WO2019142782A1 - 化粧シート - Google Patents
化粧シート Download PDFInfo
- Publication number
- WO2019142782A1 WO2019142782A1 PCT/JP2019/000922 JP2019000922W WO2019142782A1 WO 2019142782 A1 WO2019142782 A1 WO 2019142782A1 JP 2019000922 W JP2019000922 W JP 2019000922W WO 2019142782 A1 WO2019142782 A1 WO 2019142782A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- pattern
- layer
- convex
- concavo
- decorative sheet
- Prior art date
Links
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- HIFVAOIJYDXIJG-UHFFFAOYSA-N benzylbenzene;isocyanic acid Chemical class N=C=O.N=C=O.C=1C=CC=CC=1CC1=CC=CC=C1 HIFVAOIJYDXIJG-UHFFFAOYSA-N 0.000 description 1
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- NIMLQBUJDJZYEJ-UHFFFAOYSA-N isophorone diisocyanate Chemical compound CC1(C)CC(N=C=O)CC(C)(CN=C=O)C1 NIMLQBUJDJZYEJ-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B32B2451/00—Decorative or ornamental articles
Definitions
- the present invention relates to a decorative sheet.
- a decorative sheet for example, there is a sheet in which a concavo-convex pattern by embossing is formed on the outermost layer in accordance with a pattern of a pattern layer to give a three-dimensional effect by touch (see, for example, Patent Document 1).
- a concavo-convex pattern by embossing is formed on the outermost layer in accordance with a pattern of a pattern layer to give a three-dimensional effect by touch
- a glossy pattern by printing is formed on the outermost layer, and there are some that give a sense of visual three-dimensional effect and texture by contrast.
- a concavo-convex pattern or a glossy pattern a pattern having a rough, dense, and flowing direction roughly similar to the pattern of the pattern layer is used to enhance the design expression of the decorative sheet. Further, for example, in the case where the concavo-convex pattern by embossing and the gloss pattern by printing are combined, there is a possibility that the concavo-convex pattern and the gloss pattern are shifted, and the designability is deteriorated.
- the present invention has been made focusing on the above problems, and has an object to provide a decorative sheet having a three-dimensional effect by visual sense, a visual three-dimensional effect and a texture, and having excellent design. .
- one mode of the present invention was provided in the surface side of (a) base material, the picture pattern layer provided in the surface side of (b) base material, and (c) picture pattern layer.
- a transparent adhesive layer (d) a transparent thermoplastic resin layer provided on the surface side of the transparent adhesive layer, and (e) a surface protective layer provided on the surface side of the transparent thermoplastic resin layer, (f) the surface
- the surface side of the protective layer has a concavo-convex pattern and a concavo-convex pattern provided on each of the surface of the concavo-convex pattern and the surface of the convex part and having a plurality of regions in which the concavities and convexities are formed
- the height difference between the concave and convex portions of the concave and convex pattern is 3 ⁇ m or more and 200 ⁇ m or less, and the height difference between the concave and convex portions in each region of the concave and convex pattern is the difference between the
- the outermost surface has the concavo-convex pattern, and the height difference between the concave and the convex part of the concavo-convex pattern is 3 ⁇ m or more and 200 ⁇ m or less, the three-dimensional effect is felt by the tactile sense by the concave and convex parts. It can make you feel.
- it has a concavo-convex pattern having a plurality of areas in which concavities and convexities are formed on the surface of the concavo-convex pattern concavities and concavities, and the height difference between the concavities and convexities in each area of the concavo-convex pattern is Because the difference is smaller than the difference between the height and the height of the projection, a gloss contrast can be provided inside and outside the area, and a gloss pattern can be provided to visually sense a three-dimensional effect or texture.
- the concavo-convex pattern and the concavo-convex pattern can be simultaneously formed by one shaping plate, and the concavo-convex pattern and the gloss pattern can be matched by simultaneously forming them with the shaping plate.
- the concavo-convex pattern and the gloss pattern can be matched by simultaneously forming them with the shaping plate.
- a pattern pattern layer 2 a transparent adhesive layer 3, a transparent thermoplastic resin layer 4 and a surface protective layer 5 are provided on the surface 1a side of the substrate 1. It is laminated in this order.
- the surface protective layer 5 is the outermost layer.
- a back surface resin coat layer 7 is provided on the back surface 1 b side of the substrate 1.
- a concavo-convex pattern 8 by embossing is provided on the surface 4 a side of the transparent thermoplastic resin layer 4 and the surface 5 c side of the surface protective layer 5.
- the base 1 is a sheet-like layer made of resin.
- a colored thermoplastic resin can be used.
- the thermoplastic resin for example, a vinyl chloride resin, an acrylic resin, or a polyolefin resin (polypropylene resin, polyethylene resin, etc.) can be adopted.
- polyolefin resins are preferred in terms of environmental compatibility, processability, and cost.
- the grade and composition of the resin can also be selected in terms of sheeting easiness, printability, and bending processability.
- the colored thermoplastic resin can conceal the substrate (not shown) to which the decorative sheet 10 is bonded, and can form the base color of the design pattern layer 2.
- the hue of the thermoplastic resin can be appropriately selected according to the background color and the like.
- a coloring method of the thermoplastic resin for example, in the case of sheeting of a thermoplastic resin, a method of mixing or kneading a coloring agent such as a pigment with the thermoplastic resin can be adopted.
- a solid ink layer may be provided between the pattern layer 2 and the substrate 1 using a coating or printing method.
- the picture pattern layer 2 is a layer which is provided on the surface 1 a side of the substrate 1 and on which a picture for giving a design is printed or coated.
- the printing method is not particularly limited, and known printing methods can be employed.
- the gravure printing method is preferable in terms of productivity and quality of the pattern.
- the pattern for example, a pattern suitable for a place using the decorative sheet 10, such as wood grain, cork, stone, tile, grill, abstract pattern, etc. can be selected.
- the printing ink is not particularly limited, and an ink corresponding to the printing method can be appropriately selected. For example, it is preferable to select from the point of the adhesiveness with respect to the base material 1 (resin), printability, and the weather resistance of a decorative material.
- the pattern adhesive layer 2 or the transparent adhesive layer 3 An adhesive layer (not shown) may be provided on the layer 3.
- the resin used for the adhesive layer (not shown) is not particularly limited.
- a two-component curable urethane resin can be employed.
- a method of forming the adhesive layer (not shown) for example, a coating apparatus or a gravure printing apparatus can be used.
- the transparent adhesive layer 3 is provided on the surface 2 a side of the pattern layer 2 and is a layer for strengthening the adhesion between the substrate 1 and the pattern layer 2 and the transparent thermoplastic resin layer 4. When these bonds are strong, it is possible to give the decorative sheet 10 bending suitability to follow a curved surface or a right-angled surface.
- the transparent thermoplastic resin layer 4 is provided on the surface 3a side of the transparent adhesive layer 3 and is a layer for providing thickness and depth in design, and improving the weather resistance and the abrasion resistance of the decorative sheet 10 It is.
- the thermoplastic resin for example, a vinyl chloride resin, an acrylic resin, or a polyolefin resin (polypropylene resin, polyethylene resin) can be adopted.
- polyolefin resins are preferable in terms of environmental compatibility, processability, and cost.
- the grade and composition of the resin can also be selected in terms of sheeting easiness, printability, and bending processability. For suitability for bending, it is important to select in consideration of the prevention of whitening of the bent portion and the occurrence of cracks.
- the surface protective layer 5 includes a first surface protective layer 5a and a second surface protective layer 5b.
- the first surface protective layer 5 a is a layer provided on the surface 4 a side of the transparent thermoplastic resin layer 4 and covering the entire transparent thermoplastic resin layer 4.
- the first surface protective layer 5a is formed of a transparent or translucent material (resin) to such an extent that the pattern of the pattern layer 2 can be seen through the first surface protective layer 5a.
- the first surface protective layer 5a may be a single layer or a layer formed by stacking a plurality of layers.
- the thickness of the first surface protective layer 5a is, for example, 3 ⁇ m from the viewpoint of obtaining sufficient strength to protect the surface of the transparent thermoplastic resin layer 4 without completely burying the concavo-convex pattern 8 and impairing the design feeling. It is preferable to be in the range of not less than 100 ⁇ m.
- a thermosetting resin is preferable in terms of adhesion to the transparent thermoplastic resin layer 4, deformation followability of the decorative sheet 10, abrasion resistance and the like.
- a thermosetting resin (binder) having a urethane bond such as a two-component curable urethane resin is more preferable.
- matting agents such as silica particles and scratch resistance may be added to the thermosetting resin.
- the hardness of the layer may be lowered toward the surface 4 a of the transparent thermoplastic resin layer 4. By so doing, the deformation followability of the decorative sheet 10 is improved.
- the thickness of the layer may be increased toward the surface 4 a of the transparent thermoplastic resin layer 4. By so doing, the deformation followability of the decorative sheet 10 is improved.
- a urethane resin having a polyol as a main component and an isocyanate as a crosslinking agent (curing agent) can be used as the two-component curable urethane resin.
- a polyol it has a 2 or more hydroxyl group in a molecule
- numerator Comprising: For example, polyethylene glycol, polypropylene glycol, an acryl polyol, polyester polyol, polyether polyol, a polycarbonate polyol, and a polyurethane polyol can be used.
- isocyanate the polyvalent isocyanate which has a 2 or more isocyanate group in a molecule
- aromatic isocyanates such as 2,4-tolylene diisocyanate, xylene diisocyanate, 4,4'-diphenylmethane diisocyanate, or 1,6-hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, hydrogenated diphenylmethane diisocyanate, etc.
- Aliphatic (or alicyclic) isocyanates can be used.
- adducts or multimers of the above various isocyanates can be used. For example, there are adducts of tolylene diisocyanate, tolylene diisocyanate trimer, and the like.
- aliphatic (or alicyclic) isocyanates are preferable in that they are excellent in weather resistance and thermal yellowing resistance.
- 1,6-hexamethylene diisocyanate can be used.
- ionizing radiation curable resins are preferable.
- an ultraviolet curable resin can be used.
- (meth) acrylic resin, silicone resin, polyester resin, urethane resin, amide resin, epoxy resin can be adopted.
- the hardness of the surface protective layer 5, that is, the outermost layer of the decorative sheet 10 can be improved, and surface physical properties such as abrasion resistance, abrasion resistance, solvent resistance and the like of the decorative sheet 10 can be improved.
- a material of the first surface protective layer 5a for example, a mixture of a thermosetting resin and an ionizing radiation curable resin may be used.
- the second surface protective layer 5b is a layer which is partially provided on the surface 5c side of the first surface protective layer 5a and covers a part of the surface 5c of the first surface protective layer 5a.
- the portion which counters the printing ink of picture pattern layer 2 is mentioned, for example.
- the material of the second surface protective layer 5b for example, the same resin as that of the first surface protective layer 5a can be adopted.
- a filler may be added to the second surface protective layer 5b. By adding the filler, it is possible to impart mechanical properties such as glossiness, feel, texture, surface strength, friction and the like different from those of the first surface protective layer 5a.
- the filler for example, beads of resin such as acryl, polyolefin, silicone and the like, irregularly shaped particles, beads of inorganic substances such as silica, alumina and metal oxide and the like and irregularly shaped particles can be used.
- the method of forming the second surface protective layer 5b is not particularly limited, and a known printing method can be adopted.
- the thickness of the second surface protective layer 5b is, for example, not less than 0.5 times and not more than 1.0 times the thickness of the first surface protective layer 5a. Within the numerical range, both the three-dimensional effect by touch, the visual three-dimensional effect and the texture are improved.
- the back surface resin coat layer 7 is a layer provided on the back surface 1 b side of the substrate 1 for improving the adhesion between the substrate 1 and the adhesive.
- a two-component curable urethane resin can be used.
- the concavo-convex pattern 8 is a pattern comprising concave and convex portions synchronized with the pattern of the patterned layer 2.
- the concave portion and the convex portion of the concavo-convex pattern 8 can provide a three-dimensional effect by touch.
- the deviation between the uneven pattern 8 and the pattern of the pattern layer 2 is, for example, preferably 10 mm or less in the longitudinal direction and 3 mm or less in the short direction (width direction) with respect to the pattern pattern shape. .
- the direction in which the conduit of wood grain extends is "longitudinal direction to the shape of the design pattern", and the direction orthogonal to the longitudinal direction is “short direction to the shape of the design pattern”.
- the longitudinal direction of the decorative sheet 10 is “longitudinal direction relative to the shape of the design pattern”
- the width direction of the decorative sheet 10 is “the short side direction to the shape of the pattern”.
- the concavo-convex pattern 8 is strongly recognized for the first time by reflection of oblique light because the transparent thermoplastic resin layer 4 and the surface protective layer 5 are transparent, but the deviation between the concavo-convex pattern 8 and the pattern of the patterned layer 2 is within the above range. In this case, it is difficult to visually recognize the transmitted light of the design pattern layer 2 simultaneously with the reflected light and there is no discomfort. By suppressing the deviation between the concavo-convex pattern 8 and the pattern of the pattern layer 2 within a certain range, it is possible to obtain a decorative sheet in which the shape and distribution of the pattern are equally matched on the entire sheet surface with high accuracy.
- the height difference between the concave and convex portions of the concavo-convex pattern 8 is in the range of 3 ⁇ m to 200 ⁇ m.
- the difference in height can be selected as a numerical value suitable for the design of the target decorative sheet 10.
- the height difference is more preferably in the range of 10 ⁇ m or more and 150 ⁇ m or less.
- the “height difference” refers to the distance from the lowest position of the concave portions of the concave / convex pattern 8 to the highest position of the convex portions of the concave / convex pattern 8.
- the value is, for example, in the range of 3 ⁇ m to 200 ⁇ m.
- An uneven pattern 9 having a plurality of regions 9a, 9b, and 9c in which the unevenness is formed is provided on each of the surface of the concave portion and the convex portion of the uneven pattern 8.
- the area 9 a is an area formed on the surface of the convex portion of the concavo-convex pattern 8
- the area 9 b is an area formed on the surface of the concave portion of the concavo-convex pattern 8
- the area 9 c is the surface and convex of the concave portion of the concavo-convex pattern 8. It is a region formed across the surface.
- the uneven pattern 9 also includes an area 9d having no unevenness.
- the regions 9a, 9b, 9c have various surface roughness, and together with the gloss outside the regions 9a, 9b, 9c, form a gloss pattern and texture synchronized with the pattern of the pattern layer 2.
- the difference between the gloss in the regions 9a, 9b and 9c and the gloss outside the regions 9a, 9b and 9c (that is, the region 9d) is 60 degrees in accordance with JIS Z 8741 in that a decorative sheet 10 significant as a design is obtained.
- the mirror glossiness is preferably in the range of 3 or more and 30 or less.
- the height difference between the concave portion and the convex portion in each of the regions 9a, 9b, and 9c is smaller than the height difference between the concave portion and the convex portion of the concavo-convex pattern 8.
- the height difference between the concave portion and the convex portion in each of the regions 9a, 9b, and 9c is preferably 0.5 ⁇ m to 10 ⁇ m.
- the height difference between the concave and the convex of the concavo-convex pattern 8 may be in the range of 10 times to 15 times the height difference between the concave and the convex in each of the regions 9a, 9b, 9c. Within the numerical range, both the three-dimensional effect by touch, the visual three-dimensional effect and the texture are improved.
- corrugated pattern 9 can employ
- the concavo-convex pattern 8 and the glossy pattern can be perfectly matched (synchronized).
- the shaping of the concavo-convex pattern 9, the concavo-convex pattern 8 and the regions 9a, 9b, 9c is performed, for example, on the transparent thermoplastic resin layer 4 before providing the first surface protective layer 5a and the second surface protective layer 5b.
- the process may be performed on the surface protective layer 5 and the transparent thermoplastic resin layer 4 .
- the shape may be buried with the thickness of the surface protective layer 5 or the concave and convex parts of the concavo-convex pattern 8. Since it is possible to avoid the problem that the surface protective layer 5 is difficult to form in the recess due to the height difference, it is possible to more finely transfer the shape of the shaped plate (press die).
- a roll shape As a shaped plate, it is preferable to use a roll shape in the point of continuous processing.
- the method of forming the concavo-convex pattern 8 and the concavo-convex pattern 9 on the surface of the shaped plate is not particularly limited, and a known plate-making method can be adopted. For example, a combination of embossing etching, multistage mask chemical etching, mechanical engraving, laser engraving, whole surface or partial sand blasting, partial polishing, etc. can be adopted.
- embossing etching, multistage mask chemical etching, mechanical engraving, laser engraving, whole surface or partial sand blasting, partial polishing, etc. can be adopted.
- corrugated pattern 8 was formed only in the transparent thermoplastic resin layer 4 and the surface protective layer 5 was shown in FIG. 1, this embodiment is not limited to this.
- the concavo-convex pattern 8 may be formed on the substrate 1, the pattern pattern layer 2, the transparent adhesive layer 3, the transparent thermoplastic resin layer 4 and the surface protective layer 5.
- the three-dimensional effect by touch is further improved and the contrast of gloss is further increased, so that the visual three-dimensional effect and the texture are further improved.
- the decorative sheet 10 comprises a substrate 1, a pattern pattern layer 2 provided on the surface 1a side of the substrate 1, and a transparent adhesive layer 3 provided on the surface 2a side of the pattern pattern layer 2.
- the transparent thermoplastic resin layer 4 provided on the surface 3 a side of the transparent adhesive layer 3 and the surface protective layer 5 provided on the surface 4 a side of the transparent thermoplastic resin layer 4 were provided.
- a plurality of regions 9a, 9b, 9c are provided on the surface of the concave and convex pattern 8 and the surface of the concave and the convex of the concave and convex pattern 8 respectively.
- the height difference between the concave and convex portions of the concave and convex pattern 8 is 3 ⁇ m or more and 200 ⁇ m or less, and the height difference between the concave and convex portions in each region 9 a, 9 b, 9 c of the concave and convex pattern 9 The difference is smaller than the height difference between the concave and the convex of the concavo-convex pattern 8.
- the concavo-convex pattern 8 on the outermost surface, and the height difference between the concave and the convex part of the concavo-convex pattern 8 is 3 ⁇ m or more and 200 ⁇ m or less. It can make you feel.
- concave and convex patterns 9 are provided on the surface of the concave and convex portions of concave and convex pattern 8, and the height difference between the concave and the convex in each area 9a, 9b, 9c of concave and convex pattern 9 is the concave and convex portions of concave and convex pattern 8 Therefore, it is possible to provide a gloss contrast in and out of the regions 9a, 9b, and 9c, provide a gloss pattern, and visually sense a three-dimensional effect or texture.
- the concavo-convex pattern 8 and the concavo-convex pattern 9 can be simultaneously formed by one shaping plate, and by forming simultaneously, the concavo-convex pattern 8 and the glossy pattern can be matched. As a result, it is possible to provide the decorative sheet 10 having a three-dimensional effect by touch, a three-dimensional effect or texture, and an excellent design.
- the design by the design pattern layer, the three-dimensional effect by the concavo-convex pattern, the three-dimensional effect by the gloss and the texture can be mutually matched, and it is possible to provide the decorative sheet 10 more excellent in design.
- region 9a, 9b, 9c the height difference of the recessed part and convex part in each area
- region 9a, 9b, 9c was 0.5 micrometer or more and 10 micrometers or less. Therefore, the gloss in the regions 9a, 9b, 9c can be increased, the contrast of the gloss in and out of the regions 9a, 9b, 9c can be increased, and the decorative sheet 10 more advantageous as a design can be provided. Can.
- the surface protective layer 5 (the first surface protective layer 5a and the second surface protective layer 5b) is a thermosetting resin having a urethane bond, and an ionizing radiation curable type At least one of the resins was included. Therefore, it is possible to provide the decorative sheet 10 excellent in adhesion to the transparent thermoplastic resin layer 4, deformation followability of the decorative sheet 10, abrasion resistance and the like.
- the decorative sheet 10 according to the present embodiment has a difference between the gloss in the regions 9a, 9b and 9c and the gloss outside the regions 9a, 9b and 9c of 3 to 30 with a 60 degree specular gloss according to JIS Z 8741. It is as follows. Therefore, the gloss contrast in and out of the regions 9a, 9b and 9c can be surely increased, and the decorative sheet 10 more superior as a design can be provided.
- Example 1 First, as shown in FIG. 1, a colored polypropylene sheet having a thickness of 0.06 mm was prepared as the substrate 1. Subsequently, the picture pattern layer 2 was formed on the surface 1 a side of the substrate 1 by printing. As the printing ink, one containing urethane and vinyl chloride resin (Toyo Ink Co., Ltd.) was used. Subsequently, a transparent thermoplastic resin layer 4 was laminated on the surface 2 a side of the pattern layer 2 formed, with the transparent adhesive layer 3 interposed therebetween.
- the printing ink one containing urethane and vinyl chloride resin (Toyo Ink Co., Ltd.) was used.
- a transparent thermoplastic resin layer 4 was laminated on the surface 2 a side of the pattern layer 2 formed, with the transparent adhesive layer 3 interposed therebetween.
- the transparent adhesive layer 3 8 g / m 2 of a urethane-based dry lamination adhesive (Toyo Moreton Co., Ltd.) was used.
- a transparent polypropylene sheet was used as the transparent thermoplastic resin layer 4.
- a two-component curable urethane resin was applied to the back surface 1b side of the substrate 1 to form a back surface resin coat layer 7 (primer).
- the shaped plate was used to shape the surface of the transparent thermoplastic resin layer 4.
- the shaping plate used was one having a height difference of 3 ⁇ m between the concave and convex portions of the concavo-convex pattern 8 and a height difference of 0.5 ⁇ m between the concave and convex portions in each of the regions 9a, 9b and 9c.
- 3 g / m 2 of a two-component curable urethane resin mixed with 25 parts by mass of silica filler having an average particle diameter of 2 ⁇ m to 3 ⁇ m is applied to the surface 4 a side of the transparent thermoplastic resin layer 4 to obtain a first
- the surface protective layer 5a and the second surface protective layer 5b were formed.
- Example 2 In Example 2, the height difference between the concave portion and the convex portion in each of the regions 9a, 9b, and 9c is 2 ⁇ m, that is, 0.5 ⁇ m which is the height difference in Example 1 larger.
- a decorative sheet 10 was produced in the same manner as in Example 1 except for the above.
- Example 3 In Example 3, the content of the silica filler in the first surface protective layer 5a was 3 parts by mass.
- a decorative sheet 10 was produced in the same manner as in Example 1 except for the above.
- Comparative example 1 In Comparative Example 1, the formation of the concavo-convex pattern 8 was omitted.
- a decorative sheet 10 was produced in the same manner as in Example 1 except for the above.
- the gloss contrast in and out of the regions 9a, 9b, and 9c is high, and the test result of the tactile sensation and the test result of the three-dimensional effect pass "o".
- the general design passed the rating " ⁇ ".
- the gloss of the regions 9a, 9b, 9c becomes high, and the larger the gloss contrast, the better the visual three-dimensional effect. Since it reinforced, the decorative sheet 10 superior as a design was obtained.
- the decorative sheet 10 of Example 2 made the height difference of the recessed part of each area
- the shapes of 9c are mixed and difficult to distinguish, and the regions 9a, 9b, 9c hardly contribute to the improvement of the design feeling, the test result of the three-dimensional feeling is “ ⁇ ”, and the comprehensive design is “ ⁇ ”.
- the content of the silica filler in the first surface protective layer 5a is 3 parts by mass, so the test result of the tactile sensation and the test result of the three-dimensional effect become “ ⁇ ”, and the comprehensive design passes. It became " ⁇ ".
- Example 4 In Example 4, after applying the first surface protective layer 5a and the second surface protective layer 5b, the height difference between the concave and the convex of the concavo-convex pattern 8 is 200 ⁇ m, and in each of the regions 9a, 9b, 9c.
- the unevenness pattern 8 and the regions 9a, 9b, 9c were shaped using a shaped plate having a height difference of 10 ⁇ m between the concave portion and the convex portion.
- a decorative sheet 10 was produced in the same manner as in Example 1 except for the above.
- Example 5 In Example 5, the height difference between the concave and the convex in each of the regions 9a, 9b, and 9c is 0.5 ⁇ m.
- the decorative sheet 10 was produced by the same material and procedure as Example 4 except it. (Example 6) In Example 6, the height difference between the concave and the convex in each of the regions 9a, 9b, and 9c is 15 ⁇ m.
- the decorative sheet 10 was produced by the same material and procedure as Example 4 except it. (Performance evaluation and test results) The decorative sheet 10 of Examples 4 to 6 was tested for performance evaluation of gloss, touch and three-dimensional effect. The test results are shown in Table 2.
- Example 7 In Example 7, the first surface protective layer 5a and the second surface protective layer 5b were formed of an acrylic UV curable resin.
- a decorative sheet 10 was produced in the same manner as in Example 1 except for the above. (Performance evaluation) The following performance evaluation tests were conducted on a decorative board formed by bonding the decorative sheet 10 of Examples 1 and 7 to an MDF board having a thickness of 3 mm using a two-component curable emulsion adhesive (Konishi Co., Ltd.).
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
Description
しかしながら、エンボス加工による凹凸模様や印刷による光沢模様を、絵柄模様層の絵柄に完全に一致させることは、シート加工時における寸法安定性等の点から困難であった。そのため、一般的には、凹凸模様や光沢模様として、絵柄模様層の絵柄におおよそ似た粗密・流れ方向をもつ模様を用い、化粧シートの意匠表現を高めるようになっていた。
また、例えば、エンボス加工による凹凸模様と、印刷による光沢模様とを組み合わせるようにした場合、凹凸模様と光沢模様とがずれて、意匠性が低下する可能性があった。
また、凹凸模様と凹凸パターンとは1つの賦形版で同時に形成でき、賦形版で同時に形成することにより、凹凸模様と光沢模様とを合致させることができる。これにより、触感による立体感、視覚的な立体感や質感を有し、意匠性に優れた化粧シートを提供できる。
本発明の実施形態に係る化粧シート10は、図1に示すように、基材1の表面1a側に、絵柄模様層2、透明接着層3、透明熱可塑性樹脂層4及び表面保護層5がこの順に積層されている。表面保護層5は、最表層となっている。また、基材1の裏面1b側に、裏面樹脂コート層7が設けられている。また、透明熱可塑性樹脂層4の表面4a側及び表面保護層5の表面5c側には、エンボス加工による凹凸模様8が設けられている。
基材1は、樹脂からなるシート状の層である。樹脂としては、例えば、着色した熱可塑性樹脂を用いることができる。熱可塑性樹脂としては、例えば、塩化ビニル樹脂、アクリル樹脂、ポリオレフィン系の樹脂(ポリプロピレン樹脂、ポリエチレン樹脂等)を採用できる。特に、環境適合性や加工性、価格の点で、ポリオレフィン系の樹脂が好ましい。樹脂のグレードや組成は、シーティングの容易さや印刷適性、曲げ加工に対する適性等の点からも選択できる。着色した熱可塑性樹脂により、化粧シート10を貼り合せる基板(不図示)を隠蔽でき、また、絵柄模様層2の下地色を形成できる。熱可塑性樹脂の色相は、下地色等に応じて適宜選択できる。熱可塑性樹脂の着色方法としては、例えば、熱可塑性樹脂のシーティングに際して、熱可塑性樹脂に顔料等の着色剤を混合したり練りこんだりする方法を採用できる。また、絵柄模様層2を設ける前に、絵柄模様層2と基材1との間に、コーティングあるいは印刷の手法を用いてベタインキ層(着色層)を設けてもよい。
絵柄模様層2は、基材1の表面1a側に設けられ、意匠性を付与するための絵柄が印刷または塗工されてなる層である。印刷手法は、特に限定されるものではなく、既知の印刷手法を採用できる。例えば、生産性や絵柄の品位の点からは、グラビア印刷法が好ましい。絵柄としては、例えば、木目、コルク、石目、タイル、焼き物、抽象柄等、化粧シート10を用いる箇所に適した絵柄を選ぶことができる。また、印刷インキは、特に限定されるものではなく、印刷方式に対応したインキを適宜選択できる。例えば、基材1(樹脂)に対する密着性や印刷適性、また、化粧材の耐候性の点から選択することが好ましい。
透明接着層3は、絵柄模様層2の表面2a側に設けられ、基材1及び絵柄模様層2と透明熱可塑性樹脂層4との接着を強固にするための層である。これらの接着が強固であることにより、化粧シート10に対して曲面や直角面に追随する曲げ加工適性を付与できる。
透明熱可塑性樹脂層4は、透明接着層3の表面3a側に設けられ、意匠的に厚さや深みを付与したり、化粧シート10の耐候性や耐磨耗性能を向上させたりするための層である。熱可塑性樹脂としては、例えば、塩化ビニル樹脂、アクリル樹脂、ポリオレフィン系の樹脂(ポリプロピレン樹脂、ポリエチレン樹脂)を採用できる。特に、環境適合性や加工性、価格の点で、ポリオレフィン系樹脂が好ましい。樹脂のグレードや組成は、シーティングの容易さや印刷適性、曲げ加工に対する適性等の点からも選択できる。曲げ加工に対する適性では、屈曲部の白化や割れの発生の防止を考慮して選択することが重要である。
表面保護層5は、第1の表面保護層5aと、第2の表面保護層5bとを備えている。
第1の表面保護層5aは、透明熱可塑性樹脂層4の表面4a側に設けられ、透明熱可塑性樹脂層4の全体を被覆する層である。第1の表面保護層5aは、第1の表面保護層5aを通して、絵柄模様層2の絵柄を透視できる程度に透明または半透明な材料(樹脂)で形成されている。第1の表面保護層5aは、単層でもよく、複数の層を重ねてなる層でもよい。また、第1の表面保護層5aの厚さは、例えば、凹凸模様8を完全に埋めて意匠感を損なうことなく透明熱可塑性樹脂層4の表面を保護するに足る強度を得る点から、3μm以上100μm以下の範囲内にあることが好ましい。さらに、第1の表面保護層5aの材料としては、例えば、透明熱可塑性樹脂層4への接着性、化粧シート10の変形追従性、耐擦傷性等の点で、熱硬化型樹脂が好ましい。特に、コスト、汎用性の点からは、2液硬化型ウレタン樹脂等のウレタン結合を有する熱硬化型樹脂(バインダー)がより好ましい。熱硬化型樹脂には、例えば、シリカ粒子等の艶消剤や耐傷剤を添加してもよい。
また、イソシアネートとしては、分子中に2個以上のイソシアネート基を有する多価イソシアネートを用いることができる。例えば、2,4-トリレンジイソシアネート、キシレンジイソシアネート、4,4′-ジフェニルメタンジイソシアネート等の芳香族イソシアネート、或いは、1,6-ヘキサメチレンジイソシアネート、イソホロンジイソシアネート、水素添加トリレンジイソシアネート、水素添加ジフェニルメタンジイソシアネート等の脂肪族(乃至は脂環式)イソシアネートを用いることができる。また、上記各種イソシアネートの付加体又は多量体を用いることができる。例えば、トリレンジイソシアネートの付加体、トリレンジイソシアネート3量体(trimer)等がある。なお、上記イソシアネートにおいて脂肪族(乃至は脂環式)イソシアネートは、耐候性、耐熱黄変性も良好にできる点で好ましく、例えば、1,6-ヘキサメチレンジイソシアネートを使用できる。
なお、第2の表面保護層5bの厚さは、例えば、第1の表面保護層5aの厚さの0.5倍以上1.0倍以下である。当該数値範囲内であれば、触感による立体感、視覚的な立体感や質感が共に向上する。
裏面樹脂コート層7は、基材1の裏面1b側に設けられ、基材1と接着剤との密着性を向上させるための層である。例えば、2液硬化型ウレタン樹脂を用いることができる。
凹凸模様8は、絵柄模様層2の絵柄と同調した凹部と凸部とからなる模様である。凹凸模様8の凹部と凸部により、触感による立体感を付与可能となっている。凹凸模様8と絵柄模様層2の絵柄とのずれは、例えば、絵柄模様の形状に対して長手方向には10mm以下、短手方向(幅方向)には3mm以下の範囲内とすることが好ましい。例えば、絵柄模様が木目である場合には、木目の導管が伸びている方向が「絵柄模様の形状に対する長手方向」となり、長手方向と直交する方向が「絵柄模様の形状に対する短手方向」となる。特に、木目の導管が化粧シート10の長手方向に沿って伸びている場合には、化粧シート10の長手方向が「絵柄模様の形状に対する長手方向」となり、化粧シート10の短手方向(幅方向)が「絵柄模様の形状に対する短手方向」となる。凹凸模様8は、透明熱可塑性樹脂層4及び表面保護層5が透明であるため、斜光の反射により初めて強く視認されるが、凹凸模様8と絵柄模様層2の絵柄とのずれが上記範囲内であれば、反射光と同時に絵柄模様層2の透過光を視認することが困難なため違和感がない。凹凸模様8と絵柄模様層2の絵柄とのずれを一定範囲内へ抑えることにより、パターンの形状と分布を等しくシート全面で精度よく一致させた化粧シートを得ることができる。また、凹凸模様8の凹部と凸部との高低差は、3μm以上200μm以下の範囲内とする。高低差は、目的とする化粧シート10の意匠に適した数値を選ぶことができる。例えば、最大高低差(200μm)内で連続的な多段形状を取ることもできる。特に、巨視的な立体物としての形状を得るために、高低差は、10μm以上150μm以下の範囲がより好ましい。ここで、「高低差」とは、凹凸模様8の凹部のうち最も低い位置から、凹凸模様8の凸部のうち最も高い位置までの距離をいう。また、凹凸模様8の凹部と凸部との高低差を算術平均粗さ(Ra)で表現した場合、その値は、例えば3μm以上200μm以下の範囲内である。
また、凹凸模様8の凹部と凸部との高低差は、各領域9a、9b、9c内の凹部と凸部との高低差の10倍以上15倍以下の範囲内であってもよい。当該数値範囲内であれば、触感による立体感、視覚的な立体感や質感が共に向上する。
なお、図1には、凹凸模様8を透明熱可塑性樹脂層4と表面保護層5にのみ形成した場合を示したが、本実施形態はこれに限定されるものではない。例えば、凹凸模様8は、基材1、絵柄模様層2、透明接着層3、透明熱可塑性樹脂層4及び表面保護層5に形成されていてもよい。上記態様であれば、触感による立体感がさらに向上に、且つ、光沢のコントラストがさらに増大するため、視覚的な立体感や質感がさらに向上する。
本実施形態に係る発明は、以下の効果を奏する。
(1)本実施形態に係る化粧シート10は、基材1と、基材1の表面1a側に設けた絵柄模様層2と、絵柄模様層2の表面2a側に設けた透明接着層3と、透明接着層3の表面3a側に設けた透明熱可塑性樹脂層4と、透明熱可塑性樹脂層4の表面4a側に設けた表面保護層5と、を備えるようにした。そして、表面保護層5の表面5c側には、凹凸模様8と、凹凸模様8の凹部の表面と凸部の表面とのそれぞれに設けられ、凹凸が形成された複数の領域9a、9b、9cを有する凹凸パターン9とを有し、凹凸模様8の凹部と凸部との高低差は、3μm以上200μm以下とし、凹凸パターン9の各領域9a、9b、9c内の凹部と凸部との高低差は、凹凸模様8の凹部と凸部との高低差よりも小さくした。
また、凹凸模様8と凹凸パターン9とは1つの賦形版で同時に形成でき、同時に形成することにより、凹凸模様8と光沢模様とを合致させることができる。これにより、触感による立体感、視覚的な立体感や質感を有し意匠性に優れた化粧シート10を提供できる。
(実施例1)
まず、図1に示すように、基材1として、厚さ0.06mmの着色ポリプロピレンシートを用意した。続いて、基材1の表面1a側に、印刷によって、絵柄模様層2を形成した。印刷インキとしては、ウレタン・塩酢ビ形樹脂(東洋インキ株式会社)を含むものを用いた。続いて、形成した絵柄模様層2の表面2a側に、透明接着層3を介して、透明熱可塑性樹脂層4を積層した。透明接着層3としては、ウレタン系ドライラミ接着剤(東洋モートン株式会社)8g/m2を用いた。また、透明熱可塑性樹脂層4としては、透明ポリプロピレンシートを用いた。続いて、基材1の裏面1b側に、2液硬化型ウレタン樹脂を塗工して、裏面樹脂コート層7(プライマー)を形成した。続いて、賦形版(エンボス版)を用いて透明熱可塑性樹脂層4の表面に賦形した。賦形版としては、凹凸模様8の凹部と凸部との高低差を3μm、各領域9a、9b、9c内の凹部と凸部との高低差を0.5μmとするものを用いた。続いて、透明熱可塑性樹脂層4の表面4a側に、平均粒径2μm以上3μm以下のシリカフィラーを25質量部混合した2液硬化型ウレタン樹脂を3g/m2塗工して、第1の表面保護層5a及び第2の表面保護層5bを形成した。
実施例2では、各領域9a、9b、9cの凹部と凸部との高低差を2μm、つまり、実施例1の高低差である0.5μmより大きくした。それ以外は実施例1と同じ材料・手順で化粧シート10を作製した。
(実施例3)
実施例3では、第1の表面保護層5aにおけるシリカフィラー含有量を3質量部とした。それ以外は実施例1と同じ材料・手順で化粧シート10を作製した。
(比較例1)
比較例1では、凹凸模様8の形成を省略した。それ以外は実施例1と同じ材料・手順で化粧シート10を作製した。
実施例1~3、比較例1の化粧シート10に対して、以下の性能評価の試験を行った。(光沢)
光沢の試験では、領域9a、9b、9c内の光沢と領域9a、9b、9c外の光沢(つまり領域9dの光沢)とを、JIS Z 8741に準拠した60度鏡面光沢で測定した。
(触感)
触感の試験では、指触による立体感の評価を行った。指触により立体感を感じる場合を合格「○」とし、指触により立体感を感じない場合を不合格「×」とした。
(立体感)
立体感の試験では、目視による立体感の評価を行った。目視により立体感を感じる場合を合格「○」とし、目視により立体感を感じない場合を不合格「×」とした。
(試験結果)
試験結果を表1に示す。
実施例4では、第1の表面保護層5a及び第2の表面保護層5bを塗工した後に、凹凸模様8の凹部と凸部との高低差を200μm、各領域9a、9b、9c内の凹部と凸部との高低差を10μmとする賦形版を用い、凹凸模様8及び領域9a、9b、9cを賦形した。それ以外は実施例1と同じ材料・手順で化粧シート10を作製した。
(実施例5)
実施例5では、各領域9a、9b、9c内の凹部と凸部との高低差を0.5μmとした。それ以外は実施例4と同じ材料・手順で化粧シート10を作製した。
(実施例6)
実施例6では、各領域9a、9b、9c内の凹部と凸部との高低差を15μmとした。それ以外は実施例4と同じ材料・手順で化粧シート10を作製した。
(性能評価・試験結果)
実施例4~6の化粧シート10に対して、光沢、触感、立体感の性能評価の試験を行った。
試験結果を表2へ示す。
実施例7では、第1の表面保護層5a及び第2の表面保護層5bを、アクリル系UV硬化樹脂で形成した。それ以外は実施例1と同じ材料・手順で化粧シート10を作製した。(性能評価)
実施例1、7の化粧シート10を厚さ3mmのMDF板へ2液硬化型エマルジョン接着剤(コニシ株式会社)を用いて接着してなる化粧板に、以下の性能評価の試験を行った。
鉛筆硬度試験では、JIS K5600-5-4 引っかき硬度(鉛筆法)に準じた試験を行った。すなわち、硬度3B、2B、B、HB、F、H、2H、3Hの鉛筆を用い、化粧シート10に対して鉛筆の角度を45±1°に固定して、鉛筆に1kgの荷重を付加した状態でスライドさせて化粧シート10(表面保護層5)に凹み(傷)が形成されるかを観察した。そして、凹みが確認されなかった鉛筆の最大硬度を試験結果として得た。
なお、ISO 3270に準じた試験を行っても、上述のJIS K5600-5-4の場合と同じ結果を得た。また、ISO 2808に準じた試験を行っても、JIS K5600-5-4の場合と同じ結果を得た。
1mmR折り曲げ試験では、化粧板に1mmRの折り曲げ加工を行い、クラックや白化が発生するかを観察した。そして、クラック及び白化のいずれも確認されなかった場合を合格「○」とし、クラック及び白化のいずれかが確認された場合を不合格「×」とした。
なお、「1mmR」とは、半径(R)が1mmであることを意味する。
(試験結果)
試験結果を表3に示す。
一方、実施例7の化粧シート10は、第1の表面保護層5a及び第2の表面保護層5bをアクリル系UV硬化樹脂で形成するようにしたため、鉛筆硬度試験の試験結果が「F」となり、優れた耐傷性を持つ化粧シート10が得られた。ただし、1mmR折り曲げ試験では、クラックが発生し、角が白化したため、試験結果が不合格「×」となり、実施例1の化粧シート10(合格「○」)に比較して、折り曲げ加工適性が劣るものとなった。
Claims (4)
- 基材と、
前記基材の表面側に設けた絵柄模様層と、
前記絵柄模様層の表面側に設けた透明接着層と、
前記透明接着層の表面側に設けた透明熱可塑性樹脂層と、
前記透明熱可塑性樹脂層の表面側に設けた表面保護層と、を備え、
前記透明熱可塑性樹脂層の表面側及び前記表面保護層の表面側には、凹凸模様と、前記凹凸模様の凹部の表面と凸部の表面とのそれぞれに設けられ、凹凸が形成された複数の領域を有する凹凸パターンと、を有し、
前記凹凸模様の凹部と凸部との高低差は、3μm以上200μm以下であり、
前記凹凸パターンの各領域内の凹部と凸部との高低差は、前記凹凸模様の凹部と凸部との高低差よりも小さいことを特徴とする化粧シート。 - 各領域内の凹部と凸部との高低差は、0.5μm以上10μm以下であることを特徴とする請求項1に記載の化粧シート。
- 前記表面保護層は、ウレタン結合を有する熱硬化型樹脂、及び電離放射線硬化型樹脂の少なくともいずれかを含むことを特徴とする請求項1または2に記載の化粧シート。
- 前記領域内の光沢と前記領域外の光沢との差がJIS Z 8741に準拠した60度鏡面光沢で3以上30以下であることを特徴とする請求項1から3のいずれか1項に記載の化粧シート。
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