WO2019043542A1 - Feuille décorative, structure comprenant une feuille décorative et procédé de production d'une feuille décorative - Google Patents

Feuille décorative, structure comprenant une feuille décorative et procédé de production d'une feuille décorative Download PDF

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Publication number
WO2019043542A1
WO2019043542A1 PCT/IB2018/056452 IB2018056452W WO2019043542A1 WO 2019043542 A1 WO2019043542 A1 WO 2019043542A1 IB 2018056452 W IB2018056452 W IB 2018056452W WO 2019043542 A1 WO2019043542 A1 WO 2019043542A1
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WO
WIPO (PCT)
Prior art keywords
layer
decorative sheet
approximately
decorative
printing
Prior art date
Application number
PCT/IB2018/056452
Other languages
English (en)
Inventor
Norihito Shibahara
Daigo Yasuda
Yorinobu Takamatsu
Original Assignee
3M Innovative Properties Company
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Filing date
Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Publication of WO2019043542A1 publication Critical patent/WO2019043542A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/0027—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using protective coatings or layers by lamination or by fusion of the coatings or layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14688—Coating articles provided with a decoration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/10—Applying flat materials, e.g. leaflets, pieces of fabrics
    • B44C1/105—Applying flat materials, e.g. leaflets, pieces of fabrics comprising an adhesive layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/28—Multiple coating on one surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4023—Coloured on the layer surface, e.g. ink
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538—Roughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/08—Print finishing devices, e.g. for glossing prints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00—Inking and printing with a printer's forme
    • B41M1/26—Printing on other surfaces than ordinary paper

Definitions

  • the present disclosure relates to a decorative sheet to be applied to a substrate using a vacuum-pressure molding method or an injection molding method, a structure including a decorative sheet, and a production method for a decorative sheet.
  • a known method of decorating the surfaces of a three-dimensional substrate such as the interior and exterior of an automobile is a method of attaching a decorative sheet or a film to the surface of the substrate.
  • a representative method for attaching a decorative sheet is an in-mold injection molding method. In this method, a decorative sheet in which a decorative layer or the like is formed on a base sheet is set in a mold for injection molding directly or after being preformed, and a molded article with a three-dimensional shape is injection-molded, while the decorative sheet is simultaneously attached integrally to the molded article to achieve decoration.
  • a vacuum-pressure molding method is also known as a method for attaching a decorative sheet to a substrate.
  • a decorative sheet is attached to a substrate molded in advance using a pressure difference while stretching the decorative sheet with respect to the substrate at room temperature or in a heated atmosphere. Since the decorative sheet is attached to the substrate surface of the part in an operation separate from the formation of the substrate, a decorative sheet can be attached to substrates of various shapes with a single vacuum-pressure molding device.
  • a sheet can be attached with good conformity to the three-dimensional shape of the substrate surface, and continuous coating, that is, roll coating, from the front to the back near the end of the substrate, which is difficult with an in-mold injection molding method, also becomes possible. In this way, with the vacuum-pressure molding method, a decorative sheet can be attached with excellent coatability to three-dimensional substrates with various complex shapes.
  • JP 2009-035588A describes "an adhesive film including a substrate and an adhesive layer on the substrate, wherein the adhesive layer includes: (A) a carboxyl group- containing (meth)acrylic polymer having a glass transition temperature (Tg) of not higher than 25°C, a ratio of a number of repeating units containing carboxyl groups to a total number of repeating units of the polymer being from 4.0 to 25%; and (B) an amino group- containing (meth)acrylic polymer having a glass transition temperature (Tg) of not less than 75°C, a ratio of a number of repeating units containing amino groups to a total number of repeating units of the polymer being from 3.5 to 15%; and a compounding ratio of component (A) and component (B) is from 62:38 to 75:25 in terms of weight ratio.”
  • Tg glass transition temperature
  • the decorative layer of a decorative sheet is typically formed using a printing technique such as gravure printing, inkjet printing, offset printing, or screen printing.
  • the present inventors discovered that, when attaching a decorative sheet to a substrate while deforming the decorative sheet, in particular, while stretching the decorative sheet, using a vacuum -pressure molding method or an injection molding method, small concavities and convexities present on the printing surface may propagate to the decorative sheet surface, and the surface quality such as the image clarity or glossiness, for example, of the decorative sheet may be lost. This phenomenon had not been confirmed when attaching a decorative sheet to a flat substrate without deforming the decorative sheet.
  • the present disclosure provides a decorative sheet capable of yielding high surface quality when attached to a substrate by a vacuum-pressure molding method or an injection molding method.
  • the present disclosure also provides a structure including such a decorative sheet and a production method for such a decorative sheet.
  • One embodiment of the present disclosure provides a decorative sheet to be attached to a substrate by a vacuum-pressure molding method or an injection molding method, the decorative sheet including: a decorative layer including a printing surface having concavities and convexities; and a smoothing resin layer disposed on the printing surface of the decorative layer or above the decorative layer; wherein a surface of the smoothing resin layer is smoother than the printing surface.
  • Another embodiment of the present disclosure provides a structure including a substrate and the decorative sheet applied to a surface of the substrate.
  • Yet another embodiment of the present disclosure provides a method for producing a decorative sheet to be attached to a substrate by a vacuum-pressure molding method or an injection molding method, the production method including: forming a decorative layer including a printing surface having concavities and convexities; and forming a smoothing resin layer on the printing surface of the decorative layer or above the decorative layer and forming a surface of the smoothing resin layer to be smoother than the printing surface.
  • the smoothing resin layer on the printing surface having concavities and convexities of the decorative layer or above the decorative layer and using the smoothing resin layer to impart the decorative sheet with a surface that is smoother than the printing surface, high surface quality such as image clarity or glossiness, for example, can be achieved even when the decorative sheet is attached to a substrate by a vacuum-pressure molding method or an injection molding method.
  • FIG. 1 is a schematic cross-sectional view of a decorative sheet according to one embodiment.
  • FIG. 2 is a schematic cross-sectional view of a decorative sheet according to another embodiment.
  • FIG. 3 is a photograph of the decorative sheet of Example 1 attached to a curved surface by a vacuum-pressure molding method, wherein the portion enclosed by the ellipse indicates the glare of an indoor fluorescent lamp.
  • FIG. 4 is a photograph of the decorative sheet of Comparative Example 1 attached to a curved surface by a vacuum-pressure molding method, wherein the portion enclosed by the ellipse indicates the glare of an indoor fluorescent lamp.
  • a "sheet” is a flexible laminate and also encompasses a thin laminate called a "film”.
  • the "storage modulus (E')" refers to the storage modulus at a specified temperature when the viscoelasticity is measured in a stretched mode at a heating rate of 5.0°C/min and a frequency of 10 Hz in the temperature range from -40°C to 200°C.
  • transparent means that the total light transmittance in the wavelength range of 400 to 700 nm is not less than approximately 60%, not less than approximately 80%, or not less than approximately 90%.
  • the total light transmittance can be determined in accordance with JIS K 7361-1 : 1997 (ISO 13468-1 : 1996).
  • (meth)acryl refers to acryl or methacryl
  • (meth)acrylate refers to acrylate or methacrylate.
  • a "vacuum-pressure molding method” refers to a molding method including: preparing a sheet and an article having a three-dimensional shape; disposing the sheet and the article inside a vacuum chamber including a heating device therein, the sheet dividing the internal space of the vacuum chamber into two, and the article being disposed in one of the divided internal spaces; heating the sheet with the heating device; setting both the internal space in which the article is disposed and the internal space on the opposite side to a reduced-pressure atmosphere; and bringing the article and the sheet into contact with one another while setting the internal space in which the article is disposed to a reduced-pressure atmosphere and setting the internal space on the opposite side to an increased-pressure atmosphere or a normal pressure atmosphere.
  • This method is also called a "Three-dimensional Overlay Method"
  • the decorative sheet according to one embodiment of the present disclosure is attached to a substrate by a vacuum-pressure molding method or an injection molding method and includes: a decorative layer including a printing surface having concavities and convexities; and a smoothing resin layer disposed on the printing surface of the decorative layer or above the decorative layer; wherein the surface of the smoothing resin layer is smoother than the printing surface.
  • FIG. 1 illustrates a cross-sectional view of a decorative sheet 10 according to one embodiment of the present disclosure.
  • the decorative sheet 10 includes a decorative layer 12 including a printing surface 122 having concavities and convexities; and a smoothing resin layer 14 disposed on the printing 122 of the decorative layer 12; wherein the surface 142 of the smoothing resin layer 14 is smoother than the printing surface 122 of the decorative layer 12.
  • the decorative sheet may further include additional layers such as a support layer, an adhesive layer, a surface layer, a design layer other than a decorative layer, a junction layer, or a release liner as optional components but the number, type, disposition, and the like of the decorative layers are not particularly limited.
  • the decorative sheet 10 is illustrated as a sheet further including, as optional components, a support layer 16, an adhesive layer 18 for attaching the decorative sheet to a substrate, a transparent surface layer 22 which contributes to the protection of the surface of the decorative sheet, and a junction layer 24 for joining together the layers constituting the decorative sheet (the surface layer 22 and the smoothing resin layer 14 in FIG. 1).
  • the decorative layer is typically formed using a printing technique such as gravure printing, inkjet printing, offset printing, or screen printing and includes a printing surface having concavities and convexities.
  • the decorative layer may be formed by monochromatic printing or multicolor printing.
  • the decorative layer may be continuous or discontinuous. In one embodiment, the decorative layer is formed by a collection of individual dots and is discontinuous.
  • the printing surface of the decorative layer is a gravure printing surface.
  • Gravure printing yields high image quality and excellent productivity, but the concavities and convexities on the printing surface tend to become large.
  • the aforementioned advantages of gravure printing can be achieved while mitigating the effects of the concavities and convexities of the printing surface on the surface quality of the decorative sheet after molding.
  • the shape of the ink dots forming the printing surface of the decorative layer is not particularly limited, but the height may be, for example, not less than approximately 0.1 ⁇ , not less than approximately 0.2 ⁇ , or not less than approximately 0.3 ⁇ and not greater than approximately 5 ⁇ , not greater than approximately 3 ⁇ , or not greater than approximately 1 ⁇ .
  • the density of the ink dots depends on the cell density or the number of lines per inch of the printing plate that is used. For example, the number of lines may be not fewer than approximately 18, not fewer than approximately 50, or not fewer than approximately 100 and not greater than approximately 500, not greater than approximately 300, or not greater than approximately 200.
  • Printing is typically repeated multiple times to form complex colors, patterns, or the like. When printing is repeated multiple times, plates with different numbers of lines may be used each time.
  • the surface roughness Rzl of the printing surface of the decorative layer is not less than approximately 0.2 ⁇ , not less than approximately 0.5 ⁇ , or not less than approximately 0.8 ⁇ and not greater than approximately 5 ⁇ , not greater than approximately 4 ⁇ , or not greater than approximately 3 ⁇ .
  • the concavities and convexities on the printing surface having a surface roughness Rzl in the range described above are very fine, but when a decorative sheet that does not include a smoothing resin layer is attached to a substrate by a vacuum-pressure molding method or an injection molding method, the concavities and convexities propagate to the decorative sheet surface and diminish the surface quality.
  • the surface roughness in the present disclosure is the maximum height roughness measured in accordance with JIS B 0601 :2001.
  • the decorative layer may contain an adhesive.
  • a decorative layer containing an adhesive can be joined with the other layers constituting the decorative sheet without an intermediate junction layer.
  • Solvent type, emulsion type, pressure-sensitive type, heat-sensitive type, thermosetting type, or UV-curing type adhesives such as commonly used acrylic, polyolefin, polyurethane, polyester, or rubber adhesives may be used as an adhesive.
  • the adhesive may be incorporated into the decorative layer using a printing technique such as gravure printing, inkjet printing, offset printing, or screen printing.
  • the adhesive is a heat-sensitive type adhesive and contains at least one thermoplastic resin selected from the group consisting of vinyl chloride/vinyl acetate copolymers, polyurethanes, polyesters, (meth)acrylic resins, and phenoxy resins.
  • a "phenoxy resin” refers to a thermoplastic polyhydroxy polyether which is synthesized using a bisphenol and epichlorohydrin, and this also includes substances containing a minute amount of epoxy groups derived from epichlorohydrin in the molecule (for example, at a terminal).
  • the epoxy equivalent of a phenoxy resin is higher than that of an ordinary epoxy resin and is, for example, not less than 5000, not less than 7000, or not less than 10000.
  • the smoothing resin layer is disposed on the printing surface of the decorative layer or above the decorative layer and has a surface which is smoother than the printing surface of the decorative layer.
  • “disclosed on” means that the smoothing resin layer is disposed in contact with the printing surface of the decorative layer
  • “disposed above” means that the smoothing resin layer is disposed at a distance from the decorative layer on the surface side from the perspective of the decorative layer.
  • the smoothing resin layer suppresses the propagation of the concavities and convexities on the printing surface of the decorative layer to the decorative sheet surface during vacuum-pressure molding or injection molding.
  • the stretching of the decorative sheet may become nonuniform within the plane, and this is particularly prominent in locations where the stress applied to the decorative sheet is large at the time of attachment, such as locations where the radius of curvature of the substrate surface is large.
  • the decorative sheet tends to be difficult to stretch due to fusion or the like between ink dots, whereas in locations where the density of ink dots is low (light color), the decorative sheet tends to stretch easily and become thin. In portions where the decorative sheet has become thin, the concavities and convexities on the printing surface of the decorative layer propagate more easily to the decorative sheet surface, and the surface quality of the decorative sheet is diminished in these portions.
  • the smoothing resin layer of the present disclosure is thought to suppress the propagation of the concavities and convexities on the printing surface of the decorative layer to the decorative sheet surface by flowing while maintaining a moderate internal stress so that the printing surface of the decorative layer spreads out uniformly within the lane and so that the concavities and convexities on the printing surface are absorbed when the decorative sheet is deformed, in particular, when the decorative sheet is stretched.
  • the smoothing resin layer may completely cover the printing surface of the decorative layer or may cover a portion of the printing surface of the decorative layer while not covering other portions. For example, at least some of the gaps between the ink dots on the printing surface of the decorative layer may be filled with the smoothing resin layer.
  • the smoothing resin layer is located inside the decorative sheet, and the surface of the smoothing resin layer is not exposed.
  • acrylic resins including polymethyl methacrylate (PMMA) and (meth)acrylic copolymers, polyolefins such as polyurethane (PU), polyvinyl chloride (PVD), polycarbonate (PC), acrylonitrile- butadiene-styrene copolymers (ABS), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), copolymers such as ethylene-acrylic acid copolymers (EAA), ethyl ene-ethyl acrylate copolymers, and ethyl ene-vinyl acetate copolymers (EVA), or combinations thereof.
  • PMMA polymethyl methacrylate
  • PVD polyvinyl chloride
  • PC polycarbonate
  • ABS acrylonitrile- butadiene-styrene copolymers
  • PE polyethylene
  • PP polypropylene
  • the propagation of the concavities and convexities on the printing surface of the decorative layer can be effectively suppressed. It is more advantageous for the decorative layer to contain a polyurethane.
  • the surface roughness Rz2 of the smoothing resin layer is lower than the surface roughness Rzl of the printing surface of the decorative layer. In some embodiments, the surface roughness Rz2 of the smoothing resin layer is not less than approximately 0.05 ⁇ , not less than approximately 0.1 ⁇ , or not less than approximately 0.15 ⁇ and not greater than approximately 1.0 ⁇ , not greater than approximately 0.5 ⁇ , or not greater than approximately 0.3 ⁇ .
  • the surface roughness Rz2 of the smoothing resin layer is not greater than approximately 0.95 times, not greater than approximately 0.8 times, or not greater than approximately 0.6 times the surface roughness Rzl of the printing surface of the decorative layer.
  • the smoothing resin layer is a coating layer produced by applying a resin solvent prepared by mixing a resin and a solvent to the printing surface.
  • the resin solvent having fluidity can fill the concavities and convexities on the printing surface, and therefore a smoother surface can be formed in comparison to the surface roughness of the printing surface.
  • Coating methods include methods such as gravure printing, screen printing, and casting, and the viscosity of the resin solvent can be selected appropriately in accordance with the type of the coating method.
  • the storage modulus of the smoothing resin layer is not less than approximately 1.0 x 10 6 Pa, not less than approximately 1.5 x 10 6 Pa, or not less than approximately 2.0 x 10 6 Pa and not greater than approximately 1.5 x 10 8 Pa or not greater than approximately 1.3 x 10 8 Pa within a temperature range from 100°C to 150°C when measured under stretched mode conditions at a frequency of 10 Hz.
  • the smoothing resin layer maintains a moderate internal stress during molding due to the presence of the smoothing resin layer which fills the concavities and convexities of the printing surface, and the printing surface of the decorative layer is stretched uniformly within the plane. As a result, the surface roughness of the decorative layer can be made even smaller, and the smoothness can be increased.
  • the thickness of the smoothing resin layer after the coating and drying is not less than approximately 2 times, not less than approximately 5 times, or not less than approximately 10 times and not greater than approximately 200 times, not greater than approximately 150 times, or not greater than approximately 100 times the surface roughness Rzl of the printing surface of the decorative layer.
  • the thickness of the smoothing resin layer in the present disclosure refers to the thickness at the thickest part of the smoothing resin layer.
  • the thickness of the smoothing resin layer is not less than approximately 3 ⁇ , not less than approximately 5 ⁇ , or not less than approximately 10 ⁇ and not greater than approximately 100 ⁇ , not greater than approximately 75 ⁇ , or not greater than approximately 50 ⁇ .
  • Various resins may be used as a support layer, which is an optional component, for example, acrylic resins including polymethyl methacrylate (PMMA) and
  • polystyrene copolymers such as polyurethane (PU), polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile-butadiene-styrene copolymers (ABS), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene
  • PU polyurethane
  • PVC polyvinyl chloride
  • PC polycarbonate
  • ABS acrylonitrile-butadiene-styrene copolymers
  • PE polyethylene
  • PP polypropylene
  • PET terephthalate
  • PEN polyethylene naphthalate
  • copolymers such as ethylene- acrylic acid copolymers (EAA), ethyl ene-ethyl acrylate copolymers, and ethylene-vinyl acetate copolymers (EVA), or combinations thereof.
  • EAA ethylene- acrylic acid copolymers
  • EVA ethylene-vinyl acetate copolymers
  • polyurethane, polyvinyl chloride, polyethylene terephthalate, acrylonitrile-butadiene-styrene copolymers, and polycarbonate can be advantageously used as a support layer.
  • the support layer is a support for the decorative layer or the like and may also function as a protective layer for imparting uniform stretching at the time of molding and more effectively protecting the structure from external puncture, impact, or the like.
  • the support layer has adhesiveness.
  • the decorative sheet can be attached to an article without requiring the adhesive layer described below.
  • the adhesive support layer can be formed from the same material as that of the adhesive layer described below.
  • the thickness of the support layer varies, but from the perspective of providing the functions described above to the decorative sheet without adversely affecting the moldability of the decorative sheet, the thickness is typically not less than approximately 2 ⁇ , not less than approximately 5 ⁇ , or not less than approximately 10 ⁇ and not greater than approximately 100 ⁇ , not greater than approximately 75 ⁇ , or not greater than
  • the thickness of the support layer when the support layer is not flat refers to the thickness of the thinnest portion of the support layer.
  • the storage modulus of the support layer is not less than approximately 1.0 x 10 6 Pa, not less than approximately 1.5 x 10 6 Pa, or not less than approximately 2.0 x 10 6 Pa and not greater than approximately 1.5 x 10 8 Pa or not greater than approximately 1.3 x 10 8 Pa within a temperature range from 100°C to
  • the storage modulus of the support layer is within the range described above, the strength and elongation at high temperatures required for vacuum-pressure molding or injection molding can be provided to the decorative sheet.
  • the support layer may be a single layer or may have a multilayer structure.
  • the storage modulus of the support layer refers to one value observed for the entire multilayer structure as a composite of the storage moduli of each individual layer.
  • the decorative sheet may further include an adhesive layer for attaching the decorative sheet to the substrate.
  • Solvent type, emulsion type, pressure-sensitive type, heat-sensitive type, thermosetting type, or UV-curing type adhesives such as commonly used acrylic, poly olefin, polyurethane, polyester, or rubber adhesives may be used as the adhesive layer, and acrylic adhesives and thermosetting polyurethane adhesives are advantageously used.
  • a layer in which a thermoplastic polyurethane is formed into a film shape by molding, extrusion, stretching or the like may also be used as the adhesive layer.
  • the thickness of the adhesive layer is typically not less than approximately 5 ⁇ , not less than approximately 10 ⁇ , or not less than approximately 20 ⁇ and not greater than approximately 200 ⁇ , not greater than approximately 100 ⁇ , or not greater than approximately 80 ⁇ .
  • the adhesive layer may be protected using an optional suitable release liner.
  • release liners include liners made from paper (for example, craft paper) or polymer materials (for example, polyolefms such as polyethylene or polypropylene, polyesters such as ethylene vinyl acetate, polyurethane, or polyethylene terephthalate).
  • the release liner may be coated with a release agent such as a silicon-containing material or a fluorocarbon- containing material as necessary.
  • the thickness of the release liner is typically not less than approximately 5 ⁇ , not less than approximately 15 ⁇ , or not less than approximately 25 ⁇ and not greater than approximately 300 ⁇ , not greater than approximately 200 ⁇ , or not greater than approximately 150 ⁇ .
  • Various resins may be used as a surface layer, which is an optional component, for example, acrylic resins including polymethyl methacrylate (PMMA) and (meth)acrylic copolymers, polyolefms such as polyurethane (PU), fluorine resins such as ethylene- tetrafluoroethylene copolymers (ETFE), polyvinylidene fluoride (PVDF), and methyl methacrylate-vinylidene fluoride copolymers (PMMA/PVDF), polyolefms such as polyvinyl chloride (PVD), polycarbonate (PC), polyethylene (PE), and polypropylene (PP), polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), copolymers such as ethylene-acrylic acid copolymers (EAA) and ionomers thereof, ethyl ene-ethyl acrylate copolymers, and ethylene-vinyl acetate
  • Acrylic resins, polyurethane, fluorine resins, and polyvinyl chloride are preferable due to their excellent weather resistance, and acrylic resins and polyurethane are more preferable due to their excellent scratch resistance and small environmental burden when burned or buried as waste.
  • the surface layer may contain an isosorbide-based polycarbonate.
  • a surface layer containing an isosorbide-based polycarbonate can be formed by applying a solution obtained by dissolving an isosorbide-based polycarbonate in a solvent to a substrate by means of casting and then drying the solution.
  • a surface layer formed in this way has excellent flatness and can further enhance the surface quality of the decorative sheet.
  • the surface layer may also have a multilayer structure.
  • the surface layer may be a laminate of films formed from the resins described above or may be a multilayer coating of the resins described above.
  • the thickness of the surface layer varies but is typically not less than
  • the surface layer When the decorative sheet is applied to a substrate with a complex shape, it is advantageous for the surface layer to be thinner from the perspective of shape conformity, and the thickness is preferably not greater than approximately 100 ⁇ or not greater than approximately 80 ⁇ , for example.
  • the surface layer when imparting the structure with high light resistance and/or weather resistance, it is advantageous for the surface layer to be thicker, and the thickness is preferably not less than approximately 5 ⁇ or not less than approximately 10 ⁇ , for example.
  • the surface layer may also contain, as necessary, a UV absorber such as benzotriazole or Tinuvin (trade name) 400 (available from BASF), a hindered amine light stabilizer (HALS) such as Tinuvin (trade name) 292 (available from BASF), or the like.
  • a UV absorber such as benzotriazole or Tinuvin (trade name) 400 (available from BASF), a hindered amine light stabilizer (HALS) such as Tinuvin (trade name) 292 (available from BASF), or the like.
  • HALS hindered amine light stabilizer
  • the surface layer may contain a gloss imparting agent or the like and may also include an additional bar code layer.
  • the surface layer is typically transparent.
  • the total light transmittance of the surface layer is not less than approximately 85% or not less than approximately 90% in a wavelength range from 400 to 700 nm.
  • the surface layer may be completely or partially translucent and may be partially opaque.
  • a junction layer may be used to join the layers described above.
  • Solvent type, emulsion type, pressure-sensitive type, heat-sensitive type, thermosetting type, or UV- curing type adhesives such as commonly used acrylic, polyolefin, polyurethane, polyester, or rubber adhesives may be used as a junction layer.
  • the thickness of the junction layer is typically not less than approximately 0.05 ⁇ , not less than
  • the decorative sheet may include a design layer other than the decorative layer.
  • Examples of design layers include a color layer of a painted color, a metallic color, or the like, a relief (relief pattern) layer, or a brilliant layer.
  • the design layer may have a multilayer structure and may include the junction layer described above between layers.
  • Examples of color layers that may be used include layers in which a pigment such as inorganic pigment such as titanium oxide, carbon black, chrome yellow, yellow iron oxide, red oxide, or red iron oxide, an organic pigment such as a phthalocyanine pigment such as phthalocyanine blue or phthalocyanine green, an azo lake pigment, an indigo pigment, a perinone pigment, a perylene pigment, a quinophthalone pigment, a dioxazine pigment, or a quinacridone pigment such as quinacridone red, an aluminum radiant material such as aluminum flakes, evaporated aluminum flakes, metal oxide-coated aluminum flakes, or colored aluminum flakes, or a pearl radiant material such as flake-like mica and synthetic mica coated with a metal material such as
  • a relief layer that may be used is a thermoplastic resin film having an irregular shape on the surface due to embossing, scratching, laser processing dry etching, or heat pressing, for example, in accordance with a known method.
  • the relief layer can also be formed by applying a thermosetting or radiation curable resin such as a curable acrylic resin to a release film having an irregular shape, curing the resin by heating or radiation, and then removing the release film.
  • a thermosetting or radiation curable resin such as a curable acrylic resin
  • thermosetting resin, and the radiation curable resin used in the relief layer are not particularly limited, but fluorine-based resins, polyester resins such as PET or PEN, acrylic resins, polyethylenes, polypropylenes, thermoplastic elastomers, polycarbonates, polyamides, ABS resins, acrylonitrile-styrene resins, polystyrenes, vinyl chlorides, polyurethanes, and the like may be used.
  • the thickness of the color layer and the relief layer may vary and is typically not less than approximately 5 ⁇ , not less than approximately 10 ⁇ , or not less than approximately 20 ⁇ and not greater than approximately 500 ⁇ , not greater than approximately 300 ⁇ , or not greater than approximately 200 ⁇ .
  • a thin film in which a metal such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, or germanium or an alloy or compound thereof is formed on another layer of the decorative sheet by vacuum deposition, sputtering, ion plating, plating, or the like may be used as a brilliant layer.
  • the brilliant layer has high glossiness and is therefore suitably used for a chrome plating replacement film or the like.
  • the thickness of the metal layer may be not less than approximately 5 nm, not less than approximately 10 nm, or not less than approximately 20 nm and not greater than approximately 10 ⁇ , not greater than approximately 5 ⁇ , or not greater than approximately 2 ⁇ .
  • FIG. 2 illustrates a cross-sectional view of a decorative sheet 10 according to another embodiment of the present disclosure.
  • a support layer 16 is a laminate of a first support layer 162, a brilliant layer 26, and a second support layer 164.
  • the first support layer 162 and the second support layer 164 include a relief surface formed by embossing or the like on the inside thereof, and the image of the decorative sheet changes visually due to the brilliant layer 26 provided on the relief surface.
  • Such a support layer 16 can be formed, for example, by forming the first support layer 162 including a relief surface by pressing a mold having an emboss pattern while heating as necessary into a flat layer formed from the material constituting the first support layer 162, forming the brilliant layer 26 by depositing a thin metal film thereon, and applying a composition containing the material constituting the second support layer 164 thereon and then drying or curing the composition.
  • the pattern or design of the relief layer may be regular or irregular and is not particularly limited, and examples thereof include a parallel line pattern, a woody texture, a sandy texture, a rocky texture, a fabric texture, a satin texture, a leather drawing pattern, a matte texture, a hair line pattern, a spinning pattern, characters, symbols, geometrical figures, or the like.
  • the width of the grooves is typically in the range of not less than approximately 5 ⁇ or not less than
  • the depth of the relief pattern is defined as the elevation difference from the top of a convex shape to the base of a continuous concave shape.
  • the depth of the relief surface may be uniform or may have various values over the entire relief surface.
  • the depth of the relief surface is typically in the range of not less than approximately 5 ⁇ or not less than approximately 10 ⁇ and not greater than approximately 100 ⁇ or not greater than approximately 50 ⁇ .
  • the surface layer, the support layer, the adhesive layer, and/or the junction layer may include colorants such as the same inorganic pigments, organic pigments, aluminum radiant materials, or pear radiant materials as those described above for the design layer.
  • the method for producing a decorative sheet includes: forming a decorative layer including a printing surface having concavities and convexities; and forming a smoothing resin layer on the printing surface of the decorative layer or above the decorative layer and forming the surface of the smoothing resin layer to be smoother than the printing surface.
  • the formation of the decorative layer and the smoothing resin layer is as described above.
  • Layers formed into a film shape by extrusion, stretching, or the like, for example, may be used for other layers as well, and these layers may be laminated with or without using junction layers.
  • Each layer may also be formed by coating another layer or a liner with a resin composition by means of knife coating, bar coating, blade coating, doctor coating, roll coating, cast coating, or the like and drying or curing the resin composition by heating as necessary.
  • the decorative sheet can be formed by forming each layer on a liner such as a
  • each layer may be sequentially laminated on a single liner by repeating the coating step and the curing step as necessary.
  • the decorative sheet may also be formed by extruding the material of each layer into multiple layers.
  • the thickness of the decorative sheet is typically not less than approximately 25 ⁇ , not less than approximately 50 ⁇ , or not less than approximately 100 ⁇ and not greater than approximately 2 mm, not greater than approximately 1 mm, or not greater than approximately 500 ⁇ .
  • the undulated surface roughness Wz in which the surface state is captured by undulations in the surface rather than the surface roughness Rz of the decorative sheet surface.
  • the undulated surface roughness Wza of the decorative sheet prior to molding is typically not less than approximately 0.1 ⁇ , not less than approximately 0.3 ⁇ , or not less than approximately 0.5 ⁇ and not greater than approximately 5 ⁇ , not greater than approximately 3 ⁇ , or not greater than
  • the propagation of the concavities and convexities on the printing surface of the decorative layer to the decorative sheet surface is suppressed, and thus the undulated surface roughness Wzb of the decorative sheet after molding is substantially the same as the undulated surface roughness Wza prior to molding, or is smaller because the decorative sheet surface is additionally smoothened by deformation during molding, and is not greater than approximately 1.2 times, not greater than approximately 1 time, or not greater than approximately 0.8 times the roughness, for example.
  • the scratch resistance of the decorative sheet can be evaluated by the pencil hardness in accordance with JIS K5600-5-4: 1999.
  • the pencil hardness is not less than 2B when the decorative sheet is fixed to the top of a glass sheet while the adhesive layer is oriented toward the surface of the glass sheet and the surface layer is scratched at a rate of 600 mm/min.
  • the pencil hardness may be not less than 6B, not less than 5B, not less than 4B, or not less than 3B.
  • the maximum area elongation of the decorative sheet after molding is typically not less than approximately 50%, not less than approximately 100%, or not less than
  • the maximum area elongation refers to the value at the location of the highest area elongation of the decorative sheet over the entire surface of the molded article.
  • the area elongation greatly differs depending on the location; for example, the portion in which the film initially touches the article is stretched minimally, and thus the area elongation is approximately 0%, whereas the film is greatly stretched at the ends where it is attached, and thus the area elongation increases to 200%> or greater. Since the quality of molding is determined by whether problems such as
  • the area elongation of the portion stretched to the greatest degree serves as the essential index for the quality of the molded article rather than the average area elongation of the entire molded article.
  • the maximum area elongation can be confirmed, for example, by printing 1 mm squares over the entire surface of the decorative sheet prior to molding and then measuring the change in area after molding or measuring the thickness of the decorative sheet before and after molding.
  • One embodiment of the present disclosure provides a structure including a substrate and a decorative sheet applied to a surface of the substrate.
  • the substrate may be made from various materials such as polypropylene, polycarbonate, acrylonitrile- butadiene-styrene copolymers, or mixtures or blends thereof, and materials having various planes and three-dimensional shapes can be used.
  • a vacuum-pressure molding method or an injection molding method By applying the decorative sheet to the substrate by a vacuum-pressure molding method or an injection molding method, a structure in which the decorative sheet and the substrate are formed integrally can be formed. Vacuum-pressure molding and injection molding can be performed with known methods.
  • the decorative sheet of the present disclosure can be used for the decoration of automobile parts, household electric appliances, railroad cars, construction materials, or the like.
  • the decorative sheet can be advantageously used for the decoration of the interior and exterior of an automobile, household electric appliances, or the like having high glossiness or a minute pattern.
  • a D-6260 polyurethane solution was applied to a G2 PET film and dried for 5 minutes at 80°C and then for 5 more minutes at 100°C to form a polyurethane layer with a thickness of 25 ⁇ .
  • vacuum deposition device EX-400 (available from ULVAC, Inc., Chigasaki- shi, Kanagawa, Japan)
  • Target metal deposition energy source electron beam
  • Thickness of tin deposition layer 430 Angstrom
  • Tin deposition layer forming rate 5 Angstrom/sec
  • a D-6260 polyurethane solution was applied to the embossed surface of the polyurethane layer and dried under the same conditions as in (1) to fill the concavities and convexities of the embossed surface of the polyurethane layer.
  • SK1506BHE 17 parts by mass of YM-5, and 33 parts by mass of methyl isobutyl ketone (MIBK) was applied to a G2 PET film subjected to release treatment, and this was dried for 5 minutes at 80°C and then for 5 more minutes at 120°C to form an acrylic adhesive layer with a thickness of 40 ⁇ .
  • MIBK methyl isobutyl ketone
  • a decorative layer was formed by sequentially gravure-printing a
  • a D-6260 polyurethane solution was applied thereon in a coated amount such that the dried thickness on a flat surface would be 10 ⁇ , and this was dried under the same conditions as in (1) to form a smoothing resin layer.
  • a D-6260 polyurethane solution was applied to a G2 PET film and dried for 5 minutes at 80°C and then for 5 more minutes at 100°C to form a polyurethane layer with a thickness of 25 ⁇ .
  • vacuum deposition device EX-400 (available from ULVAC)
  • Energy source for depositing target metal electron beam
  • Thickness of tin deposition layer 430 Angstrom
  • Tin deposition layer forming rate 5 Angstrom/sec (4)
  • a D-6260 polyurethane solution was applied to the embossed surface of the polyurethane layer and dried under the same conditions as in (1) to fill the concavities and convexities of the embossed surface of the polyurethane layer.
  • SK1506BHE 17 parts by mass of YM-5, and 33 parts by mass of methyl isobutyl ketone (MIBK) was applied to a G2 PET film subjected to release treatment, and this was dried for 5 minutes at 80°C and then for 5 more minutes at 120°C to form an acrylic adhesive layer with a thickness of 40 ⁇ .
  • MIBK methyl isobutyl ketone
  • a decorative layer was formed by sequentially gravure-printing an adhesive with 1 plate, ink with 5 plates, and then an adhesive with 1 plate on the G2 PET film.
  • Example 2 (Mitutoyo Co., Ltd., Kawasaki-shi, Kanagawa, Japan), a D-6260 polyurethane solution was applied to the decorative layer formed in (7) of Example 1 such that the dried thickness on the smooth surface was 10 ⁇ , and the surface roughness Rz ( ⁇ ) before and after coating was measured.
  • the surface roughness prior to coating corresponds to the surface roughness Rzl of the printing surface of the decorative layer
  • the surface roughness after coating corresponds to the surface roughness Rz2 of the smoothing resin layer.
  • Table 2 Note that the coating direction with respect to the sheet is defined as the Machine Direction (MD), while the direction orthogonal to this direction is defined as the Cross
  • Cutoff value 0.25 mm
  • evaluation measurement length 1.25 mm
  • the viscoelasticity properties of the smoothing resin layer were measured in accordance with the following procedure.
  • a D-6260 polyurethane solution was applied to a G2 PET film and dried for 5 minutes at 80°C and then for 5 more minutes at 100°C to form a polyurethane layer with a thickness of 25 ⁇ as a smoothing resin layer.
  • Comparative Example 1 were attached at 145 °C by vacuum-pressure molding to plastic substrates (flat sheet and semi -cylindrical shape).
  • the undulated surface roughnesses Wza and Wzb before and after vacuum-pressure molding were measured in each of the MD and CD directions for the decorative sheets of Example 1 and Comparative Example 1. The results are shown in Table 3 together with the visual image clarity.
  • the values of the surface roughness Ra before and after vacuum-pressure molding, which were measured together with the undulated surface roughness Wz are shown in Table 4.
  • the undulated rate of improvement in Table 3 is (Wza- Wzb)/Wza (%)
  • the planar rate of improvement in Table 4 is (Raa-Rab)/Raa (%).
  • Cutoff value 0.25 mm
  • evaluation measurement length 1.25 mm
  • the surface roughness of the decorative sheet increases after molding, and in particular when stretched and attached to a curved surface. This suggests that in Comparative Example 1 , in which no smoothing resin layer is present, the surface roughness of the decorative sheet increases due to a combination of the propagation of the concavities and convexities on the printing surface of the decorative layer to the decorative sheet surface during molding, the stretching and thinning of the decorative sheet during molding.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

La présente invention concerne une feuille décorative susceptible de produire une qualité de surface élevée lorsqu'elle est fixée à un substrat par un procédé de moulage par pression sous vide ou un procédé de moulage par injection. La feuille décorative comprend une couche décorative comprenant une surface d'impression ayant des concavités et convexités ; et une couche de résine lissante disposée sur la surface d'impression de la couche décorative ou au-dessus de la couche décorative, la surface de la couche de résine lissante étant plus lisse que la surface d'impression.
PCT/IB2018/056452 2017-08-29 2018-08-24 Feuille décorative, structure comprenant une feuille décorative et procédé de production d'une feuille décorative WO2019043542A1 (fr)

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JP2017164118A JP7074436B2 (ja) 2017-08-29 2017-08-29 装飾シート、装飾シートを含む構造体及び装飾シートの製造方法

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JP2022084972A (ja) * 2019-04-12 2022-06-08 アルプスアルパイン株式会社 加飾シート、加飾加工品、および製造方法
JP7369558B2 (ja) 2019-07-30 2023-10-26 日本ペイント・オートモーティブコーティングス株式会社 ３次元成型品加飾用積層フィルム
WO2023163072A1 (fr) * 2022-02-25 2023-08-31 富士フイルム株式会社 Stratifié, son procédé de production, film décoratif, article, panneau décoratif et dispositif d'affichage

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JP6709018B2 (ja) 2015-02-04 2020-06-10 スリーエム イノベイティブ プロパティズ カンパニー 加飾フィルム及びそれと一体化した物品
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EP1857268A1 (fr) * 2005-03-08 2007-11-21 Nissha Printing Co., Ltd. Film de transfert, film de décoration et procédé de fabrication idoine, et décoration
JP2009035588A (ja) 2007-07-31 2009-02-19 Three M Innovative Properties Co 接着フィルム、それを用いる成形体の製造方法及び得られる成形体
EP2248846A1 (fr) * 2008-02-28 2010-11-10 Techno Polymer Co., Ltd. Film pour impression et matière de surfaçage
EP3124238A1 (fr) * 2014-03-26 2017-02-01 Dai Nippon Printing Co., Ltd. Feuille pour moulage tridimensionnel

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