through the embossing roll 24 and the rubber back roll 25. Eject from 20.

As described above, the embossing device 20 includes the main heat drum 21, the infrastructure heater 22, and the bar heater 23 for heating the laminated body 10a. The embossing device 20 has an embossing unit including an embossing roll 24 having irregularities on the surface and a rubber back roll 25. The embossing device 20 sandwiches the heated laminated body 10a between embossing units, passes between them, and embosses the laminated body 10a. By heating the laminated body 10a, the thermoplastic resin layer 3 is softened, and an embossed shape is easily imparted to the laminated body 10a. Further, since the thermoplastic resin layer 3 located between the base paper 1 and the base paper 2 is softened, the tensile strength of the laminated body 10a is increased and the laminated body 10a is hardly broken. As the rubber back roll 25, a rubber back roll 25 having a flat surface may be used.

FIG. 4 is a diagram schematically showing a convex portion on the surface of the embossing roll. As shown in FIG. 4, the embossing roll 24 has a plurality of convex portions 24b extending along the circumferential direction on the surface 24a. FIG. 4 shows a convex portion 24b having a triangular cross section in the circumferential direction. In addition, the circumferential cross section of the convex portion 24b is not limited to a triangular shape, and may be, for example, a trapezoidal shape, a rectangular shape, or the like. In the following description, the height of the convex portion 24b formed highest in the radial direction from the surface 24a is referred to as “depth of the embossing roll 24 (maximum depth)”. Embossing is performed using an embossing roll 24 having a depth of 15 μm or more. Thereby, the height difference of the emboss in the finished decorative sheet 10 and the decorative board is 15 μm or more. As a result, the emboss has a sense of unevenness in design, and is visually perceived effectively.

The hardness of the rubber back roll 25 is 50 ° or more and less than 95 °. The hardness here is measured based on ISO7619. The rubber back roll 25 having a hardness of 65 ° or less is more preferably used, and the rubber back roll 25 having a hardness of 50 ° is particularly preferably used. On the other hand, when the rubber back roll 25 having a hardness of 95 ° is used, the design of the emboss is extremely inferior. The hardness of the rubber back roll 25 may be measured based on JIS K 6301 A type or JIS K 6253, and the hardness measured based on these is equivalent to the hardness measured based on ISO7619. .

The laminated body 10a subjected to the embossing is further subjected to inkjet printing on the surface. As an inkjet printer and inkjet ink, the thing similar to what was mentioned above can be used. This ink jet printing is performed on the pattern printing layer 4 already provided on the surface of the laminate 10a, and constitutes the pattern printing layer 4 as a whole.

The laminated body 10a which has been subjected to embossing and provided with irregularities on the surface is the decorative sheet 10 of the present embodiment. Moreover, this decorative sheet 10 is bonded to a base material using an adhesive to obtain the decorative board of this embodiment. FIG. 5 is a flowchart of the manufacturing method of the decorative sheet. The decorative sheet 10 is prepared using the method for manufacturing the decorative sheet 10 described above (decorative sheet preparation process: step S20), and the decorative sheet 10 is bonded to at least one surface of the base material (adhesive process: step S21). ), A decorative board can be obtained. As the base material, for example, wood-based MDF, plywood, or particle board, inorganic gypsum board, or metal plate can be used.

The present invention is not limited to the above embodiment. For example, in the above-described embodiment, inkjet printing is performed on the surface of the laminate 10a after the embossing processing step. However, ink jet printing may be performed before this processing step.

Moreover, although the manufacturing method of the decorative sheet 10 according to the above-described embodiment has the pattern printing process, it may not have this printing process. In this case, the laminated body 10a is composed of the base papers 1 and 2 and the thermoplastic resin layer 3. Therefore, when ink jet printing is performed on the surface of the laminated body 10a before or after embossing is performed on the laminated body 10a, the ink jet printing is directly performed on the surface of the base paper 1.

Hereinafter, the present invention will be described in more detail using examples and comparative examples. However, the present invention is not limited only to these examples.

<Example 1>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) Nitrified cotton ink (manufactured by Toyo Ink Co., Ltd.) on the surface of a mixed paper (TP23 manufactured by Tenma Special Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 33 μm) containing 50% by mass or more of cellulose fibers. The pattern was printed using PCNT ink) and urethane ink (Toyo Ink Co., Ltd. PCRNT ink). Further, on the surface of the mixed paper, a transparent surface protective coat in which an isocyanate curing agent was added to a main component mainly composed of acrylic polyol was applied at a dry weight of 7 g / m ² . This produced the base paper with a pattern.
(2) The base paper with a pattern on which the above-described pattern printing was applied was cured at 60 ° C. for 48 hours to promote the curing reaction of the surface protective layer. Thereafter, between the side on which the base paper with the pattern is not printed and a mixed paper (FIXW23 manufactured by Oji Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 30 μm) containing 50% by mass or more of cellulose fibers. Then, the high-density polyethylene heated to 300 ° C. and melted by heat was extruded into a film shape and pressure-bonded, and then immediately cooled. This obtained the embossing laminated body (laminated body) which has a base paper layer on the front and back of a polyethylene layer (thermoplastic resin layer). The thickness of the polyethylene layer was 50 μm, and the total thickness of the laminate before embossing was 116 μm.
(3) It heated so that the surface temperature of the pattern printing surface of the obtained laminated body before embossing might be 130 degreeC close | similar to melting | fusing point of polyethylene. Between an embossing roll with a maximum depth of 150 μm produced by the corrosion method and a rubber back roll having a hardness of HS (Hardness spring) of 50 ° by a hardness tester according to JIS K 6301 A type (ISO 7619 is also the same). An uneven shape was imparted to the laminate before embossing by sandwiching the laminate before embossing, and it was cooled immediately after. This produced the decorative sheet which has an uneven | corrugated shape. The unevenness of the resulting decorative sheet had a height difference of a maximum of 70.1 μm, and good design properties were confirmed.
(4) One g of ethylene vinyl acetate emulsion adhesive is applied to a 2.5 mm thick MDF (medium density fiber) substrate at a coating weight of 55 g / m ^2, and the resulting decorative sheet is brought to a surface temperature of 100 ° C. It was bonded to this MDF substrate using a heated laminate roll. Thereby, the decorative board which has an uneven | corrugated shape was produced. The unevenness of the obtained decorative board was 59.0 μm at the maximum, and a decorative board having a good uneven design could be produced.

<Example 2>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) A pattern is printed on the surface and the surface is printed by the same material and procedure as in (1) of Example 1 except that a mixed paper (HP45 manufactured by Tenma Special Paper Co., Ltd.) having a thickness of 52 μm is used as the base paper. A patterned base paper with a protective coat was prepared.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the resulting decorative sheet had a maximum height difference of 42.4 μm, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Example 3>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) A pattern is printed on the surface and the surface is printed by the same material and procedure as in (1) of Example 1 except that a mixed paper (HP45 manufactured by Tenma Special Paper Co., Ltd.) having a thickness of 52 μm is used as the base paper. A patterned base paper with a protective coat was prepared.
(2) A base paper layer is provided on both sides of the thermoplastic resin layer by the same material and procedure as in (2) of Example 1 except that a mixed paper of 55 μm thickness (HPS45 manufactured by Oji Paper Co., Ltd.) is used as the base paper. A laminate before embossing was produced.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a maximum height difference of 21.1 μm, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Example 4>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 24 μm.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a height difference of a maximum of 70.5 μm, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Example 5>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was prepared by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 66 μm.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a maximum height difference of 67.2 μm, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Example 6>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) The laminate before embossing was embossed by the same material and procedure as in (3) of Example 1 except that a rubber back roll having a hardness of 60 ° was used. The unevenness of the resulting decorative sheet had a maximum height difference of 52.3 μm, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Example 7>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) The laminate before embossing was embossed by the same material and procedure as in (3) of Example 1 except that a rubber back roll having a hardness of 94 ° was used. The unevenness of the obtained decorative sheet was a height difference of 28.5 μm at the maximum, and good design properties were confirmed.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Comparative Example 1>
A decorative sheet was prepared using the following materials and procedures.
(1) A pattern is printed on the surface and the surface is printed by the same material and procedure as in (1) of Example 1 except that a mixed paper (HC50 manufactured by Tenma Special Paper Co., Ltd.) having a thickness of 60 μm is used as the base paper. A patterned base paper with a protective coat was prepared.
(2) A base paper layer is provided on both sides of the thermoplastic resin layer by the same material and procedure as in (2) of Example 1 except that a mixed paper (HC50 manufactured by Oji Paper Co., Ltd.) having a thickness of 60 μm is used as the base paper. A laminate before embossing was produced.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a height difference of 9.5 μm at the maximum, and the designability was not possible.
(4) Since the design of the decorative sheet was not possible, the decorative board was not produced.

<Comparative example 2>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) A base paper with a pattern on which a pattern is printed and a surface protective coat is applied is produced by the same material and procedure as in (1) of Example 1 except that a mixed paper having a thickness of 12 μm is used as the base paper. did.
(2) A pre-embossed laminate having a base paper layer on both sides of the thermoplastic resin layer was prepared by the same material and procedure as in (2) of Example 1 except that a mixed paper having a thickness of 10 μm was used as the base paper.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the resulting decorative sheet had a maximum height difference of 44.7 μm, and good design properties were confirmed. However, the embossing suitability was not possible.
(4) Although a decorative board was produced by the same material and procedure as (4) of Example 1, since the base paper was thin, the unevenness | corrugation disappeared at the time of lamination.

<Comparative Example 3>
A decorative sheet was prepared using the following materials and procedures.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) The same material and procedure as in (2) of Example 1 except that polybutylene terephthalate (melting point: 240 ° C.) was used instead of high-density polyethylene as the thermoplastic resin and the polybutylene phthalate was melted at 350 ° C. A laminate body before embossing having a base paper layer on both sides of the thermoplastic resin layer was produced.
(3) In the embossing process, the embossing effect could not be obtained unless the surface temperature was heated to 200 ° C. or higher. Further, at this temperature, swelling occurred due to moisture contained in the base paper, and embossing could not be performed.
(4) Since the embossing was not possible and the decorative sheet could not be prepared, the decorative board was not prepared.

<Comparative example 4>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was prepared by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 18 μm.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the resulting decorative sheet had a height difference of 72.3 μm at the maximum, and good design properties were confirmed.
(4) A decorative board was produced by the same material and procedure as in (4) of Example 1, but the unevenness disappeared during lamination because the thermoplastic resin layer was thin.

<Comparative Example 5>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 78 μm.
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a maximum height difference of 67.2 μm, and good design properties were confirmed. However, the embossing speed was lower than the processing speed of (1) in Example 1.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Comparative Example 6>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having a base paper layer on the front and back of the thermoplastic resin layer was prepared by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 90 μm. .
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the obtained decorative sheet had a maximum height difference of 69.9 μm, and good design properties were confirmed. However, the embossing speed was lower than the processing speed of (1) in Example 1.
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Comparative Example 7>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having a base paper layer on the front and back of the thermoplastic resin layer was prepared by the same material and procedure as in (2) of Example 1 except that the thickness of the polyethylene layer was changed from 50 μm to 105 μm. .
(3) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. The unevenness of the resulting decorative sheet had a height difference of 72.7 μm at the maximum, and good design properties were confirmed. However, the embossing speed was significantly reduced as compared with the processing speed of Example 1 (3).
(4) A decorative board was produced using the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Comparative Example 8>
A decorative sheet was prepared by the following materials and procedures, and a decorative board using the decorative sheet was prepared.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) Embossing was performed on the pre-embossed laminate by the same materials and procedures as in (3) of Example 1 except that a rubber back roll having a hardness of 40 ° was used. The unevenness of the resulting decorative sheet had a height difference of 81.6 μm at maximum, but the rubber back roll was abraded so that the embossing suitability was not possible.
(4) A decorative board was produced with the same materials and procedures as in (4) of Example 1. A decorative board having good uneven design was able to be produced.

<Comparative Example 9>
A decorative sheet was prepared using the following materials and procedures.
(1) By using the same materials and procedures as in (1) of Example 1, a base paper with a pattern on which a pattern was printed and a surface protective coat was applied was produced.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) The laminate before embossing was embossed by the same material and procedure as in (3) of Example 1 except that a rubber back roll having a hardness of 95 ° was used. Although the unevenness of the obtained decorative sheet had a maximum height difference of 20.9 μm, the paper layer was torn and design was not possible.
(4) Since the paper layer was torn due to the embossing of the laminate before embossing, a decorative board was not produced.

<Comparative Example 10>
A decorative sheet was prepared using the following materials and procedures.
(1) A pattern is printed on the surface and the surface is printed by the same material and procedure as in (1) of Example 1 except that a mixed paper (HP45 manufactured by Tenma Special Paper Co., Ltd.) having a thickness of 52 μm is used as the base paper. A patterned base paper with a protective coat was prepared.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) The laminate before embossing was embossed by the same material and procedure as in (3) of Example 1 except that a rubber back roll having a hardness of 95 ° was used. Although the unevenness of the obtained decorative sheet had a height difference of 11.8 μm at the maximum, the paper layer was torn and design was not possible.
(4) Since the paper layer was torn due to the embossing of the laminate before embossing, a decorative board was not produced.

<Comparative Example 11>
A decorative sheet was prepared using the following materials and procedures.
(1) A pattern is printed on the surface and the surface is printed by the same material and procedure as in (1) of Example 1 except that a mixed paper (HP45 manufactured by Tenma Special Paper Co., Ltd.) having a thickness of 52 μm is used as the base paper. A patterned base paper with a protective coat was prepared.
(2) A base paper layer on both sides of the thermoplastic resin layer by the same material and procedure as in (2) of Example 1 except that a mixed paper having a thickness of 55 μm (HPS45 manufactured by Tenma Special Paper Co., Ltd.) was used as the base paper. A pre-embossed laminate having the following characteristics was prepared.
(3) The laminate before embossing was embossed by the same material and procedure as in (3) of Example 1 except that a rubber back roll having a hardness of 95 ° was used. Although the unevenness of the resulting decorative sheet had a maximum height difference of 5.3 μm, the paper layer was torn and design was not possible.
(4) Since the paper layer was torn due to the embossing of the laminate before embossing, a decorative board was not produced.

Table 1 shows a summary of the configurations and evaluation results of Examples 1 to 7 and Comparative Examples 1 to 11.

In Table 1, the following abbreviations are used for the types of thermoplastic resins. That is, HDPE represents high density polyethylene (melting point 125 ° C.), and PBT represents polybutylene terephthalate (melting point 240 ° C.). The notation “*” in Table 1 indicates that processing could not be performed, or that the design of the appearance was poor, and further processing was not performed.

In the comprehensive evaluation, Examples 1 to 7 have good results. In Examples 1 to 3 and Comparative Examples 1 to 2, when high-density polyethylene is used for the thermoplastic resin layer, the uneven height difference after embossing tends to decrease as the thickness of the base paper increases. was there. When the thickness of the base paper was 60 μm, visually good embossed design was not observed.

In Comparative Example 3, a pre-embossed laminate was prepared using polybutylene terephthalate having a melting point of 240 ° C. for the thermoplastic resin layer. When the obtained pre-embossed laminate was subjected to hot embossing, under these conditions, the moisture contained in the base paper caused swelling between the thermoplastic resin layer and the base paper, and stable processing could not be performed. This is due to the fact that the sheet surface temperature must be heated to 200 ° C. or higher in order to give a favorable uneven shape to the thermoplastic resin layer. In addition, the obtained decorative sheet was confirmed to be deteriorated and discolored in the base paper due to heat during processing, and the color tone of the pattern layer was changed.

In Example 4 and Comparative Example 4, high-density polyethylene was used for the thermoplastic resin layer, and a laminate before embossing was produced in which the thickness of the thermoplastic resin layer was 24 μm and 18 μm, respectively. The resulting embossed laminate was hot embossed. As a result, in Example 4 in which the thickness of the thermoplastic resin layer was 24 μm, it was confirmed that a favorable uneven shape was formed, and the suitability for lamination was also good. On the other hand, in Comparative Example 4 in which the thickness of the thermoplastic resin layer is 18 μm, although it was confirmed that a good uneven shape was formed, the decorative sheet and the MDF base material were bonded together using a laminate roll. In the decorative board, the uneven shape disappeared due to the heat pressure of the laminate roll.

In Example 5 and Comparative Examples 5 to 7, high-density polyethylene was used for the thermoplastic resin layer, and laminates before embossing were prepared with the thickness of the thermoplastic resin layer being 66 μm, 78 μm, 90 μm, and 105 μm, respectively. The resulting embossed laminate was hot embossed. As a result, in Example 5 in which the thickness of the thermoplastic resin layer was 66 μm, it was confirmed that a favorable uneven shape was formed, and the suitability for lamination was also good. On the other hand, in Comparative Examples 5 to 7 in which the thermoplastic resin layer has a thickness of 78 μm, 90 μm, and 105 μm, decorative sheets having good uneven shapes were obtained, but the thermoplastic resin layer was sufficiently heated. In order to do so, the need to reduce the hot embossing speed has arisen. Particularly in Comparative Example 7, the processing speed was significantly reduced.

In Example 6 and Example 7, rubber back rolls having hardnesses of 60 ° and 94 ° were used. Further, high-density polyethylene was used for the thermoplastic resin layer, and the laminate before embossing obtained by extruding the thermoplastic resin layer was embossed. As a result, in Example 6 in which the hardness of the rubber back roll was 60 °, the difference in emboss height was 52.3 μm, and a decorative sheet with good design was obtained. Further, in Example 7 where the hardness of the rubber back roll was 94 °, the difference in emboss height was 28.5 μm, and a decorative sheet that was acceptable in design was obtained.

In Comparative Example 8, a rubber back roll having a hardness of 40 ° was used. Further, high-density polyethylene was used for the thermoplastic resin layer, and the laminate before embossing obtained by extruding the thermoplastic resin layer was embossed. As a result, although the height difference of the emboss was 81.6 μm, the rubber back roll was too soft and was scraped, so that the embossing suitability was impossible.

In Comparative Examples 9 to 11, a rubber back roll having a hardness of 95 ° was used. Moreover, the high-density polyethylene was used for the thermoplastic resin layer, and it embossed on the pre-embossing laminated body obtained by extruding a thermoplastic resin. As a result, the rubber back roll was too hard and the emboss reproducibility was poor, and the design was not possible.

From these results, the advantages of Examples 1 to 7 are clear. Therefore, according to the present invention, there is provided a production method for producing a decorative sheet having a good concavo-convex shape at low cost by using a base paper having 50% or more of cellulose fibers without using a male-female embossing unit. It was verified that it was possible to provide a decorative sheet and a decorative board.

Subsequently, improvement in design properties by performing inkjet printing was confirmed by Examples 8 to 11 below.

<Example 8>
(1) Nitrified cotton ink (PCNT ink manufactured by Toyo Ink Co., Ltd.) and urethane ink (Toyo Ink Co., Ltd.) on the surface of a mixed paper (TP23 manufactured by Tenma Special Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 33 μm) A pattern was printed using PCRNT ink (produced by Co., Ltd.) to provide a pattern printing layer, and a base paper with a pattern was prepared.
(2) A pre-embossed laminate having base paper layers on the front and back sides of the thermoplastic resin layer was produced by the same materials and procedures as in (2) of Example 1.
(3) Embossing was performed on the laminate prior to embossing by the same procedure as (3) of Example 1. As a result, the unevenness had a height difference of 72.5 μm at the maximum, and good design properties were confirmed.
(4) Using the UV inkjet ink (FV03 manufactured by Toyo Ink Co., Ltd.) on the side on which the decorative sheet obtained is printed, the printing resolution is 720 dpi × 720 dpi (dots per inch), and the ink limit Inkjet printing was performed so as to be 300%. Thereafter, a transparent surface protective coat in which an isocyanate curing agent was added to the main component mainly composed of acrylic polyol was applied to a decorative sheet on which ink jet printing was performed at a dry weight of 7 g / m ² to prepare a decorative sheet. As a result, good design properties were confirmed.
(5) One liquid ethylene vinyl acetate emulsion adhesive is applied to a 2.5 mm thick MDF (medium density fiber) substrate at a coating weight of 55 g / m ^2, and the resulting decorative sheet is brought to a surface temperature of 100 ° C. It was bonded to this MDF substrate using a heated laminate roll. Thereby, the decorative board which has an uneven | corrugated shape was produced. The unevenness of the obtained decorative board was 58.7 μm at the maximum, and a decorative board having a good uneven design could be produced.

<Example 9>
(1) Mixed paper with a basis weight of 23 g / m ² (thickness 33 μm) (TP23 manufactured by Tenma Special Paper Co., Ltd.) and mixed paper with a basis weight of 23 g / m ² (thickness 30 μm) (FIXW23 manufactured by Oji Paper Co., Ltd.) In between, high-density polyethylene heated to 300 ° C. and thermally melted was extruded into a film and pressure-bonded. Immediately after that, a laminate before embossing having a base paper layer on the front and back of the polyethylene layer (thermoplastic resin layer) was obtained. The thickness of the polyethylene layer was 50 μm, and the total thickness of the laminate before embossing was 116 μm.
(2) Embossing was performed on the laminate before embossing by the same procedure as (3) of Example 1. As a result, the unevenness of the decorative sheet was 71.2 μm at the maximum, and good design properties were confirmed.
(3) Using UV inkjet ink (FV03 manufactured by Toyo Ink Co., Ltd.) on the base paper of the resulting decorative sheet, the printing resolution is 720 dpi × 720 dpi (dots per inch), and the ink limit is 300% (ink) Inkjet printing was performed so that the discharge amount was 10 ml / m ² ). Thereafter, a transparent surface protective coat in which an isocyanate curing agent was added to the main component mainly composed of acrylic polyol was applied to a decorative sheet on which ink jet printing was performed at a dry weight of 7 g / m ² to prepare a decorative sheet. As a result, good design properties were confirmed.
(4) One g of ethylene vinyl acetate emulsion adhesive is applied to a 2.5 mm thick MDF (medium density fiber) substrate at a coating weight of 55 g / m ^2, and the resulting decorative sheet is brought to a surface temperature of 100 ° C. It was bonded to this MDF substrate using a heated laminate roll. Thus, a decorative plate having a concavo-convex shape was produced. The unevenness of the obtained decorative board was 59.5 μm at the maximum, and a decorative board having a good uneven design could be produced.

<Example 10>
(1) A pattern is printed on the surface of a mixed paper (TP23 manufactured by Tenma Special Paper Co., Ltd.) with a basis weight of 23 g / m ² (thickness 33 μm) using UV inkjet ink (FV03 manufactured by Toyo Ink Co., Ltd.) A base paper with a pattern was prepared.
(2) Heated to 300 ° C. between the side on which the base paper with the pattern is not printed and the mixed paper (FIXW23 manufactured by Oji Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 30 μm). The melted high-density polyethylene was extruded into a film and pressure-bonded. Immediately after that, a laminate before embossing having a base paper layer on the front and back of the polyethylene layer (thermoplastic resin layer) was obtained. The thickness of the polyethylene layer was 50 μm, and the total thickness of the laminate before embossing was 116 μm.
(3) It heated so that the surface temperature of the pattern printing surface of the obtained laminated body before embossing might be 130 degreeC close | similar to melting | fusing point of polyethylene. By sandwiching the laminate before embossing between an embossing roll with a maximum depth of 150 μm produced by the corrosion method and a rubber back roll having a hardness of HS (Hardness spring) 50 ° by a hardness tester according to JIS K 6301 A type An uneven shape was imparted to the laminate before embossing, and the laminate was cooled immediately after. This produced the decorative sheet which has an uneven | corrugated shape. The unevenness of the resulting decorative sheet had a maximum height difference of 68.1 μm, and good design properties were confirmed.
(4) One g of ethylene vinyl acetate emulsion adhesive is applied to a 2.5 mm thick MDF (medium density fiber) substrate at a coating weight of 55 g / m ^2, and the resulting decorative sheet is brought to a surface temperature of 100 ° C. It was bonded to this MDF substrate using a heated laminate roll. Thereby, the decorative board which has an uneven | corrugated shape was produced. The unevenness of the obtained decorative board was 56.5 μm at the maximum, and a decorative board having a good uneven design could be produced.

<Example 11>
(1) A pattern was printed on the surface of a mixed paper (TP23 manufactured by Tenma Special Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 33 μm) using UV inkjet ink (FV03 manufactured by Toyo Ink Co., Ltd.). Thereafter, a transparent surface protective coat in which an isocyanate curing agent was added to the main component mainly composed of acrylic polyol was applied to the mixed paper on which the pattern was printed at a dry weight of 7 g / m ² to prepare a base paper with a pattern.
(2) Heated to 300 ° C. between the side on which the base paper with the pattern is not printed and the mixed paper (FIXW23 manufactured by Oji Paper Co., Ltd.) having a basis weight of 23 g / m ² (thickness 30 μm). The melted high-density polyethylene was extruded into a film and pressure-bonded. Immediately after that, a laminate before embossing having a base paper layer on the front and back of the polyethylene layer (thermoplastic resin layer) was obtained. The thickness of the polyethylene layer was 50 μm, and the total thickness of the laminate before embossing was 116 μm.
(3) It heated so that the surface temperature of the pattern printing surface of the obtained laminated body before embossing might be 130 degreeC close | similar to melting | fusing point of polyethylene. By sandwiching the laminate before embossing between an embossing roll with a maximum depth of 150 μm produced by the corrosion method and a rubber back roll having a hardness of HS (Hardness spring) 50 ° by a hardness tester according to JIS K 6301 A type An uneven shape was imparted to the laminate before embossing, and the laminate was cooled immediately after. This produced the decorative sheet which has an uneven | corrugated shape. The unevenness of the resulting decorative sheet had a height difference of a maximum of 69.8 μm, and good design properties were confirmed.
(4) One g of ethylene vinyl acetate emulsion adhesive is applied to a 2.5 mm thick MDF (medium density fiber) substrate at a coating weight of 55 g / m ^2, and the resulting decorative sheet is brought to a surface temperature of 100 ° C. It was bonded to this MDF substrate using a heated laminate roll. Thereby, the decorative board which has an uneven | corrugated shape was produced. The unevenness of the obtained decorative board was 57.2 μm at the maximum, and a decorative board having a good uneven design could be produced.

Table 2 summarizes the configurations and evaluation results of Examples 8 to 11.

The abbreviations in Table 2 regarding the types of thermoplastic resins are the same as the abbreviations in Table 1. In addition, the notation “*” in Table 2 indicates that it is not subject to evaluation because it is not embossed.

From the above, it was confirmed that a decorative sheet with high designability can be produced by performing inkjet printing on the surface of the sheet embossed with the pre-embossed laminate.

DESCRIPTION OF SYMBOLS 1 ... Base paper, 2 ... Base paper, 3 ... Thermoplastic resin layer, 4 ... Picture printing layer, 10 ... Cosmetic sheet, laminated body 10a.

Claims (8)

1. A preparation step of preparing a pair of base papers containing 50% by mass or more of cellulose fibers and having a thickness of 15 μm or more and less than 60 μm;
   A laminate in which a thermoplastic resin layer having a melting point of 100 ° C. or more and 200 ° C. or less and a thickness of 20 μm or more and 70 μm or less is disposed between the pair of base papers, and the pair of base papers are bonded together by the thermoplastic resin layers. A laminating process for forming a body;
   The laminate is passed through an embossing roll having a maximum depth of 15 μm or more, and a rubber back roll having a hardness measured based on ISO7619 of 50 ° or more and less than 95 °, thereby forming an embossed shape on the laminate. A process for producing a decorative sheet.
2. The method for producing a decorative sheet according to claim 1, further comprising a printing step of providing a pattern printing layer on one surface of the pair of base papers.
3. The method for producing a decorative sheet according to claim 1 or 2, wherein ink jet printing is performed on the surface of the laminate before or after the processing step.
4. The method for producing a decorative sheet according to any one of claims 1 to 3, wherein the hardness of the rubber back roll measured based on ISO7619 is 50 ° or more and 65 ° or less.
5. In the method for producing a decorative sheet that has been printed on a base paper and has an emboss on the surface,
   Using a base paper having a thickness of 15 μm to less than 60 μm containing 50% by mass or more of cellulose fibers, pattern printing is performed on the surface,
   An embossing roll having a depth of 15 μm or more on a laminate in which the opposite surface of the pattern printing layer is laminated with another base paper via a thermoplastic resin layer having a melting point of 100 ° C. to 200 ° C. and a thickness of 20 μm to 70 μm And a hardness (ISO7619) between 50 ° and less than 95 ° rubber back rolls, a method for producing a decorative sheet that imparts an embossed shape.
6. A decorative sheet preparing step of preparing a decorative sheet manufactured using the decorative sheet manufacturing method according to any one of claims 1 to 5;
   A method of manufacturing a decorative board, comprising: an attaching step of attaching the decorative sheet to at least one surface of a substrate.
7. A decorative sheet manufactured using the decorative sheet manufacturing method according to any one of claims 1 to 5.
8. The decorative sheet according to claim 7,
   A decorative board comprising: a base material on which the decorative sheet is bonded to at least one surface.

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