JP2015171811A - decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet that gives a realistic feeling, for example, a decorative sheet with a woodgrain pattern that gives a tactile feeling and gloss similar to those of real wood and that can impart a high-class impression to a decorative material.SOLUTION: The decorative sheet includes : a raised layer at least partially disposed on a substrate; and a surface protective layer covering an entire surface including an area where the raised layer is formed and an area where no raised layer is formed. The surface protective layer is a crosslinked and cured product of an ionization radiation-curable resin composition and has a ten-point average roughness of 5 to 35 μm on a surface thereof. An occupation area ratio of the raised layer is 2 to 25%.

Description

  The present invention relates to a decorative sheet used for surface decoration of buildings, interiors, exteriors, furniture, joinery and the like, interiors of vehicles, and the like.

As surface decorative boards for interiors, exteriors, furniture, joinery, and vehicle interiors of buildings, for example, those having a structure in which a decorative sheet printed with a wood grain pattern or the like is bonded with an adhesive are used.
The decorative sheet used for such a decorative sheet is required to have various characteristics such as excellent design as well as touch, matte, gloss and stain resistance.
Among these, it has been proposed to provide a raised portion on the surface of the decorative sheet, in particular, in order to obtain a tactile sensation, matte sensation, glossiness, and design.
As such a decorative sheet, for example, Patent Document 1 discloses a decorative sheet in which a polygonal or circular regular or regular raised portion is provided on the surface of the decorative sheet, and Patent Document 2 describes the unevenness of the raised portion. A decorative sheet, in which the surface area ratio of the difference and the convex portion is limited, Patent Document 3 discloses a decorative sheet provided with a concavo-convex portion made of an ionizing radiation curable resin ink on the surface.
However, these decorative sheets do not have sufficient scratch resistance, stain resistance, tactile sensation, matte feeling and glossiness as sheets, and further improvements in design properties have been demanded.

JP 2003-94592 A Japanese Patent No. 3334365 JP 2004-249586

  The subject of this invention is providing the decorative sheet which is excellent in tactile sensation, a mat | matte feeling, and a glossy feeling in the above situations, and is excellent in a flaw resistance, stain resistance, and designability.

  As a result of intensive studies to achieve the above object, the inventors of the present invention are decorative sheets having a raised layer and a surface protective layer on a substrate, and the surface 10-point average roughness is in a specific range. And it discovered that the said subject could be solved by making the occupation area ratio of a raised layer into a specific range. The present invention has been completed based on such findings.

  That is, the present invention provides a surface protective layer that covers the entire surface including a raised layer provided at least partially on a substrate, a region where the raised layer is formed, and a region where the raised layer is not formed. The surface protective layer is obtained by crosslinking and curing the ionizing radiation curable resin composition, the surface has a ten-point average roughness of 5 to 35 μm, and the occupied area ratio of the raised layer Is a decorative sheet having a content of 2 to 25%.

  The decorative sheet of the present invention is excellent in tactile sensation, matte sensation, and glossiness, and is excellent in scratch resistance, stain resistance, and design.

It is a schematic diagram which shows the cross section of the decorative sheet of this invention.

The decorative sheet of the present invention has a surface protection covering the entire surface including at least a raised layer provided on a substrate, a region where the raised layer is formed, and a region where the raised layer is not formed. Having a layer.
Hereinafter, the decorative sheet of the present invention will be described in detail with reference to FIG.

  The decorative sheet 10 of the present invention shown in FIG. 1 has a decoration layer 30 that is provided on a base material 20 as necessary, for example, a solid print layer 31 and a pattern layer 32, and on that, as necessary. It has the primer layer 40 to be formed, has a raised layer 50 partially provided thereon, and has a surface protective layer 60 on the raised layer.

<Base material>
The base material 20 in the decorative sheet 10 of the present invention is not particularly limited as long as it is normally used as a base material of a decorative sheet, and various papers, plastic films, plastic sheets, and the like are appropriately selected depending on applications. can do. Each of these materials may be used alone, but may be a laminate of any combination such as a composite of paper or a composite of paper and a plastic film.
When using these substrates, particularly plastic films or plastic sheets, as a substrate, an oxidation method or a concavo-convex method may be applied to one or both sides as desired in order to improve the adhesion to the layer provided thereon. Physical or chemical surface treatment can be applied.

Examples of the oxidation method include a corona discharge treatment method, a chromium oxidation treatment method, a flame treatment method, a hot air treatment method, ozone and an ultraviolet treatment method, and examples of the unevenness method include a sand blast method and a solvent treatment method. Can be mentioned. These surface treatments are appropriately selected depending on the type of substrate, but generally, a corona discharge treatment method is preferably used from the viewpoints of effects and operability.
Further, the substrate may be subjected to a treatment such as forming a primer layer, or a coating for adjusting the color or a pattern from a design viewpoint may be formed in advance.

As various papers used as the substrate, thin paper, kraft paper, titanium paper and the like can be used. These paper base materials are used to reinforce the interlaminar strength between the fibers of the paper base material or between the other layers and the paper base material, and to prevent the occurrence of scuffing, in addition to these paper base materials, acrylic resin, styrene butadiene rubber, A resin such as a melamine resin or a urethane resin may be added (resin impregnation after paper making or embedded during paper making). For example, inter-paper reinforced paper, resin-impregnated paper, and the like.
In addition to these, various papers often used in the field of building materials such as linter paper, paperboard, base paper for gypsum board, or a vinyl wallpaper raw material in which a vinyl chloride resin layer is provided on the surface of the paper can be mentioned. Furthermore, coated paper, art paper, sulfate paper, glassine paper, parchment paper, paraffin paper, Japanese paper, or the like used in the office field or normal printing and packaging can also be used. Moreover, although distinguished from these papers, woven fabrics and non-woven fabrics of various fibers having an appearance and properties similar to paper can be used as the base material. Examples of various fibers include inorganic fibers such as glass fibers, asbestos fibers, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers, or synthetic resin fibers such as polyester fibers, acrylic fibers, and vinylon fibers.

  As a plastic film or a plastic sheet, what consists of various synthetic resins is mentioned. Synthetic resins include polyethylene resin, polypropylene resin, polymethylpentene resin, polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl. Representative examples include alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene naphthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, nylon 6 or nylon 66 And polyamide resin, cellulose triacetate resin, cellophane, polystyrene resin, polycarbonate resin, polyarylate resin, polyimide resin, and the like.

The thickness of the substrate is not particularly limited, but when a film or sheet made of plastic is used, the thickness is usually in the range of about 20 to 150 μm, preferably 30 to 100 μm. Is used, the basis weight is usually about ²⁰ to 150 g / m ² , preferably 30 to 100 g / m ² .

The decorative sheet 10 of the present invention is characterized in that it has a raised layer 50 provided at least partially on the base material 20.
<Heisei layer>
The raised layer 50 in the decorative sheet of the present invention is located between the base material 20 and the surface protective layer 60 and has a function of imparting touch to the decorative sheet and enhancing the design.
In the present invention, it is essential that the height of the raised layer is such that the ten-point average roughness (Rz) of the surface of the decorative sheet after providing the surface protective layer is in the range of 5 to 35 μm. When the ten-point average roughness (Rz) of the decorative sheet surface is less than 5 μm, sufficient tactile sensation cannot be imparted to the decorative sheet surface. On the other hand, when the ten-point average roughness (Rz) exceeds 35 μm, the bending workability is inferior. From the above viewpoint, the ten-point average roughness (Rz) of the decorative sheet surface of the present invention is preferably in the range of 10 to 25 μm.
Moreover, the occupation area ratio of the raised layer is in the range of 2 to 25% with respect to the area of the flat surface of the decorative sheet. If the occupied area ratio is 2% or less, sufficient tactile sensation cannot be imparted to the surface of the decorative sheet. On the other hand, if the occupation area ratio exceeds 25%, the bending workability is inferior. In addition, the tactile sensation on the surface of the decorative sheet is deteriorated and the contamination is also reduced. From the above viewpoint, the occupation area ratio is preferably in the range of 5 to 25%.
By selecting the range of the thickness of the raised layer and the occupied area ratio, a particularly suitable tactile sensation can be imparted to the decorative sheet.
The occupied area ratio of the raised layer refers to the ratio of the area of the bottom surface of the raised portion to the area of the flat surface of the decorative sheet.

The shape of each raised portion constituting the raised layer in the present invention is not particularly limited, and may be a regular shape such as a regular arrangement of circles, squares, hexagons, or an irregular pattern. An irregular pattern is preferable because it is excellent in touch, matte, gloss and design.
Moreover, it does not specifically limit as a material of a raised layer, A thermosetting resin composition, an ionizing radiation curable resin composition, etc. can be used. Among these, in particular, as a vehicle component, polyisocyanate is added as a curing agent to a resin having a functional group such as a hydroxyl group, a carboxyl group, or an amino group as an acrylic, polyester, acrylic urethane, or urethane resin. A liquid curable resin is desirable from the viewpoint of maintaining surface performance and cost.

<Surface protective layer>
The surface protective layer 60 in the decorative sheet 10 of the present invention is present on the raised layer 50, a partially provided raised layer, a region where the raised layer is formed, and a region where the raised layer is not formed. The ionizing radiation curable resin composition is formed by crosslinking and curing. Here, the ionizing radiation curable resin composition is one having an energy quantum capable of crosslinking and polymerizing molecules in an electromagnetic wave or a charged particle beam, that is, crosslinking or curing by irradiating ultraviolet rays or electron beams. Refers to a resin composition. Specifically, the ionizing radiation curable resin in the ionizing radiation curable resin composition is appropriately selected from polymerizable monomers and polymerizable oligomers or prepolymers conventionally used as ionizing radiation curable resin compositions. Can be used.
Typically, a (meth) acrylate monomer having a radical polymerizable unsaturated group in the molecule is suitable as the polymerizable monomer.

  As the (meth) acrylate monomer, a polyfunctional (meth) acrylate is preferable. Here, “(meth) acrylate” means “acrylate or methacrylate”. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule. Specifically, ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) ) Acrylate, polyethylene glycol di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate, dicyclopentanyl di (meth) acrylate, caprolactone modified dicyclopentenyl di (meth) acrylate, ethylene oxide modified diphosphate ( (Meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethylene oxide modified trimethylo Propane tri (meth) acrylate, dipentaerythritol tri (meth) acrylate, propionic acid modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, propylene oxide modified trimethylolpropane tri (meth) acrylate, tris ( Acryloxyethyl) isocyanurate, propionic acid modified dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ethylene oxide modified dipentaerythritol hexa (meth) acrylate, caprolactone modified dipentaerythritol hexa (meth) acrylate, etc. Is mentioned. These polyfunctional (meth) acrylates may be used singly or in combination of two or more.

  In the present invention, a monofunctional (meth) acrylate can be used in combination with the polyfunctional (meth) acrylate as long as the object of the present invention is not impaired, for the purpose of lowering the viscosity. Examples of monofunctional (meth) acrylates include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, cyclohexyl ( Examples include meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, and isobornyl (meth) acrylate. These monofunctional (meth) acrylates may be used alone or in combination of two or more.

  Next, as the polymerizable oligomer, an oligomer having a radical polymerizable unsaturated group in the molecule, for example, epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, polyether (meth) acrylate System oligomers and the like. Here, the epoxy (meth) acrylate oligomer can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it. . Further, a carboxyl-modified epoxy (meth) acrylate oligomer obtained by partially modifying this epoxy (meth) acrylate oligomer with a dibasic carboxylic acid anhydride can also be used. The urethane (meth) acrylate oligomer can be obtained, for example, by esterifying a polyurethane oligomer obtained by reaction of polyether polyol or polyester polyol and polyisocyanate with (meth) acrylic acid. Examples of polyester (meth) acrylate oligomers include esterification of hydroxyl groups of polyester oligomers having hydroxyl groups at both ends obtained by condensation of polycarboxylic acid and polyhydric alcohol with (meth) acrylic acid, It can be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide to a carboxylic acid with (meth) acrylic acid. The polyether (meth) acrylate oligomer can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.

  Furthermore, other polymerizable oligomers include polybutadiene (meth) acrylate oligomers with high hydrophobicity that have (meth) acrylate groups in the side chain of polybutadiene oligomers, and silicone (meth) acrylate oligomers that have polysiloxane bonds in the main chain. In a molecule such as an aminoplast resin (meth) acrylate oligomer modified with an aminoplast resin having many reactive groups in a small molecule, or a novolak epoxy resin, bisphenol epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, etc. There are oligomers having a cationic polymerizable functional group.

When an ultraviolet curable resin composition is used as the ionizing radiation curable resin composition, it is desirable to add about 0.1 to 5 parts by mass of the photopolymerization initiator with respect to 100 parts by mass of the resin composition. The initiator for photopolymerization can be appropriately selected from those conventionally used and is not particularly limited. For example, for a polymerizable monomer or polymerizable oligomer having a radically polymerizable unsaturated group in the molecule. Benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-butyl ether, benzoin isobutyl ether, acetophenone, dimethylaminoacetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy-2 -Phenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1- [4- (methylthio) phenyl] -2-morpholino-propane-1 - 4- (2-hydroxyethoxy) phenyl-2 (hydroxy-2-propyl) ketone, benzophenone, p-phenylbenzophenone, 4,4′-diethylaminobenzophenone, dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone, 2 -Tertiary butylanthraquinone, 2-aminoanthraquinone, 2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone, 2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, benzyldimethyl ketal, acetophenone dimethyl ketal It is done.
Examples of the polymerizable oligomer having a cationic polymerizable functional group in the molecule include aromatic sulfonium salts, aromatic diazonium salts, aromatic iodonium salts, metallocene compounds, and benzoin sulfonic acid esters.
Moreover, as a photosensitizer, p-dimethylbenzoic acid ester, tertiary amines, a thiol type sensitizer, etc. can be used, for example.

  In the decorative sheet 10 used in the present invention, it is preferable to use an electron beam curable resin as the ionizing radiation curable resin. This is because the electron beam curable resin can be made solvent-free, is more preferable from the viewpoint of environment and health, and does not require a photopolymerization initiator, and can provide stable curing characteristics.

Moreover, various additives can be mix | blended with an ionizing radiation curable resin composition according to the desired physical property of the cured resin layer obtained. Examples of the additive include a weather resistance improver, an abrasion resistance improver, a polymerization inhibitor, a crosslinking agent, an infrared absorber, an antistatic agent, an adhesion improver, an antioxidant, a leveling agent, a thixotropic agent, Examples include coupling agents, plasticizers, antifoaming agents, fillers, and solvents.
Here, as the weather resistance improving agent, an ultraviolet absorber or a light stabilizer can be used. It is added for long-term use of the decorative sheet. The ultraviolet absorber may be either inorganic or organic, and as the inorganic ultraviolet absorber, titanium dioxide, cerium oxide, zinc oxide or the like having an average particle diameter of about 5 to 120 nm can be preferably used. Examples of the organic ultraviolet absorber include benzotriazole-based compounds, specifically 2- (2-hydroxy-5-methylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-tert-). Amylphenyl) benzotriazole, 3- [3- (benzotriazol-2-yl) -5-tert-butyl-4-hydroxyphenyl] propionic acid ester of polyethylene glycol, and the like. On the other hand, examples of the light stabilizer include hindered amines, specifically 2- (3,5-di-tert-butyl-4-hydroxybenzyl) -2′-n-butylmalonate bis (1,2,2). , 6,6-pentamethyl-4-piperidyl), bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, tetrakis (2,2,6,6-tetramethyl-4-piperidyl)- 1,2,3,4-butanetetracarboxylate and the like. Further, as the ultraviolet absorber or light stabilizer, a reactive ultraviolet absorber or light stabilizer having a polymerizable group such as a (meth) acryloyl group in the molecule can be used.

Examples of the wear resistance improver include, for inorganic substances, spherical particles such as α-alumina, silica, kaolinite, iron oxide, diamond, and silicon carbide. Examples of the particle shape include a sphere, an ellipsoid, a polyhedron, a scale shape, and the like. Although there is no particular limitation, a spherical shape is preferable. Organic materials include synthetic resin beads such as cross-linked acrylic resin and polycarbonate resin. The particle size is usually about 30 to 200% of the film thickness. Among these, spherical α-alumina is particularly preferable because it has high hardness and a large effect on improving wear resistance, and it is relatively easy to obtain spherical particles.
Examples of the polymerization inhibitor include hydroquinone, p-benzoquinone, hydroquinone monomethyl ether, pyrogallol, and t-butylcatechol. Examples of the crosslinking agent include a polyisocyanate compound, an epoxy compound, a metal chelate compound, an aziridine compound, and an oxazoline compound. Used.
As the filler, for example, barium sulfate, talc, clay, calcium carbonate, aluminum hydroxide and the like are used.
As the infrared absorber, for example, a dithiol metal complex, a phthalocyanine compound, a diimmonium compound, or the like is used.

  The surface protective layer preferably contains calcined kaolin particles as other components. By including the calcined kaolin particles in the surface protective layer, the marring resistance is improved. Here, the term “marling” means that small scratches are generated when the sheet surface is rubbed, and “excellent marring resistance” means that scratches are difficult to be made.

  The calcined kaolin particles used for imparting marring resistance to the surface of the decorative sheet are kaolin particles obtained by calcining general (hydrous) kaolin particles, but the calcined kaolin particles should be added as a filler. Thus, the improvement in marring resistance, which could not be realized with silica particles or hydrous kaolin particles before firing, is realized. The particle size of the calcined kaolin particles may be appropriately selected according to the application, required physical properties, etc. For example, those having an average particle size of about 0.5 to 2 μm are used. Also, the amount of calcined kaolin particles added may be appropriately selected according to the application, required physical properties, etc., for example, ionizing radiation curable resin (however, if the surface protective layer contains other resins, ionization The total of the radiation curable resin and other resin) is about 5 to 50 parts by mass with respect to 100 parts by mass. The calcined kaolin particles are superior in paint stability to the hydrous kaolin particles.

  As the calcined kaolin particles, those whose surfaces are further treated may be used. By using the surface-treated calcined kaolin particles, the effect of improving marring resistance can be further increased. As the surface treatment, there is a surface treatment with a silane coupling agent. Examples of the silane coupling agent include known silane coupling agents having an alkoxy group, amino group, vinyl group, epoxy group, mercapto group, chloro group and the like. For example, γ-aminopropyltriethoxysilane, γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropylmethyldimethoxysilane, γ-methacryloxypropyldimethylmethoxysilane, γ-methacryloxypropyltriethoxysilane, γ-methacryloxy Propyldimethylethoxysilane, γ-acryloxypropyltrimethoxysilane, γ-acryloxypropylmethyldimethoxysilane, γ-acryloxypropyldimethylmethoxysilane, γ-acryloxypropyltriethoxysilane, γ-acryloxypropylmethyldiethoxysilane , Γ-acryloxypropyldimethylethoxysilane, vinyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysila Etc.

The surface protective layer 60 of the decorative sheet 10 can be formed as follows, for example. First, the above-mentioned ionizing radiation curable resin, other components to be blended as necessary, and various additives are homogeneously mixed at predetermined ratios to prepare a coating liquid comprising an ionizing radiation curable resin composition. To do. The viscosity of the coating solution is not particularly limited as long as it is a viscosity capable of forming an uncured resin layer on the surface of the substrate by a coating method described later.
Gravure coating, bar coating, roll coating, reverse roll coating, comma coating, etc., so that the coating liquid prepared in this manner is applied to the surface of the substrate so that the thickness after curing is 1 to 20 μm. This method is preferably applied by gravure coating to form an uncured resin layer.

When the uncured resin layer thus formed is irradiated with ionizing radiation such as an electron beam and ultraviolet rays to cure the uncured resin layer, the desired function is obtained when the thickness after curing is 1 μm or more. A cured resin layer is obtained. The thickness of the surface protective layer after curing is preferably about 2 to 20 μm.
Here, when an electron beam is used as the ionizing radiation, the acceleration voltage can be appropriately selected according to the resin used and the thickness of the layer, but the uncured resin layer is usually cured at an acceleration voltage of about 70 to 300 kV. preferable.
In electron beam irradiation, the transmission capability increases as the acceleration voltage increases. Therefore, when using a base material that deteriorates due to the electron beam as the base material, the transmission depth of the electron beam and the thickness of the resin layer are substantially equal. By selecting the accelerating voltage so as to be equal to each other, it is possible to suppress the irradiation of the electron beam to the base material, and to minimize the deterioration of the base material due to the excessive electron beam.
The irradiation dose is preferably such that the crosslink density of the resin layer is saturated, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).
Further, the electron beam source is not particularly limited. For example, various electron beam accelerators such as a cockroft Walton type, a bandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type. Can be used.
When ultraviolet rays are used as the ionizing radiation, those containing ultraviolet rays having a wavelength of 190 to 380 nm are emitted. There is no restriction | limiting in particular as an ultraviolet-ray source, For example, a high pressure mercury lamp, a low pressure mercury lamp, a metal halide lamp, a carbon arc lamp, etc. are used.
The cured resin layer thus formed has various functions by adding various additives, for example, a so-called hard coat function, anti-fogging coat function, and anti-fouling coat having high hardness and scratch resistance. A function, an antiglare coating function, an antireflection coating function, an ultraviolet shielding coating function, an infrared shielding coating function, and the like can also be imparted.

<Decoration layer>
In the decorative sheet 10 of the present invention, a decorative layer 30 can be provided in order to impart decorativeness to the decorative sheet. The decoration layer is preferably provided between the base material 20 and the raised layer 50, and more specifically, it is preferably provided on the base material 20 as shown in a preferred embodiment in FIG. The decoration layer may consist of only the solid print layer 31 or may be constituted by the solid print layer 31 and the pattern layer 32.
In the decorative sheet of the present invention, the solid print layer provided on the substrate is also referred to as a concealing layer provided as desired in order to enhance the design of the decorative sheet of the present invention. The solid print layer is formed when the color of the surface of the base material is adjusted so that the decorative sheet itself is colored or uneven in color, and gives the intended color to the surface of the decorative sheet. Usually, it is formed with an opaque color, but it may be formed with a colored transparent color to make use of the pattern of the base. When taking advantage of the fact that the base material is white or when the base material itself is appropriately colored, there is no need to form a solid print layer.
As the ink used for forming the solid printing layer, an ink obtained by appropriately mixing a binder, a colorant such as a pigment or a dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, or a curing agent is used. The binder is not particularly limited, and examples thereof include polyurethane resins, vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated polypropylene resins, acrylic resins, polyesters. Arbitrary resins, polyamide resins, butyral resins, polystyrene resins, nitrocellulose resins, cellulose acetate resins and the like may be used alone or in combination of two or more.
Colorants include carbon black (black), iron black, titanium white, antimony white, yellow lead, titanium yellow, petal, cadmium red, ultramarine, cobalt blue and other inorganic pigments, quinacridone red, isoindolinone yellow, phthalocyanine Organic pigments or dyes such as blue, metallic pigments composed of scaly foil pieces such as aluminum and brass, pearlescent pigments composed of scaly foil pieces such as titanium dioxide-coated mica and basic lead carbonate, and the like are used.
The thickness of the solid print layer is preferably about 1 to 20 μm.

The pattern layer 32 gives decorativeness to the decorative sheet, and is formed by printing various patterns on the base material 20 or the solid print layer 31 using ink and a printing machine. As patterns, there are stone patterns imitating the surface of rocks, such as wood grain patterns, marble patterns (for example, travertine marble patterns), fabric patterns imitating cloth or cloth-like patterns, tiled patterns, brickwork patterns, etc. There are also patterns such as marquetry and patchwork that combine these. These patterns are formed by multicolor printing with the usual yellow, red, blue and black process colors, as well as by multicolor printing with special colors prepared by preparing the individual color plates that make up the pattern. Is done.
As the pattern ink used for the pattern layer 32, the same ink as that used for the solid print layer can be used.

<Primer layer>
The decorative sheet 10 of the present invention preferably has the primer layer 40 on the substrate 20 and has the raised layer 50 on the primer layer. The primer layer can have various functions.
One of the functions is a matte function. That is, the primer layer contains a matting agent to lower the gloss of the entire decorative sheet.
The matting agent may be either inorganic fine particles or organic fine particles. Examples of the fine particles include inorganic fine particles such as silica, alumina, aluminosilicate, kaolinite, calcium carbonate, barium sulfate, and glass, and the organic fine particles include acrylic resin, polycarbonate resin, and urethane. Examples thereof include particles such as resin, urea resin, benzoguanamine resin, and benzoguanamine-melamine-formaldehyde condensate. Among these, silica particles are preferable from the viewpoint of the effects of the present invention, and the particle diameter is preferably in the range of 1 to 10 μm, and more preferably in the range of 2 to 5 μm, from the viewpoints of effects and handleability.
Moreover, these fine particles may be used individually by 1 type, and may be used in combination of 2 or more type.

Another function of the primer layer is a penetration preventing function. That is, it is a function which suppresses that the resin composition which comprises an elevated part, and the ionizing radiation-curable resin composition which comprises a surface protective layer penetrate | invade in a base material. This is particularly effective when the substrate is a permeable substrate such as paper or nonwoven fabric.
Moreover, the function which improves the adhesiveness of the base material 20 or the decoration layer 30, and the build-up layer 50 can also be given together.

<Backside primer layer>
In the decorative sheet of the present invention, the back primer layer 70 can be provided on the side opposite to the side on which the decorative layer, the raised layer, the surface protective layer and the like are formed, that is, on the back side of the substrate. With the back primer layer, adhesion and adhesion to the substrate can be improved when producing a decorative board to be described later.
The material used for the back primer layer is not particularly limited as long as it can improve the adhesion and adhesion to the substrate. Specifically, urethane resin, acrylic resin, polyester resin, vinyl chloride-acetic acid Preferred examples include vinyl copolymers, chlorinated polypropylene resins, and chlorinated polyethylene resins. Among these, urethane resins are preferred. In addition, the material used for the back surface primer layer 7 is appropriately selected depending on the adherend.
Moreover, it is preferable that the thickness of a back surface primer layer is about 1-5 micrometers, More preferably, it is 1-3 micrometers. When the thickness is within the above range, excellent performance as a primer layer can be obtained efficiently.

<Decorative board>
The decorative sheet 10 of the present invention can be used as a decorative plate by sticking to various substrates. The board | substrate used as a to-be-adhered body is not specifically limited, A plastic board, a metal board, woody board | plates, such as a timber, a ceramic material, etc. can be selected suitably according to a use. When these substrates, particularly plastic sheets, are used as substrates, a physical or chemical surface treatment such as an oxidation method or a concavo-convex method is applied to one or both sides as desired in order to improve adhesion to the decorative sheet. Can be applied.
Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone treatment, and ultraviolet treatment method. Examples of the unevenness method include a sand blast method and a solvent treatment method. These surface treatments are appropriately selected depending on the type of substrate, but generally, a corona discharge treatment method is preferably used from the viewpoints of effects and operability.

  As a plastic sheet, what consists of various synthetic resins is mentioned. Synthetic resins include polyethylene resin, polypropylene resin, polymethylpentene resin, polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl. Representative examples include alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene naphthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, nylon 6 or nylon 66 And polyamide resin, cellulose triacetate resin, cellophane, polystyrene resin, polycarbonate resin, polyarylate resin, polyimide resin, and the like.

As a metal plate, what consists of aluminum, iron, stainless steel, or copper can be used, for example, and what gave these metals by plating etc. can also be used.
Examples of wood-based boards include veneer of various materials such as cedar, firewood, firewood, pine, lawan, teak and melapie, and wood materials such as wood veneer, wood plywood, particle board, and medium density fiber board (MDF). . These can be used alone or in a stacked manner. The wooden board includes not only a wooden board but also a plastic board containing paper powder and reinforced paper having strength.
Examples of the ceramic material include ceramic building materials such as a gypsum plate, a calcium silicate plate, and a wood piece cement plate, ceramics, glass, firewood, fired tiles, plates made mainly of volcanic ash, and the like.
In addition to these, composites of various materials, such as fiber reinforced plastic (FRP) plates, paper honeycombs with iron plates pasted on both sides, and two aluminum plates sandwiched with polyethylene resin can also be used as the base material. .

Further, the substrate may be subjected to a treatment such as forming a primer layer, or a coating for adjusting the color or a pattern from a design viewpoint may be formed in advance. As a substrate to be an adherend, plate materials such as flat plates and curved plates of various materials, or three-dimensional shaped articles (molded products) in which the above materials are used alone or in combination are targeted.
A backing material such as Japanese paper, Western paper, synthetic paper, non-woven fabric, woven fabric, cold paper, impregnated paper, synthetic resin sheet, or the like may be attached to the decorative sheet. By sticking the backing material, it acts to reinforce the decorative sheet itself, prevent cracking and tearing of the decorative sheet, prevent bleeding of the adhesive to the decorative sheet surface, and prevent the occurrence of defective products, Handling becomes easy and productivity can be improved.
Thus, a substrate on which a decorative sheet is placed every leaf or continuously via an adhesive is attached to a cold press, a hot press, a roll press, a laminator, a lapping, an edge pasting machine, a vacuum press, etc. The decorative sheet is bonded to the substrate surface by pressing with an apparatus to obtain a decorative plate.

The adhesive is applied using an application device such as a spray, spreader, or bar coater. As the adhesive, vinyl acetate resin-based, urea resin-based, melamine resin-based, phenol resin-based, isocyanate-based adhesives, etc., are used alone or as a mixed adhesive obtained by arbitrarily mixing them. As needed, talc, calcium carbonate, clay, titanium white and other inorganic powders, wheat flour, wood flour, plastic powder, coloring agents, insect repellents, fungicides and the like can be added and mixed in the adhesive. . In general, the adhesive is applied to the substrate surface with a solid content of 35 to 80% by mass and an application amount of 50 to 300 g / m ² .
Adhesion of the decorative sheet on the substrate is usually performed by forming an adhesive layer on the back surface of the decorative sheet of the present invention and adhering the substrate or applying an adhesive on the substrate and adhering the decorative sheet. Etc.

  The decorative board manufactured as described above can be arbitrarily cut and subjected to optional decoration such as grooving and chamfering on the surface and the end of the cut using a cutting machine such as a router or a cutter. And various uses, for example, interior or exterior materials of buildings such as walls, ceilings, floors, window frames, doors, handrails, skirting boards, margins, surface decorative boards for fittings such as malls, kitchens, furniture or light electrical appliances, It can be used for surface decorative boards of cabinets such as OA equipment, interiors and exteriors of vehicles.

<Makeup tack sheet>
The decorative sheet 10 of the present invention can be used as a decorative tack sheet by providing an adhesive layer on the substrate side. This decorative tack sheet can be attached to the substrate via an adhesive layer to produce a decorative board.
Preferable examples of the pressure-sensitive adhesive used in the pressure-sensitive adhesive layer include pressure-sensitive adhesives such as acrylic pressure-sensitive adhesives, urethane-based pressure-sensitive adhesives, rubber-based pressure-sensitive adhesives, and silicon-based pressure-sensitive adhesives. An agent is more preferable. As an acrylic adhesive, C2-C14 (meth) alkyl acrylate is mentioned preferably, for example.

  When producing a decorative board by laminating a decorative tack sheet and a substrate, the decorative tack sheet and the substrate may be laminated directly via an adhesive layer, in order to obtain stronger adhesion of these layers. It is also possible to provide an adhesive reinforcing layer between the two. This adhesion reinforcing layer may be provided on either the surface opposite to the surface on which the surface protective layer of the base material of the decorative tack sheet is provided (the surface of the back surface primer layer when the back surface primer layer is provided) or the substrate. The process of providing the adhesive reinforcing layer on the substrate and the adhesion process between the substrate and the decorative tack sheet are usually performed on site.

The adhesive reinforcing layer is preferably provided on the substrate, and is preferably applied so that the coating amount in terms of solid matter is 3 to 20 g / m ² . As the material of the adhesive reinforcing layer, a rubber adhesive made of chloroprene rubber, nitrile rubber, styrene-butadiene rubber, styrene-isoprene rubber or the like is preferable, and a chloroprene rubber adhesive is particularly preferable from the viewpoint of ensuring nonflammability. .
The thickness of the adhesive reinforcing layer is preferably 5 to 200 μm, and more preferably 20 to 100 μm. When it is 5 μm or more, good adhesion to the substrate is obtained, and when it is 200 μm or less, good bending workability is obtained.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by this example.
(Evaluation method)
The decorative sheet obtained in each example was evaluated by the following methods.
(1) Occupied area ratio of the upper part Using a non-contact surface roughness meter “three-dimensional measurement microscope” STM6ZP (trade name) manufactured by Olympus Corporation, magnification is 50 times, measurement pitch is 0.10 mm, and driving speed is high The occupied area of the upper part was measured under the conditions. The occupied area ratio was calculated by dividing the occupied area by the plane area of the decorative sheet.
(2) Ten-point average surface roughness (Rz)
Ten-point average roughness Rz was measured in accordance with JIS B 0601: 2001 with a measurement length of 8 mm and a cut-off value of 0.8 mm. (3) Surface tactile sensation Tactile sensation touched by human hands was evaluated according to the following criteria. did.
◎: There is a great feeling of sensation ○: There is a feeling of sensation △: There is a feeling of some sensation ×: There is almost no feeling of sensation (4) Contamination resistance Contaminant according to JIS K-6902 The remaining condition of the contaminants after applying and wiping off the surface of the decorative sheet was visually observed. Judgment criteria were evaluated as follows.
◎: No contamination remains ○: Contamination remains faint △: Contamination remains slight, but there is no problem in practical use △: Contamination remains in the recess ×: Contaminant remains remarkably (5) Bending processability of decorative sheet After V-cut processing, the V-cut portion was visually confirmed and evaluated according to the following criteria.
(Double-circle): The crack of the surface of a decorative sheet was not confirmed at all.
◯: Cracking of the decorative sheet is slight and there is no practical problem.
Δ: Some cracks on the decorative sheet were confirmed.
X: The crack of the decorative sheet was remarkable.

Example 1
Easy-adhesive polyethylene terephthalate (PET) film (“A4100 (thickness: 50 μm)” manufactured by Toyobo Co., Ltd.) is coated on the entire surface of the easy-adhesion treated surface using acrylic resin and nitrified cotton as a binder, A layer having a coating amount of 5 g / m ² was applied by gravure printing using an ink having a petal and chrome lead as a colorant to form a solid printing layer. On top of that, a woodgrain pattern layer was formed by gravure printing using an ink containing nitrified cotton as a binder and a colorant mainly composed of a petiole to obtain a decorative layer.
Next, an ink composition in which silica as a matting agent is added to primer ink (Showa Ink Co., Ltd. acrylic ink “EBF Tuning Primer”) is applied by gravure printing to form a primer layer having a penetration preventing function. Formed.
Next, a raised portion of an irregularly shaped pattern is formed using an ink for swelling mainly composed of acrylic resin (manufactured by Dainichi Seika Kogyo Co., Ltd., trade name: KKB Cure U Semi Matte Medium). Using such a plate, a plurality of raised portions were formed by gravure printing to form a raised layer. Here, the plate type was such that the ratio of the occupied area of the raised portion to the entire plane was 2% and the height of the raised portion was 5 μm.
An electron beam curable resin in which 5% by mass of calcined kaolin particles and 0.5% by mass of magnesium silicofluoride are added to an electron beam curable resin ("REB-GE" manufactured by Dainichi Seika Kogyo Co., Ltd.) on the top layer. The composition was applied at a coating amount of 4 g / m ² by a gravure offset coater method. After coating, an electron beam with an acceleration voltage of 175 kV and an irradiation dose of 30 kGy (3 Mrad) was applied to cure the electron beam curable resin composition to form a surface protective layer, thereby obtaining a decorative sheet.
Table 1 shows the results of the above evaluations on the decorative sheet.

Example 2
A decorative sheet was produced in the same manner as in Example 1 except that in the production process of the raised portion in Example 1, a plate mold having an occupied area ratio of 25% was used. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Example 3
In the production process of the raised portion in Example 1, the height of the raised portion was 35 μm, and the same procedure as in Example 1 was used except that a plate mold having an occupied area ratio of 2% with respect to the entire plane was used. A decorative sheet was prepared. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Example 4
In the production process of the raised portion in Example 1, the same procedure as in Example 1 was used except that a plate having a height of the raised portion of 35 μm and a ratio of the occupied area of the raised portion to the entire plane being 25% was used. A decorative sheet was prepared. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Comparative Example 1
A decorative sheet was produced in the same manner as in Example 1 except that in the process of producing the raised portion in Example 1, no raised layer was provided. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Comparative Example 2
In the manufacturing process of the raised portion in Example 1, the height of the raised portion was 2 μm, and the same procedure as in Example 1 was used except that a plate mold in which the occupied area ratio of the raised portion to the total area was 25% was used. A decorative sheet was prepared. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Comparative Example 3
In the production process of the raised portion in Example 1, the same procedure as in Example 1 was used except that the height of the raised portion was 35 μm and the ratio of the occupied area of the raised portion to the total area was 1%. A decorative sheet was prepared. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

Comparative Example 4
In the production process of the raised portion in Example 1, the height of the raised portion was 40 μm, and the same procedure as in Example 3 was used except that a plate mold having an occupied area ratio of the raised portion with respect to the total area was 30%. A decorative sheet was prepared. The results of evaluating the decorative sheet in the same manner as in Example 1 are shown in Table 1.

  According to the present invention, for example, if it is a wood grain pattern, it is possible to provide a design close to the feel and gloss of an actual tree, and it is possible to provide a decorative sheet that gives an interior material or the like a high-class feeling. The decorative sheet of the present invention is suitably used for interior decoration of buildings, exteriors, furniture for furniture, furniture for furniture, interiors of vehicles, and the like.

10. Cosmetic sheet 20. Base material 30. Decoration layer 31. Solid print layer 32. Pattern layer 40. Primer layer 50. Top layer 60. Surface protective layer 70. Back primer layer

Claims (7)

  A decorative sheet having a surface protective layer covering the entire surface including at least a partially formed overlay layer on a substrate, a region where the build-up layer is formed, and a region where the build-up layer is not formed. The surface protective layer is obtained by crosslinking and curing the ionizing radiation curable resin composition, the surface 10-point average roughness is 5 to 35 μm, and the occupying area ratio of the raised layer is 2 to 25%. A certain decorative sheet.   The decorative sheet according to claim 1, comprising a primer layer on the substrate, and the raised layer on the primer layer.   The decorative sheet according to claim 2, wherein the primer layer contains a matting agent.   The decorative sheet according to any one of claims 1 to 3, further comprising a decorative layer between the base material and the raised layer.   The decorative sheet according to claim 4, wherein the decorative layer has a solid print layer or a pattern layer on the solid print layer.   The decorative sheet according to any one of claims 1 to 5, wherein the surface protective layer has a thickness of 1 to 20 µm.   The decorative sheet according to any one of claims 1 to 6, wherein the ionizing radiation curable resin composition is an electron beam curable resin composition.