CN118076479A - Decorative sheet - Google Patents
Decorative sheet Download PDFInfo
- Publication number
- CN118076479A CN118076479A CN202280066640.5A CN202280066640A CN118076479A CN 118076479 A CN118076479 A CN 118076479A CN 202280066640 A CN202280066640 A CN 202280066640A CN 118076479 A CN118076479 A CN 118076479A
- Authority
- CN
- China
- Prior art keywords
- decorative
- film layer
- layer
- concave
- transparent resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 229920005989 resin Polymers 0.000 claims abstract description 282
- 239000011347 resin Substances 0.000 claims abstract description 282
- 238000000465 moulding Methods 0.000 claims abstract description 48
- 239000010410 layer Substances 0.000 claims description 393
- 239000012790 adhesive layer Substances 0.000 claims description 36
- 230000000694 effects Effects 0.000 abstract description 38
- 239000010408 film Substances 0.000 description 205
- 238000004049 embossing Methods 0.000 description 44
- 238000000034 method Methods 0.000 description 38
- -1 polyethylene terephthalate Polymers 0.000 description 23
- 238000001746 injection moulding Methods 0.000 description 16
- 238000010030 laminating Methods 0.000 description 14
- 239000006224 matting agent Substances 0.000 description 13
- 229920000178 Acrylic resin Polymers 0.000 description 12
- 239000004925 Acrylic resin Substances 0.000 description 12
- 238000010438 heat treatment Methods 0.000 description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 11
- 238000013461 design Methods 0.000 description 11
- 230000001747 exhibiting effect Effects 0.000 description 11
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- 230000000052 comparative effect Effects 0.000 description 9
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- 229910052751 metal Inorganic materials 0.000 description 9
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- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 8
- 229920001577 copolymer Polymers 0.000 description 8
- 238000005034 decoration Methods 0.000 description 8
- 150000002513 isocyanates Chemical class 0.000 description 8
- 239000002245 particle Substances 0.000 description 8
- 238000000576 coating method Methods 0.000 description 7
- 229920001225 polyester resin Polymers 0.000 description 7
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- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 6
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- 239000000377 silicon dioxide Substances 0.000 description 5
- 239000010409 thin film Substances 0.000 description 5
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
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- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 229920002554 vinyl polymer Polymers 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 3
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000010354 integration Effects 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 239000003973 paint Substances 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 229920005906 polyester polyol Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
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- 229920002725 thermoplastic elastomer Polymers 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 229920002845 Poly(methacrylic acid) Polymers 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- QHIWVLPBUQWDMQ-UHFFFAOYSA-N butyl prop-2-enoate;methyl 2-methylprop-2-enoate;prop-2-enoic acid Chemical compound OC(=O)C=C.COC(=O)C(C)=C.CCCCOC(=O)C=C QHIWVLPBUQWDMQ-UHFFFAOYSA-N 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- KIQKWYUGPPFMBV-UHFFFAOYSA-N diisocyanatomethane Chemical compound O=C=NCN=C=O KIQKWYUGPPFMBV-UHFFFAOYSA-N 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 2
- 239000005445 natural material Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920001490 poly(butyl methacrylate) polymer Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 235000010215 titanium dioxide Nutrition 0.000 description 2
- 239000013638 trimer Substances 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- ZXHZWRZAWJVPIC-UHFFFAOYSA-N 1,2-diisocyanatonaphthalene Chemical compound C1=CC=CC2=C(N=C=O)C(N=C=O)=CC=C21 ZXHZWRZAWJVPIC-UHFFFAOYSA-N 0.000 description 1
- 229940008841 1,6-hexamethylene diisocyanate Drugs 0.000 description 1
- OSNILPMOSNGHLC-UHFFFAOYSA-N 1-[4-methoxy-3-(piperidin-1-ylmethyl)phenyl]ethanone Chemical compound COC1=CC=C(C(C)=O)C=C1CN1CCCCC1 OSNILPMOSNGHLC-UHFFFAOYSA-N 0.000 description 1
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 1
- WZSFTHVIIGGDOI-UHFFFAOYSA-N 4,5,6,7-tetrachloro-3-[2-methyl-3-[(4,5,6,7-tetrachloro-3-oxoisoindol-1-yl)amino]anilino]isoindol-1-one Chemical compound ClC1=C(Cl)C(Cl)=C(Cl)C2=C1C(NC1=CC=CC(NC=3C4=C(C(=C(Cl)C(Cl)=C4Cl)Cl)C(=O)N=3)=C1C)=NC2=O WZSFTHVIIGGDOI-UHFFFAOYSA-N 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004606 Fillers/Extenders Substances 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- NRCMAYZCPIVABH-UHFFFAOYSA-N Quinacridone Chemical compound N1C2=CC=CC=C2C(=O)C2=C1C=C1C(=O)C3=CC=CC=C3NC1=C2 NRCMAYZCPIVABH-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 229910000004 White lead Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 1
- AUNAPVYQLLNFOI-UHFFFAOYSA-L [Pb++].[Pb++].[Pb++].[O-]S([O-])(=O)=O.[O-][Cr]([O-])(=O)=O.[O-][Mo]([O-])(=O)=O Chemical compound [Pb++].[Pb++].[Pb++].[O-]S([O-])(=O)=O.[O-][Cr]([O-])(=O)=O.[O-][Mo]([O-])(=O)=O AUNAPVYQLLNFOI-UHFFFAOYSA-L 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- BAPJBEWLBFYGME-UHFFFAOYSA-N acrylic acid methyl ester Natural products COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- IRERQBUNZFJFGC-UHFFFAOYSA-L azure blue Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Al+3].[Al+3].[Al+3].[Al+3].[Al+3].[Al+3].[S-]S[S-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] IRERQBUNZFJFGC-UHFFFAOYSA-L 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 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
- 238000000071 blow moulding Methods 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 235000019241 carbon black Nutrition 0.000 description 1
- 239000012461 cellulose resin Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- XCJYREBRNVKWGJ-UHFFFAOYSA-N copper(II) phthalocyanine Chemical compound [Cu+2].C12=CC=CC=C2C(N=C2[N-]C(C3=CC=CC=C32)=N2)=NC1=NC([C]1C=CC=CC1=1)=NC=1N=C1[C]3C=CC=CC3=C2[N-]1 XCJYREBRNVKWGJ-UHFFFAOYSA-N 0.000 description 1
- 238000003851 corona treatment Methods 0.000 description 1
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- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- UHOKSCJSTAHBSO-UHFFFAOYSA-N indanthrone blue Chemical compound C1=CC=C2C(=O)C3=CC=C4NC5=C6C(=O)C7=CC=CC=C7C(=O)C6=CC=C5NC4=C3C(=O)C2=C1 UHOKSCJSTAHBSO-UHFFFAOYSA-N 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
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- 239000001023 inorganic pigment Substances 0.000 description 1
- 238000007733 ion plating Methods 0.000 description 1
- 230000005865 ionizing radiation Effects 0.000 description 1
- YOBAEOGBNPPUQV-UHFFFAOYSA-N iron;trihydrate Chemical compound O.O.O.[Fe].[Fe] YOBAEOGBNPPUQV-UHFFFAOYSA-N 0.000 description 1
- 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
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 229910052622 kaolinite Inorganic materials 0.000 description 1
- MOUPNEIJQCETIW-UHFFFAOYSA-N lead chromate Chemical compound [Pb+2].[O-][Cr]([O-])(=O)=O MOUPNEIJQCETIW-UHFFFAOYSA-N 0.000 description 1
- RYZCLUQMCYZBJQ-UHFFFAOYSA-H lead(2+);dicarbonate;dihydroxide Chemical compound [OH-].[OH-].[Pb+2].[Pb+2].[Pb+2].[O-]C([O-])=O.[O-]C([O-])=O RYZCLUQMCYZBJQ-UHFFFAOYSA-H 0.000 description 1
- 239000010985 leather Substances 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- IBIKHMZPHNKTHM-RDTXWAMCSA-N merck compound 25 Chemical compound C1C[C@@H](C(O)=O)[C@H](O)CN1C(C1=C(F)C=CC=C11)=NN1C(=O)C1=C(Cl)C=CC=C1C1CC1 IBIKHMZPHNKTHM-RDTXWAMCSA-N 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 125000002347 octyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000007645 offset printing Methods 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000011146 organic particle Substances 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- ZZSIDSMUTXFKNS-UHFFFAOYSA-N perylene red Chemical compound CC(C)C1=CC=CC(C(C)C)=C1N(C(=O)C=1C2=C3C4=C(OC=5C=CC=CC=5)C=1)C(=O)C2=CC(OC=1C=CC=CC=1)=C3C(C(OC=1C=CC=CC=1)=CC1=C2C(C(N(C=3C(=CC=CC=3C(C)C)C(C)C)C1=O)=O)=C1)=C2C4=C1OC1=CC=CC=C1 ZZSIDSMUTXFKNS-UHFFFAOYSA-N 0.000 description 1
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- 239000004033 plastic Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920001083 polybutene Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000005056 polyisocyanate Substances 0.000 description 1
- 229920001228 polyisocyanate Polymers 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 239000004945 silicone rubber Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 235000014692 zinc oxide Nutrition 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
Abstract
The invention provides a decorative sheet having excellent three-dimensional effect generated by internal concave-convex shape even after molding. The decorative sheet has a transparent resin film layer having a concave-convex shape on one surface thereof and a decorative layer formed along the concave-convex shape of the transparent resin film layer, wherein the concave-convex shape has a plurality of convex portions protruding from the transparent resin film layer side toward the decorative layer side, and the plurality of convex portions are each formed in a multi-stage shape.
Description
Technical Field
The present invention relates to a decorative sheet and a decorative resin molded article using the same.
Background
Conventionally, a decorative resin molded article in which a decorative sheet is laminated on the surface of a resin molded article is used as an interior and exterior decorative member for a vehicle, an interior decorative material for a building material, a housing for a home appliance, and the like. In the production of such a decorative resin molded article, a molding method or the like is used in which a decorative sheet to which a design has been previously applied is integrated with a resin by injection molding. Typical examples of such molding methods include: an insert molding method in which a decorative sheet is molded into a three-dimensional shape in advance by a vacuum molding die, the decorative sheet is inserted into an injection molding die, and a resin in a flowing state is injected into the die, thereby integrating the resin and the decorative sheet; the decoration method is to integrate the decoration sheet inserted into the mold during injection molding and the melted resin injected into the mold cavity.
For example, a printed layer is provided on the back surface of an acrylic film on the front surface of a decorative sheet, and a concave-convex shape is formed on the printed layer side, whereby a decorative sheet exhibiting a three-dimensional shape is provided inside the decorative sheet. In such a decorative sheet, the fine lines and shadows of the uneven shape give a sense of reality and a sense of high quality as compared with the pattern expression by printing alone.
In recent years, designs required for decorative sheets are various, and it is demanded to exhibit more various three-dimensional effects.
In addition, there is a problem that the uneven shape formed inside the decorative sheet becomes gentle or small due to heat and pressure at the time of injection molding such as insert molding of the decorative sheet or at the time of preforming (vacuum molding) before that, and thus, the high texture due to the uneven shape is deteriorated.
In addition, in recent years, designs required for decorative sheets are required to exhibit a higher degree of three-dimensional effect such as an artificial geometric pattern and a layered effect in addition to a physical effect simulating natural substances and natural substances such as real carbon lines (real carbon) and hairlines.
Prior art literature
Patent literature
Patent document 1: japanese patent application laid-open No. 2010-82912
Disclosure of Invention
Technical problem to be solved by the invention
A main object of the first aspect of the present invention is to provide a decorative sheet having an excellent three-dimensional effect due to an internal uneven shape even after molding. Another object of the first aspect of the present invention is to provide a decorative resin molded article using the decorative sheet.
A second aspect of the present invention is directed to a decorative sheet having an excellent three-dimensional effect due to an internal uneven shape. A second aspect of the present invention is to provide a decorative resin molded article using the decorative sheet.
Technical scheme for solving technical problems
The inventors of the present invention have made intensive studies in order to solve the above-mentioned technical problems. As a result, it has been found that in a decorative sheet having a transparent resin film layer with a concave-convex shape on one surface and a decorative layer formed along the concave-convex shape of the transparent resin film layer, the concave-convex shape has a plurality of convex portions having different heights protruding from the transparent resin film layer side toward the decorative layer side, and the plurality of convex portions are each formed in a multi-stage shape, whereby excellent three-dimensional sensation due to the concave-convex shape inside the decorative sheet can be achieved even after molding. The first aspect of the present invention is an invention that has been further studied based on such an insight.
That is, a first aspect of the present invention provides the following aspects of the present invention.
Item 1A. A decorative sheet having:
A transparent resin film layer having a concave-convex shape on one side surface; and
A decorative layer formed along the concave-convex shape of the transparent resin film layer,
The concave-convex shape has a plurality of convex parts protruding from the transparent resin film layer side to the decorative layer side,
The plurality of convex portions are formed in a multi-stage shape.
The decorative sheet according to item 1A, wherein the decorative sheet further comprises a support film layer on the decorative layer side.
The decorative sheet according to item 3A, wherein the support film layer is formed so as to cover the concave portion on the decorative layer side.
The decorative sheet according to item 4A or 3A, wherein an adhesive layer is further provided between the decorative layer and the support film layer.
The decorative sheet according to item 5A, wherein a surface of the transparent resin film layer on a side opposite to the decorative layer is smooth.
Item 6A. A decorative resin molded article comprising:
A transparent resin film layer having a concave-convex shape on one side surface;
a decorative layer formed along the concave-convex shape of the transparent resin film layer; and
The resin layer is formed by molding the resin layer,
The concave-convex shape has a plurality of convex parts protruding from the transparent resin film layer side to the decorative layer side,
The plurality of convex portions are formed in a multi-stage shape.
In addition, the inventors of the present invention have made intensive studies in order to solve the above-mentioned problems. As a result, in the decorative sheet having the transparent resin film layer having the concave-convex shape on one side surface and the decorative layer formed along the concave-convex shape of the transparent resin film layer, the concave-convex shape has the plurality of convex portions having different heights protruding from the transparent resin film layer side to the decorative layer side, and the ratio (h/w) of the height h (μm) to the width w (μm) is set to 100% or less for each of the plurality of convex portions, so that the excellent three-dimensional effect generated by the concave-convex shape inside the decorative sheet can be realized. The second aspect of the present invention is an invention which has been further studied based on such an insight.
That is, a second aspect of the present invention provides the following aspects of the present invention.
Item 1B. A decorative sheet having:
A transparent resin film layer having a concave-convex shape on one side surface; and
A decorative layer formed along the concave-convex shape of the transparent resin film layer,
The concave-convex shape has a plurality of convex portions with different heights protruding from the transparent resin film layer side to the decorative layer side,
The ratio (h/w) of the height h (μm) of the plurality of projections to the width w (μm) is 100% or less, respectively.
The decorative sheet according to item 1B, wherein the decorative sheet further comprises a support film layer on the decorative layer side.
The decorative sheet according to item 2B, wherein the support film layer is formed so as to cover the concave portion on the decorative layer side.
The decorative sheet according to item 4B or 3B, wherein an adhesive layer is further provided between the decorative layer and the support film layer.
The decorative sheet according to any one of items 1B to 4B, wherein a surface of the transparent resin film layer on a side opposite to the decorative layer side is smooth.
Item 6B. A decorative resin molded article, comprising:
A transparent resin film layer having a concave-convex shape on one side surface;
a decorative layer formed along the concave-convex shape of the transparent resin film layer; and
The resin layer is formed by molding the resin layer,
The concave-convex shape has a plurality of convex portions with different heights protruding from the transparent resin film layer side to the decorative layer side,
The ratio (h/w) of the height h (μm) of the plurality of projections to the width w (μm) is 100% or less, respectively.
Effects of the invention
With the first aspect of the present invention, a decorative sheet having an excellent three-dimensional effect due to the internal uneven shape even after molding can be provided. With the first aspect of the present invention, a decorative resin molded article using the decorative sheet can be provided.
Further, according to the second aspect of the present invention, a decorative sheet having an excellent three-dimensional effect due to the internal uneven shape can be provided. With the second aspect of the present invention, a decorative resin molded article using the decorative sheet can be provided.
Drawings
Fig. 1 is a schematic view showing a cross-sectional structure of one form of a decorative sheet according to a first embodiment of the present invention.
Fig. 2 is a schematic cross-sectional view for explaining the multi-stage shape of the convex portion of the transparent resin film layer according to the first embodiment.
Fig. 3 is a schematic view showing a cross-sectional structure of one form of the decorative sheet according to the first embodiment of the present invention.
Fig. 4 is a schematic view of a cross-sectional structure of one form of the decorative resin molded article according to the first embodiment of the present invention.
Fig. 5 is a schematic plan view for explaining a method of measuring the width of each segment and the width of the uppermost segment of the convex portion of the transparent resin film layer according to the first embodiment.
Fig. 6 is a schematic view of a cross-sectional structure of one form of a decorative sheet according to a second embodiment of the present invention.
Fig. 7 is a schematic view of a cross-sectional structure of one form of a decorative sheet according to a second embodiment of the present invention.
Fig. 8 is a schematic view of a cross-sectional structure of one form of a decorative sheet according to a second embodiment of the present invention.
Fig. 9 is a schematic view showing a cross-sectional structure of one form of the decorative sheet according to the second embodiment of the present invention.
Fig. 10 is a schematic view of a cross-sectional structure of one form of a decorative sheet according to a second embodiment of the present invention.
Fig. 11 is a schematic view of a cross-sectional structure of one form of a decorative resin molded article according to a second embodiment of the present invention.
Detailed Description
1. Decorative sheet
The decorative sheet according to the first aspect of the present invention is characterized in that: the decorative sheet has a transparent resin film layer having a concave-convex shape on one surface and a decorative layer formed along the concave-convex shape of the transparent resin film layer, the concave-convex shape having a plurality of convex portions protruding from the transparent resin film layer side toward the decorative layer side, the plurality of convex portions being formed in a multi-stage shape, respectively. The decorative sheet of the present invention has such a structure, and thus can realize an excellent three-dimensional effect due to the internal uneven shape even after molding.
The decorative sheet according to the second aspect of the present invention is characterized in that: the decorative sheet has a transparent resin film layer having a concave-convex shape on one surface thereof and a decorative layer formed along the concave-convex shape of the transparent resin film layer, wherein the concave-convex shape has a plurality of convex portions having different heights protruding from the transparent resin film layer side toward the decorative layer side, and a ratio (h/w) of the height h (μm) of the plurality of convex portions to the width w (μm) is 100% or less. The decorative sheet of the present invention has such a configuration, and thus can realize excellent three-dimensional effect due to the internal uneven shape.
Hereinafter, the decorative sheet of the present invention will be described in detail. In the following description, the first aspect and the second aspect of the present invention are described with reference to specific matters, and matters common to the first aspect and the second aspect are not particularly described with reference to the present invention.
Lamination structure of decorative sheet
As shown in fig. 1, a decorative sheet 10 according to a first embodiment of the present invention includes at least a transparent resin film layer 1 and a decorative layer 2. The transparent resin film layer 1 has a concave-convex shape on one surface. The decorative layer 2 is formed along the concave-convex shape of the transparent resin film layer 1. That is, the surface of the decorative layer 2 opposite to the transparent resin film layer 1 has a concave-convex shape. Among them, the surface of the transparent resin film layer 1 on the opposite side to the surface having the concave-convex shape is preferably smooth.
The decorative sheet 10 according to the first aspect of the present invention may have the support film layer 3 on the decorative layer 2 side as needed for the purpose of improving the shape retention and the like. The support film layer 3 may be formed to bury concave-convex shaped recesses on the decorative layer 2 side. The entire recess may be buried in the support film layer 3, or a part of the recess may be buried in the support film layer 3, and a space may be provided between the support film layer 3 and the concave-convex shape on the decorative layer 2 side.
In the decorative sheet 10 according to the first aspect of the present invention, the adhesive layer 4 may be provided between the decorative layer 2 and the support film layer 3 as necessary. Although not shown, an adhesive layer may be provided on the surface of the support film layer 3 opposite to the decorative layer 2 side, if necessary.
As a laminated structure of the decorative sheet according to the first aspect of the present invention, there may be mentioned: a laminated structure formed by sequentially laminating transparent resin film layers/decorative layers; a laminated structure formed by sequentially laminating a transparent resin film layer, a decorative layer and a supporting film layer; a laminated structure formed by sequentially laminating a transparent resin film layer, a decorative layer, an adhesive layer and a supporting film layer; and a laminated structure in which a transparent resin film layer, a decorative layer, an adhesive layer, a support film layer, and an adhesive layer are laminated in this order. Fig. 1 is a schematic view showing a cross-sectional structure of one embodiment of a decorative sheet formed by laminating a transparent resin film layer, a decorative layer, and a support film, as one embodiment of a laminated structure of a decorative sheet according to a first embodiment of the present invention. Fig. 3 is a schematic view showing a cross-sectional structure of one form of a decorative sheet in which a transparent resin film layer, a decorative layer, an adhesive layer, and a support film layer are laminated in this order as one embodiment of the laminated structure of the decorative sheet according to the first embodiment of the present invention.
As shown in fig. 6, the decorative sheet 10 according to the second aspect of the present invention includes at least a transparent resin film layer 1 and a decorative layer 2. The transparent resin film layer 1 has a concave-convex shape on one surface. The decorative layer 2 is formed along the concave-convex shape of the transparent resin film layer 1. That is, the surface of the decorative layer 2 opposite to the transparent resin film layer 1 has a concave-convex shape. Among them, the surface of the transparent resin film layer 1 on the opposite side to the surface having the concave-convex shape is preferably smooth.
The decorative sheet 10 according to the second aspect of the present invention may have the support film layer 3 on the decorative layer 2 side as needed for the purpose of improving the shape retention and the like. The support film layer 3 may be formed to bury concave-convex shaped recesses on the decorative layer 2 side. The entire recess may be buried in the support film layer 3, or a part of the recess may be buried in the support film layer 3, and a space may be provided between the support film layer 3 and the concave-convex shape on the decorative layer 2 side.
In the decorative sheet 10 according to the second aspect of the present invention, the adhesive layer 4 may be provided between the decorative layer 2 and the support film layer 3 as needed. Although not shown, an adhesive layer may be provided on the surface of the support film layer 3 opposite to the decorative layer 2 side, if necessary.
As a laminate structure of the decorative sheet according to the second aspect of the present invention, there may be mentioned: a laminated structure formed by sequentially laminating transparent resin film layers/decorative layers; a laminated structure formed by sequentially laminating a transparent resin film layer, a decorative layer and a supporting film layer; a laminated structure formed by sequentially laminating a transparent resin film layer, a decorative layer, an adhesive layer and a supporting film layer; and a laminated structure in which a transparent resin film layer, a decorative layer, an adhesive layer, a support film layer, and an adhesive layer are laminated in this order. Fig. 6 and 7 are schematic views showing a cross-sectional structure of one form of a decorative sheet formed by laminating a transparent resin film layer and a decorative layer as one embodiment of a laminated structure of a decorative sheet according to a second embodiment of the present invention. Fig. 8 and 9 are schematic views showing a cross-sectional structure of one form of a decorative sheet in which a transparent resin film layer, a decorative layer, and a support film layer are laminated in this order as one embodiment of a laminated structure of a decorative sheet according to a second embodiment of the present invention. Fig. 10 is a schematic view showing a cross-sectional structure of one form of a decorative sheet in which a transparent resin film layer, a decorative layer, an adhesive layer, and a support film layer are laminated in this order as one embodiment of a laminated structure of a decorative sheet according to a second embodiment of the present invention.
Concave-convex shape of decorative sheet
The decorative sheet 10 according to the first aspect of the present invention includes a transparent resin film layer 1 having a concave-convex shape on one side surface, and a decorative layer 2 formed along the concave-convex shape of the transparent resin film layer 1. That is, the concave-convex shape formed at the interface between the transparent resin film layer 1 and the decorative layer 2 constitutes the concave-convex shape of the interior of the decorative sheet. When the decorative sheet according to the first aspect of the present invention is viewed from the transparent resin film layer 1 side (i.e., the side identified when the decorative sheet 10 and the molded resin layer 5 are laminated to form the decorative resin molded article 20), the uneven shape is identified by the transparent resin film layer 1, and a high three-dimensional effect can be perceived.
In the first aspect of the present invention, the concave-convex shape of the transparent resin film layer 1 has a plurality of convex portions 1a protruding from the transparent resin film layer 1 side toward the decorative layer 2 side. In the concave-convex shape, the plurality of convex portions 1a are each formed in a multi-stage shape. That is, in the decorative sheet according to the first aspect of the present invention, the convex portions 1a formed in the transparent resin film layer 1 are formed in a multi-stage shape, whereby a three-dimensional design such as a pyramid can be expressed from above, and the stepped edges are formed in the convex portions, whereby damage to the three-dimensional shape due to heat and pressure during molding of the decorative sheet can be appropriately suppressed, and excellent three-dimensional effect due to the internal concave-convex shape can be exhibited even after molding.
In the decorative sheet 10 according to the first aspect of the present invention, the height H, the number of segments, the height H of each segment, the width wn of each segment, the width w of the uppermost segment, the shape of the top-view convex portion 1a, and the like of each convex portion 1a are adjusted, and the shape of the top-view convex portion 1a is made polygonal or circular, so that each convex portion can be made into a plurality of segments having various shapes, and various designs can be provided to the surface of the decorative resin molded product.
For example, in the schematic diagram of fig. 2, the number of segments of the convex portion 1a is 3, the entire height H of the convex portion 1a, the height H1 of the 1 st segment, the height H2 of the 2 nd segment, the height H3 of the 3 rd segment, the width w1 of the 1 st segment, the width w2 of the 2 nd segment, and the width w of the 3 rd segment (i.e., the width of the uppermost segment) are illustrated. Fig. 5 is a schematic view showing a case where the shape of the protruding portion 1a is diamond-shaped in a plan view.
The number of the protruding portions 1a is not particularly limited, and, even when the shape of each protruding portion is multi-segmented after the decorative sheet is formed, it is preferable that the number of the protruding portions is about 2 to 9, for example, depending on the width w, height h, and the like of each segment.
The height H (overall height) of the protruding portion 1a is preferably about 3 to 100 μm, more preferably about 8 to 60 μm, from the viewpoint of suitably exhibiting the effect of the invention according to the first aspect of the present invention.
The height h of each step of the convex portion 1a is preferably about 3 to 50 μm, and more preferably about 8 to 30 μm, from the viewpoint of suitably exhibiting the effect of the invention according to the first aspect of the present invention.
Further, from the viewpoint of suitably exhibiting the effects of the invention according to the first aspect of the present invention, the width wn of each segment of the convex portion 1a is preferably about 10 to 200 μm, and more preferably about 20 to 100 μm.
In order to suitably exhibit the effect of the invention according to the first aspect of the present invention, the width of the uppermost stage of the convex portion 1a is preferably about 10 to 300 μm, more preferably about 20 to 200 μm.
In the case of the convex portion in plan view, the width of each segment and the width of the uppermost segment are measured in directions perpendicular to the sides forming the peripheral edge (outer edge) of the convex portion (directions perpendicular to the sides facing each other, for example, directions perpendicular to the tangential line in the case of a diamond shape, and directions perpendicular to the tangential line in the case of a circle, as shown in the schematic diagram of fig. 5).
In fig. 1,3 and 4, the convex portions 1a are illustrated as being arranged independently of each other, but the convex portions 1a may be connected to each other at least in part. As a method of connecting the convex portions 1a, a method of connecting a plurality of convex portions (convex portions in a multi-stage shape) constituting the convex portions 1a to each other to constitute 1 layer of the concave-convex shape is exemplified.
The pattern in which the convex portions 1a are arranged is not particularly limited. For example, by arranging the plurality of convex portions 1a in a matrix, the decorative sheet 10 in which the convex portions 1a are formed in a matrix on the surface can be obtained.
The shape (shape of the outer edge) of each convex portion 1a in plan view is not particularly limited, and may be, for example, a polygon (for example, a triangle, a quadrangle (square, rectangle, diamond, etc.), a pentagon, hexagon, etc.), a circle (perfect circle, ellipse, etc.), other geometric figures, etc.
In the decorative sheet according to the first aspect of the present invention, the above-described uneven shape may be formed in at least a partial region where a high three-dimensional effect is imparted by the uneven shape when the decorative sheet is viewed from the transparent resin film layer 1. That is, in the decorative sheet according to the first aspect of the present invention, the concave-convex shape may be formed in a part of the area or may be formed in the entire area.
The decorative sheet 10 according to the second aspect of the present invention includes a transparent resin film layer 1 having a concave-convex shape on one side surface, and a decorative layer 2 formed along the concave-convex shape of the transparent resin film layer 1. That is, the concave-convex shape formed at the interface between the transparent resin film layer 1 and the decorative layer 2 constitutes the concave-convex shape inside the decorative sheet. When the decorative sheet according to the second aspect of the present invention is observed from the transparent resin film layer 1 side (i.e., the side identified when the decorative sheet 10 and the molded resin layer 5 are laminated to form the decorative resin molded article 20), the uneven shape is identified by the transparent resin film layer 1, and a high three-dimensional effect can be perceived.
In the second aspect of the present invention, the concave-convex shape of the transparent resin film layer 1 has a plurality of convex portions 1a having different heights protruding from the transparent resin film layer 1 side toward the decorative layer 2 side. Specifically, the plurality of convex portions 1a having different heights are a plurality of convex portions having a height of 5 μm or more. In the concave-convex shape, the ratio (h/w) of the height h (μm) to the width w (μm) of the plurality of convex portions 1a is 100% or less, respectively. That is, in the decorative sheet according to the second aspect of the present invention, the concave-convex shape of the transparent resin film layer 1 formed inside the decorative sheet is reduced in the ratio (h/w) of the height h to the width w of the convex portion after the plurality of convex portions 1a having different heights are formed, so that the concave-convex shape can be recognized from a plurality of angles, and an excellent three-dimensional effect can be obtained.
From the viewpoint of more suitably exhibiting the effects of the second aspect of the present invention, the ratio (h/w) is preferably about 10 to 100%, and more preferably about 20 to 60%.
The height h of each convex portion 1a is obtained by measuring the difference (distance) from the position (line B) of the concave portion 1B to the highest position of the convex portion 1a on the cross section in the thickness direction of the transparent resin film layer 1 of the decorative sheet 10, as shown in schematic diagrams of fig. 6 to 11, for example. For example, as shown in fig. 7, when the heights of both ends of the convex portion 1a of the transparent resin film layer are different (line B1 and line B2) in the cross section in the thickness direction of the decorative sheet, a large value of height h is used. As shown in fig. 7, when the plurality of projections 1a having different heights are coupled to form 1 projection 1a having different heights, a large height h is used. The above-described cross section was measured at 3 or more points with respect to the plurality of projections, and evaluated.
The height h of the convex portion 1a is preferably about 3 to 100 μm, and more preferably about 8 to 60 μm, from the viewpoint of more suitably exhibiting the effect of the invention according to the second aspect of the present invention.
In addition, from the viewpoint of more suitably exhibiting the effects of the invention according to the second aspect of the present invention, the width w of the convex portion 1a is preferably about 30 to 500 μm, and more preferably about 100 to 300 μm.
In addition, from the viewpoint of more suitably exhibiting the effects of the invention according to the second aspect of the present invention, the width x between the convex portions 1a is preferably about 3 to 200 μm, and more preferably about 10 to 150 μm. The width x between the projections is the distance between the projections and the projections located on both sides of the projection 1a, and the measurement height h and width w is one of the smaller values.
In the decorative sheet according to the second aspect of the present invention, the design represented by the concave-convex shape of the transparent resin film layer 1 formed inside is not particularly limited, and for example, stripes, carbon stripes, and the like are particularly suitable.
In the decorative sheet according to the second aspect of the present invention, the above-described uneven shape may be formed in at least a partial region where a high three-dimensional effect is imparted by the uneven shape when the decorative sheet is viewed from the transparent resin film layer 1. That is, in the decorative sheet according to the second aspect of the present invention, the concave-convex shape satisfying the above relation may be formed in a part of the area or may be formed in the entire area.
Composition of layers forming a decorative sheet
[ Transparent resin film layer 1]
In the decorative sheet 10 of the present invention, the transparent resin film layer 1 is a layer that is generally provided so as to be located at the outermost surfaces of the decorative sheet 10 and the decorative resin molded article 20. From the viewpoint of improving the moldability of the decorative sheet 10 of the present invention, thermoplastic resins are preferably used as the material of the transparent resin film layer 1. In addition, since the decorative resin molded article using the decorative sheet of the present invention is observed from the transparent resin film layer 1 side, the transparent resin film layer 1 needs to have transparency in order to exhibit a high three-dimensional effect due to the above-described uneven shape. Here, the term "transparent" includes translucent or colored transparent to such an extent that the uneven shape can be recognized through the transparent resin film layer 1.
The transparent resin film layer 1 has a concave-convex shape on one surface. As described below, the concave-convex shape is formed by embossing. For example, by laminating the transparent resin film layer 1 and the decorative layer 2 and embossing the decorative layer 2, the uneven shape from the decorative layer 2 to the transparent resin film layer 1 can be formed.
The thermoplastic resin used for the transparent resin film layer 1 is preferably an acrylic resin, a vinyl chloride resin, an ABS resin (acrylonitrile-styrene-butadiene copolymer), a styrene resin, a polycarbonate resin, a polyester resin such as polyethylene terephthalate and a molded polyester resin, a polyolefin resin such as polyethylene, polypropylene, polymethylpentene, polybutene, an ethylene-propylene copolymer, a propylene-butene copolymer and an olefin thermoplastic elastomer, or the like. Among these, acrylic resins and polyester resins are more preferable, and acrylic resins are particularly preferable. The thermoplastic resin may be used alone or in combination of at least 2 kinds.
As the acrylic resin, for example, an acrylic resin such as poly (meth) acrylic acid methyl ester, poly (meth) acrylic acid butyl ester, a (meth) acrylic acid methyl ester- (meth) acrylic acid butyl ester copolymer, or a (meth) acrylic acid methyl ester-styrene copolymer may be used alone or in a mixture of 2 or more. Wherein, in the present invention, (meth) acrylate means acrylate or methacrylate.
As the polyester resin, a polyester-based thermoplastic elastomer, an amorphous polyester, or the like can be used. Examples of the polyester-based thermoplastic elastomer include a block polymer in which a high-crystalline and high-melting aromatic polyester such as polybutylene terephthalate is used as a hard segment and an amorphous polyether such as polytetramethylene glycol is used as a soft segment, the glass transition temperature of which is-70 ℃. Further, as the amorphous polyester, ethylene glycol-1, 4-cyclohexanedimethanol-terephthalic acid copolymer is typically used.
As the transparent resin film layer 1, for example, a resin film composed of a single layer or a plurality of layers including a resin as described above can be used. In addition, various additives such as a stabilizer, a plasticizer, a colorant, an ultraviolet absorber, a hindered amine light stabilizer, and an extender pigment may be added to the transparent resin film layer 1 as necessary to adjust physical properties. These additives may be used alone or in combination of 1 or more than 2. The transparent resin film layer 1 may be colored within a range that does not impair transparency. For example, a known colorant exemplified for the decorative layer 2 described later can be used for coloring the transparent resin film layer 1.
The thickness (total thickness in the case of multiple layers) of the transparent resin film layer 1 is not particularly limited, but is preferably about 30 to 300 μm, more preferably about 100 to 200 μm, from the viewpoints of cost, performance required for the decorative resin molded article, moldability of the decorative sheet, and the like. The thickness of the transparent resin film layer 1 is the thickness of the portion where the concave-convex-shaped concave portion is not formed.
In order to improve adhesion to other layers in contact with the transparent resin film layer 1, the front surface, the back surface, or both surfaces of the transparent resin film layer 1 may be subjected to a known easy-to-adhere treatment such as corona discharge treatment, plasma treatment, or formation of an undercoat layer using a urethane resin, etc., as necessary.
A surface protective layer (not shown) may be provided on at least a part of the surface of the transparent resin film layer 1 on the side opposite to the decorative layer 2 for the purpose of improving the surface physical properties of the decorative sheet, designing a matting feel, and the like, if necessary.
The resin forming the surface protective layer is not particularly limited, and examples thereof include thermosetting resins, ionizing radiation curable resins, thermoplastic resins, and the like. Specific examples of the resin forming the surface protective layer include a two-part curable resin and a matt (matt) paint containing a matting agent. Among them, a two-part curable resin of a polyol and an isocyanate is preferable.
The polyol includes various polyols such as acrylic polyol, polyester polyol and epoxy polyol, and acrylic polyol is preferable. Examples of the acrylic polyol include a vinyl chloride-modified acrylic polyol, a vinyl chloride-vinyl acetate-modified acrylic polyol, a chlorinated polyolefin-modified acrylic polyol, a methyl (meth) acrylate-2-hydroxyethyl (meth) acrylate copolymer, a octyl (meth) acrylate-2-hydroxyethyl (meth) acrylate copolymer, a methyl (meth) acrylate-butyl (meth) acrylate-2-hydroxyethyl (meth) acrylate-styrene copolymer, and the like, and particularly a vinyl chloride-modified acrylic polyol is preferable.
Further, as the isocyanate, conventionally known compounds may be appropriately used. For example, aromatic isocyanates such as 2, 4-Toluene Diisocyanate (TDI), xylene Diisocyanate (XDI), naphthalene diisocyanate, and 4,4' -diphenylmethane diisocyanate, and polyisocyanates such as aliphatic (or alicyclic) isocyanates such as 1, 6-hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), methylene Diisocyanate (MDI), hydrogenated toluene diisocyanate, and hydrogenated diphenylmethane diisocyanate can be used. Alternatively, adducts or polymers of these various isocyanates, for example, adducts of toluene diisocyanate, toluene diisocyanate trimers (trimers), and the like can also be used.
The matting agent used in the matte paint is not particularly limited, and for example, particles made of inorganic substances such as silica, alumina, calcium carbonate, aluminosilicate, barium sulfate, organic polymers such as acrylic beads, polyethylene, polyurethane resin, polycarbonate, polyamide (nylon), and the like can be used. The average particle diameter of the particles is preferably 0.5 to 20. Mu.m, more preferably 0.5 to 10. Mu.m, and the amount to be added is preferably 2 to 40% by mass, more preferably 5 to 30% by mass, based on the matte paint (excluding the solvent component). The particles may have a polyhedral shape, a spherical shape, a scaly shape, or the like. Among the above inorganic or organic particles, silica is preferred.
Further, as the matting agent, a compound having transparency is preferable. Examples of such matting agents include inorganic matting agents composed of particles of silica, spherical silica, alumina, kaolinite, calcium carbonate, barium sulfate, glass, and the like, and organic matting agents such as polycarbonate resins, acrylic resins, polyamide (nylon) resins, urea resins, and silicone resins. The particle shape of the matting agent is spherical, polyhedral, scaly, etc. The particle size of the matting agent is about 1 to 10. Mu.m. The amount of matting agent to be added may be an amount corresponding to the required low gloss level. Further, as the matting agent, a matting agent excellent in abrasion resistance is preferably selected because the surface protective layer is the outermost surface. Matting agents such as spherical silica and alumina are examples thereof. The average particle diameter of the matting agent is usually 1 to 10. Mu.m.
[ Decorative layer 2]
In the decorative sheet of the present invention, the decorative layer 2 is a layer provided along the concave-convex shape of the transparent resin film layer in order to impart a high three-dimensional effect to the decorative sheet due to the concave-convex shape. For example, as shown in fig. 1, 3, 4, and 6 to 11, the decorative layer 2 is laminated along the concave-convex shape of the transparent resin film layer 1, and the decorative layer 2 buries the concave-convex shaped recess 1b of the transparent resin film layer 1. In addition, the surface of the decorative layer 2 opposite to the transparent resin film layer 1 has a concave portion.
The decorative layer 2 may be formed of a pattern layer and/or a full-coat printed layer. The pattern of the pattern layer is arbitrary and may be selected in accordance with the design represented by the concave-convex shape of the transparent resin film layer 1. As the pattern of the pattern layer, in addition to the above-described stripes, carbon lines, etc., for example, wood grain, stone lines, cloth lines, sand lines, leather lines, tile patterns, brickwork patterns, geometric patterns, characters, symbols, etc., may be used in combination of 1 or 2 or more kinds according to the purpose.
The decorative layer 2 can be formed by coating (printing) an ink composition for forming a decorative layer on the transparent resin film layer 1. The ink composition for forming the decorative layer is composed of a binder resin, a colorant such as a pigment or a dye, and various additives appropriately added thereto. Examples of the binder resin include acrylic resins, vinyl chloride-vinyl acetate copolymers, polyester resins, cellulose resins, chlorinated polypropylene, polyurethane resins, and polyamide resins. Further, 1 kind of the selected resin alone, or a mixed resin of 2 or more kinds may be used. The binder resin may be used alone or in combination of 1 or more than 2.
Examples of the colorant include inorganic pigments such as titanium white, zinc white, carbon black, iron red, chrome vermilion, cadmium red, ultramarine, cobalt blue, chrome yellow, and titanium yellow, organic pigments (including dyes) such as phthalocyanine blue, indanthrene blue, isoindolinone yellow, benzidine yellow, quinacridone red, polyazo red, and perylene red, metallic pigments including flake foil powder such as aluminum and brass, and pearlescent (pearl) pigments including flake foil powder such as titanium dioxide coated mica and basic lead carbonate. The colorant may be used alone or in combination of at least 2.
Specific examples of the decorative layer 2 include a metallic full-coat printed layer.
The decorative layer 2 can be formed by applying an ink for forming a decorative layer to the transparent resin film layer 1 by a printing method such as gravure printing, screen printing, offset printing, or the like, a known coating method such as roll coating, or the like.
The thickness of the decorative layer 2 is not particularly limited, but is preferably about 0.5 to 20 μm, and more preferably about 1 to 10 μm. The thickness of the decorative layer 2 is the thickness of the portion where the concave portion having the concave-convex shape is not formed.
The decorative layer 2 may be a metal thin film layer. Examples of the metal forming the metal thin film layer include tin, indium, chromium, aluminum, nickel, copper, silver, gold, platinum, zinc, and an alloy containing at least 1 of these metals. The method for forming the metal thin film layer is not particularly limited, and examples thereof include vapor deposition methods such as vacuum vapor deposition using the above metal, sputtering methods, ion plating methods, and the like. In this case, the thickness of the decorative layer 2 (metal thin film layer) is not particularly limited, and the optical density (OD value) may be about 0.6 to 1.8, preferably about 0.8 to 1.5, from the viewpoint of improving the design property and the moldability of the decorative sheet. In order to improve adhesion to the adjacent layer, an adhesive layer using a known resin may be provided on the front or back surface of the metal thin film layer.
[ Support film layer 3]
In the decorative sheet of the present invention, the support film layer 3 is a layer that functions as a support member and is provided on the decorative layer 2 side (the side opposite to the transparent resin film layer 1) of the decorative sheet 10 as needed. When used for producing a decorative resin molded article by insert molding, which will be described later, the decorative sheet of the present invention preferably has a support film layer 3.
The material of the support film layer 3 is not particularly limited, and examples thereof include ABS resin, polyolefin resin, styrene resin, (meth) acrylic resin, vinyl chloride resin, and polycarbonate resin. As the polyolefin resin, polypropylene resin is preferable. Among these resins, particularly preferred are ABS resins and polypropylene resins. In addition, in the case where the molding resin constituting the molding resin layer 5 is ABS resin, ABS resin is preferable, and in the case where it is polypropylene resin, polypropylene resin is preferable.
As shown in fig. 1, 3, 4, and 8 to 11, in the decorative sheet of the present invention, the support film layer 3 may be laminated so as to fill concave portions of the concave-convex shape on the decorative layer 2 side. As a method of burying the concave portion with the support film layer 3, for example, a method of softening the support film layer 3 by heating and then laminating the support film layer on a surface on which the concave-convex shape is formed is cited.
In the decorative sheet 10 of the present invention, the concave portions of the concave-convex shape on the decorative layer 2 side (when the concave portions of the concave-convex shape of the decorative layer 2 further include the adhesive layer 4 described later, the concave portions of the concave-convex shape of the adhesive layer 4, etc.) may be entirely buried by the support film layer 3, or a part of the concave portions may be buried by the support film layer 3, and a gap may exist between the support film layer 3 and the concave-convex shape on the decorative layer 2 side.
The thickness of the support film layer 3 is not particularly limited, and may be, for example, about 0.1 to 0.5mm, and more preferably about 0.2 to 0.4 mm. The thickness of the support film layer 3 is the thickness of the portion where the concave-convex shaped concave portion of the decorative layer 2 side of the decorative sheet 10 is not buried.
[ Adhesive layer 4]
In the decorative sheet 10 of the present invention, the adhesive layer 4 may be provided between the decorative layer 2 and the support film layer 3 for the purpose of improving the adhesion between these layers, if necessary. Although not shown, an adhesive layer may be provided on the surface of the support film layer 3 opposite to the decorative layer 2 side, if necessary.
In the present invention, when the adhesive layer 4 is provided between the decorative layer 2 and the support film layer 3, the adhesive layer may be formed from the concave-convex shape after the concave-convex shape is formed by embossing from the side of the decorative layer 2 opposite to the transparent resin film layer 1 side.
Examples of the raw material of the adhesive constituting the adhesive layer 4 include a two-component curable polyurethane resin using isocyanate as a curing agent, a chlorinated polyolefin such as chlorinated polypropylene, a (meth) acrylic resin, a vinyl chloride-vinyl acetate copolymer, and a mixture of a (meth) acrylic resin and a vinyl chloride-vinyl acetate copolymer. The same compound as the decorative layer 2 described above may be used as the (meth) acrylic resin or the vinyl chloride-vinyl acetate copolymer in the adhesive layer. When the support film layer 3 is an ABS resin or a polyolefin resin, it is preferable to use a chlorinated polyolefin such as chlorinated polypropylene or a two-component curable polyurethane resin using isocyanate as a curing agent as the adhesive layer.
The adhesive layer 4 may be formed of the adhesive as described above by a known printing or coating method such as gravure printing or roll coating. The thickness of the adhesive layer is not particularly limited, but is usually about 1 to 50. Mu.m.
Embossing process
In the decorative sheet 10 according to the first aspect of the present invention, the internal concave-convex shape described above may be formed by embossing. Specifically, a sheet having at least the transparent resin film layer 1 and the decorative layer 2 is prepared, and embossing is performed on the sheet from the decorative layer 2 side to form concave portions reaching the concave-convex shape of the transparent resin film layer 1. By forming the convex portions of the embossed plate in a multi-stage shape, the concave-convex shape having a plurality of multi-stage convex portions 1a protruding from the transparent resin film layer 1 side toward the decorative layer 2 side can be formed.
In the decorative sheet 10 according to the second aspect of the present invention, the internal uneven shape described above may be formed by embossing. Specifically, a sheet having at least the transparent resin film layer 1 and the decorative layer 2 is prepared, and embossing is performed on the sheet from the decorative layer 2 side to form concave portions reaching the concave-convex shape of the transparent resin film layer 1. By adjusting the plate depth of the embossed plate used for the embossing, it is possible to form a plurality of convex portions 1a having different heights protruding from the transparent resin film layer 1 side toward the decorative layer 2 side, and to make the ratio (h/w) of the height h (μm) of the plurality of convex portions 1a to the width w (μm) 100% or less.
As a method for performing embossing, an embossing method using heat and pressure is generally used. The embossing method by heating and pressurizing is a method of softening the surface of a sheet by heating, pressurizing by an embossing plate, imparting an embossed pattern to the embossing plate, cooling, and fixing. The shape of the embossing plate used in the embossing corresponds to the concave-convex shape formed in the transparent resin film layer 1 and the decorative layer 2. The embossing may be performed using a known single-piece or rotary type embosser.
In the first aspect, the embossing method using heat and pressure includes, for example: a method of embossing the decorative layer 2; and a method of coating the decorative layer 2 along the concave-convex shape from the concave-convex shape of the transparent resin film layer 1 after the concave-convex shape is given. For example, by embossing, the embossed plate reaches the transparent resin film layer 1 from the decorative layer 2, whereby the concave portion reaching the transparent resin film layer 1 can be formed. Specifically, a sheet having a layer including at least the decorative layer 2 and the transparent resin film layer 1 is prepared, and embossing is performed from the decorative layer 2 to form a region having a concave-convex shape including a plurality of multi-stage convex portions 1a.
In the second aspect, the embossing method by heating and pressurizing includes, for example: a method of embossing the decorative layer 2; and a method of coating the decorative layer 2 along the concave-convex shape from the concave-convex shape of the transparent resin film layer 1 after the concave-convex shape is given. For example, by embossing, the embossed plate reaches the transparent resin film layer 1 from the decorative layer 2, whereby the concave portion reaching the transparent resin film layer 1 can be formed. Specifically, a sheet having a layer including at least the decorative layer 2 and the transparent resin film layer 1 is prepared, embossing is performed from the decorative layer 2, and the plurality of convex portions 1a having the concave-convex shape are formed in the region where the above ratio (h/w) is satisfied.
The heating temperature for embossing is not particularly limited, but is preferably about 180 to 220 ℃.
As described above, in the first aspect, the surface of the transparent resin film layer 1 on the side opposite to the surface having the concave-convex shape is preferably smooth, and the smoothness can be improved by mirror finishing. The mirror surface of the transparent resin film layer 1 may be finished by using a mirror roller or the like. Specifically, the embossing may be performed by passing the sheet after embossing between a mirror roller and a rubber roller after heating and applying hot pressing. The mirror roller is pressed against the surface of the transparent resin film layer 1, and is pressed with a rubber sheet from the back side of the sheet. Among them, a metal roller having a mirror surface formed by chromium plating or the like on the surface of an iron core or the like may be used as the mirror surface roller, and a roller having a surface of an iron core or the like covered with rubber such as silicone rubber may be used as the rubber roller. In the second aspect, the concave-convex shape immediately after the formation can be deformed by embossing by pressing the mirror roller, and the ratio (h/w) can be adjusted to 100% or less. In the second aspect, when the above-described ratio (h/w) is satisfied by embossing, the mirror surface may be formed so that the above-described ratio (h/w) does not substantially change.
By the mirror surface processing, excellent mirror surface properties can be imparted to the surface side of the transparent resin film layer 1. Among them, the specular property is preferably 1 μm or less, more preferably 0.1 μm or less, in terms of the arithmetic average roughness Ra of JIS B0601 (1996). That is, the surface after mirror finishing is a surface having the above arithmetic average roughness Ra of preferably 1 μm or less, more preferably 0.1 μm or less.
In the second aspect of the present invention, the support film 3 is laminated so that the concave and convex-shaped concave portions of the sheet are buried after the embossing step, whereby the above-described ratio (h/w) can be adjusted to 55% or less. As a method of stacking the concave portions so as to bury the concave portions with the support film layer 3, as described above. The adjustment of the ratio (h/w) by laminating the support film layer 3 may be performed when the ratio (h/w) of the convex portions 1a of the concave-convex shape is not 100% or less, or may be performed when the ratio is 100% or less in the embossing process. In addition, when the above-described ratio (h/w) is satisfied by embossing, the support film 3 may be laminated so that the above-described ratio (h/w) does not substantially change.
In the second aspect of the present invention, by performing both the mirror finishing and the lamination of the support film 3 after the embossing, the ratio (h/w) can be adjusted to 100% or less. Specifically, after the embossing step, a step of laminating a support film so that concave and convex-shaped recesses of the sheet are buried, and a step of mirror finishing the surface of the transparent resin film layer 1 on the side opposite to the side on which the concave and convex shapes are formed may be performed, and the ratio (h/w) may be adjusted to 100% or less. In the case of performing both the mirror finishing and the lamination of the support film 3, the order is not particularly limited, and it is preferable to perform the mirror finishing after laminating the support film 3 from the viewpoint of protecting the mirror formed by the mirror finishing.
2. Decorative resin molded article
The decorative resin molded article 20 according to the first aspect of the present invention is obtained by integrally molding the decorative sheet 10 according to the first aspect of the present invention and a molding resin. That is, the decorative resin molded article 20 according to the first aspect of the present invention is a decorative resin molded article having at least a transparent resin film layer 1 having a concave-convex shape on one side surface, a decorative layer 2 formed along the concave-convex shape of the transparent resin film layer 1, and a molded resin layer 5, the concave-convex shape having a plurality of convex portions 1a having different heights protruding from the transparent resin film layer 1 side toward the decorative layer 2 side, the plurality of convex portions 1a being formed in a multi-stage shape. As described in the description of the decorative sheet 10 according to the first embodiment of the present invention, the decorative resin molded product may be provided with the support film layer 3, the adhesive layer 4, the adhesive layer provided on the surface of the support film layer 3 opposite to the decorative layer 2, and the like.
The decorative resin molded article 20 according to the second aspect of the present invention is obtained by integrally molding the decorative sheet 10 according to the present invention and a molding resin. That is, the decorative resin molded article 20 of the present invention is a decorative resin molded article having at least a transparent resin film layer 1 having a concave-convex shape on one side surface, a decorative layer 2 formed along the concave-convex shape of the transparent resin film layer 1, and a molded resin layer 5, the concave-convex shape having a plurality of convex portions 1a having different heights protruding from the transparent resin film layer 1 side toward the decorative layer 2 side, and the ratio (h/w) of the height h (μm) to the width w (μm) of the plurality of convex portions 1a being 100% or less, respectively. As described in the description of the decorative sheet 10 according to the second aspect of the present invention, the decorative resin molded product may be provided with the support film layer 3, the adhesive layer 4, the adhesive layer provided on the surface of the support film layer 3 opposite to the decorative layer 2, and the like.
The decorative resin molded article of the present invention can be produced by various injection molding methods such as insert molding, injection molding simultaneous decoration, blow molding, and gas injection molding, for example, using the decorative sheet of the present invention. Among these injection molding methods, the insert molding method and the injection molding simultaneous decoration method are preferable. The decorative resin molded article of the present invention may be produced by a decoration method in which the decorative sheet of the present invention is bonded to a three-dimensional resin molded article (molded resin layer) prepared in advance by vacuum compression bonding or the like.
In the insert molding method, first, in the vacuum molding step, the decorative sheet of the present invention is vacuum-molded (off-line pre-molded) into a molded article surface shape in advance by a vacuum molding die, and then the remaining part is cut as needed to obtain a molded sheet. The molded sheet is inserted into an injection mold, the injection mold is closed, the resin in a flowing state is injected into the mold, and the resin is cured, and simultaneously with the injection molding, the decorative sheet and the outer surface of the resin molded article are integrated, thereby producing a decorative resin molded article.
More specifically, the decorative resin molded article of the present invention is produced by an insert molding method comprising the following steps.
A vacuum molding step of preliminarily molding the decorative sheet of the present invention into a three-dimensional shape by using a vacuum molding die;
a cutting step of cutting the remainder of the vacuum-molded decorative sheet to obtain a molded sheet; and
And an integration step of inserting the molded piece into the injection mold, closing the injection mold, injecting the resin in a flowing state into the injection mold, and integrating the resin and the molded piece.
In the vacuum molding step of the insert molding method, the decorative sheet may be heated and molded. The heating temperature in this case is not particularly limited, and may be appropriately selected depending on the type of resin constituting the decorative sheet, the thickness of the decorative sheet, and the like, and may be generally about 100 to 250 ℃, preferably about 130 to 200 ℃. In the integration step, the temperature of the resin in a fluidized state is not particularly limited, and may be generally about 180 to 320 ℃, preferably about 220 to 280 ℃.
In the injection molding simultaneous decoration method, the decorative sheet of the present invention is placed on a female mold that serves as a vacuum mold provided with a suction hole, the female mold is used for performing the preliminary molding (in-line preliminary molding), the injection molding is closed, the resin in a fluidized state is injected and filled into the mold, and the resin is cured, and the decorative sheet of the present invention is integrated with the outer surface of the resin molded article simultaneously with the injection molding, thereby producing a decorative resin molded article.
More specifically, the decorative resin molded article of the present invention is produced by an injection molding simultaneous decoration method including the following steps.
A preforming step of, after providing the decorative sheet of the present invention, making the surface of the decorative sheet opposite to the transparent resin film layer 1 face the molding surface of a movable mold having a molding surface of a predetermined shape, heating and softening the decorative sheet, and simultaneously vacuum-sucking the decorative sheet from the movable mold side to closely adhere the softened decorative sheet along the molding surface of the movable mold, thereby preforming the decorative sheet;
An integration step of closing a movable mold and a fixed mold having a decorative sheet adhered along a molding surface, injecting and filling a resin in a flowing state into a cavity formed by the two molds, and curing the resin to form a resin molded body, and integrating the resin molded body and the decorative sheet in a laminated manner; and
And a take-out step of separating the movable mold from the fixed mold and taking out the resin molded body obtained by laminating the decorative sheets entirely.
In the preforming step of the injection molding simultaneous decoration method, the heating temperature of the decorative sheet is not particularly limited, and may be appropriately selected depending on the kind of resin constituting the decorative sheet, the thickness of the decorative sheet, and the like, and may be generally about 70 to 130 ℃. In the injection molding step, the temperature of the resin in a fluidized state is not particularly limited, and may be generally about 180 to 320 ℃, preferably about 220 to 280 ℃.
In the vacuum bonding method, first, in a vacuum bonding machine composed of a first vacuum chamber located at an upper side and a second vacuum chamber located at a lower side, the decorative sheet and the resin molded body of the present invention are set in the vacuum bonding machine, the decorative sheet is located at the first vacuum chamber side, the resin molded body is located at the second vacuum chamber side, and the decorative sheet is located at a side opposite to the transparent resin film layer 1 toward the resin molded body side, and 2 vacuum chambers are brought into a vacuum state. The resin molded body is provided on a vertically movable lift table provided on the second vacuum chamber side. Next, the first vacuum chamber was pressurized, and the molded article was brought into contact with the decorative sheet using a lift table, and the decorative sheet was stretched and stuck to the surface of the resin molded article by a pressure difference of 2 vacuum chambers. Finally, the 2 vacuum chambers are opened to atmospheric pressure, and the remaining part of the decorative sheet is cut as needed, whereby the decorative resin molded article of the present invention can be obtained.
In the vacuum compression bonding method, before the step of bringing the molded article into contact with the decorative sheet, it is preferable to include a step of heating the decorative sheet in order to soften the decorative sheet and improve the moldability. The vacuum compression bonding method having this step is sometimes referred to as a vacuum heating compression bonding method. The heating temperature in this step may be appropriately selected depending on the type of resin constituting the decorative sheet, the thickness of the decorative sheet, and the like, and may be generally about 60 to 200 ℃.
In the decorative resin molded article of the present invention, the molding resin layer may be formed by selecting a resin corresponding to the application. The resin forming the molding resin layer may be a thermoplastic resin or a thermosetting resin.
Examples of the thermoplastic resin include polyolefin resins such as polyethylene and polypropylene, ABS resins, styrene resins, polycarbonate resins, acrylic resins, and vinyl chloride resins. These thermoplastic resins may be used singly in an amount of 1 kind, or may be used in an amount of 2 or more kinds in combination.
Examples of the thermosetting resin include polyurethane resin and epoxy resin. These thermosetting resins may be used alone in 1 kind, or may be used in combination of 2 or more kinds.
The decorative resin molded article of the present invention has a high three-dimensional effect such as a concave-convex effect, a three-dimensional effect, a profound effect, etc. due to the concave-convex shape, and also has a high surface smoothness, and thus can be used, for example, as an interior or exterior decorative material for a vehicle such as an automobile; door and window partitions such as window frames and door frames; interior materials for buildings such as walls, floors, and ceilings; housing of household electrical appliances such as television receiver, air conditioner, etc.; containers, etc.
Examples
Hereinafter, the present invention will be described in detail with reference to examples and comparative examples. However, the present invention is not limited to the examples.
Examples 1A to 5A and comparative example 1A
Manufacturing of decorative sheet of the first mode
As the transparent resin film layer, an acrylic film (thickness 125 μm) having smooth both sides was prepared. An ink composition (polybutylmethacrylate/vinyl chloride-vinyl acetate copolymer) was applied to one side surface of the transparent resin film layer by gravure printing to form a decorative layer (thickness 5 μm). Next, embossing is performed from the decorative layer using an embossing plate (embossing plate in which a plurality of concave portions of the embossing plate are formed by convex portions of the embossing plate in a diamond shape, a triangle shape, or a quadrangle shape (see table 1) in plan view, and the convex portions have a shape corresponding to the shape of the convex portions of the transparent resin film layer), thereby forming concave-convex shapes. With example 5A, an adhesive (polyester resin composition, polyester polyol: isocyanate=100:10) was further applied by gravure printing from the decorative layer to form an adhesive layer (thickness 30 μm).
The embossing plates used in each example and comparative example were different. In examples 1A to 5A, the convex portions of the embossed plate (i.e., the convex portions of the transparent resin film layer) were formed in a multi-stage shape, and the number of stages, the height H of the convex portions, the height H of each stage, the widths w1 to w6 of each stage, and the width w of the uppermost stage are shown in table 1, respectively. For example, each convex portion of the transparent resin film layer of example 1A is diamond-shaped in plan view and is formed in a multi-stage shape (step-like shape), the height H of the convex portion is 76 μm, the height H of each stage is 11 μm, the width wn of each stage is 35 μm, and the width w of the uppermost stage is 100 μm. The width of each segment and the width of the uppermost segment are measured in a direction perpendicular to the side forming the peripheral edge (outer edge) of the convex portion (for example, in a direction perpendicular to the sides facing each other in the case of a diamond shape as shown in the schematic diagram of fig. 5) in a plan view of the convex portion. The results are shown in Table 1.
Production of the decorative resin molded article of the first embodiment
The decorative sheet was placed in a vacuum molding machine ("VPF-T1" manufactured by the company of vacuum application), and was heated to a surface temperature of 160 ℃ by a heater, and vacuum-molded. And taking out the molded decorative sheet, cutting, and performing insert molding to integrate the decorative layer side and the molding resin to obtain a decorative resin molded product. As the molding resin, a mixture of polycarbonate and ABS resin (trade name: CYCOLOY IP1000BK, manufactured by GE PLASTICS) was used.
(Evaluation of stereoscopic impression)
The obtained decorative sheet, the molded decorative sheet and the molded decorative resin product were each used as a test sample, and were placed on a horizontal plane under a fluorescent lamp of white light with the transparent resin film layer facing upward. Then, the three-dimensional effect was evaluated by visual observation from a direction of 90 ° (directly above) with respect to the horizontal plane at a distance of about 50cm from the test sample, according to the following evaluation criteria. The evaluation criteria are as follows.
A+: the concave-convex shape can be clearly recognized, and the stereoscopic impression can be strongly perceived by visual inspection.
A: the concave-convex shape can be recognized, and the stereoscopic impression can be perceived through visual inspection.
B: it is slightly difficult to recognize the concave-convex shape, but it is possible to confirm a design exhibiting a three-dimensional effect generated by the concave-convex shape.
C: the concave-convex shape cannot be confirmed.
TABLE 1
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Examples 1B to 7B and comparative examples 1B to 3B
Production of decorative sheet of the second mode
As the transparent resin film layer, an acrylic film (thickness 125 μm) having smooth both sides was prepared. An ink composition (polybutylmethacrylate/vinyl chloride-vinyl acetate copolymer) was applied to one side surface of the transparent resin film layer by gravure printing to form a decorative layer (thickness 5 μm). Then, embossing is performed from the decorative layer using an embossing plate (forming a stripe) to form a concave-convex shape. With example 6B, an adhesive (polyester resin composition, polyester polyol: isocyanate=100:10) was further applied by gravure printing from the decorative layer to form an adhesive layer (thickness 30 μm).
The embossing plate used in each example and comparative example was different in plate depth. In examples 1B to 7B and comparative example 3B, the depth of the embossed plate was not uniform (about the plate depth, examples 1B and 4B to 9B were 30 to 60 μm, example 2B was 10 to 45 μm, and example 3B was 5 to 30 μm), and in comparative examples 1B to 2B, the depth of the embossed plate was uniform (about the plate depth, comparative example 1 was 26 μm, and comparative example 2B was 45 μm). The cross section of the obtained decorative sheet was observed by a microscope, and 3 points (points having a difference in height of 5 μm or more) were randomly selected for the convex portions with respect to the concave-convex shape formed on the transparent resin film layer, and the width w (μm) of the convex portions, the height h (μm) of the convex portions, the ratio (h/w) of the height h of the convex portions to the width w, and the width x (μm) between the convex portions were measured. As shown in fig. 7, when the heights h of the two ends of the convex portion of the transparent resin film layer are different in the cross section in the thickness direction of the decorative sheet, a large value of the height h is used. As shown in fig. 7, when 1 convex portion having different heights is formed by coupling a plurality of convex portions having different heights, a large height h is used. The width x between the projections is the distance between the projections on both sides of the projection at the measurement height h and width w, and the smaller value is used. The results are shown in Table 2.
(Evaluation of stereoscopic sensation 1)
The decorative sheet obtained above was placed on a horizontal plane under a fluorescent lamp of white light with the transparent resin film layer facing upward as a test sample. Then, the three-dimensional effect was evaluated by visual observation from a direction of 90 ° (directly above) with respect to the horizontal plane at a distance of about 50cm from the test sample, according to the following evaluation criteria. The evaluation criteria are as follows.
A+: the concave-convex shape can be clearly recognized, and the stereoscopic impression can be strongly perceived by visual inspection.
A: the concave-convex shape can be recognized, and the stereoscopic impression can be perceived through visual inspection.
B: it is slightly difficult to recognize the concave-convex shape, but it is possible to confirm a design exhibiting a three-dimensional effect generated by the concave-convex shape.
C: the concave-convex shape cannot be confirmed.
(Evaluation of stereoscopic sensation 2)
The decorative sheet obtained above was placed on a horizontal plane under a fluorescent lamp of white light with the transparent resin film layer facing upward as a test sample. Then, the three-dimensional effect was evaluated by visual observation from a direction of 45 ° with respect to the horizontal plane at a distance of about 50cm from the test sample according to the following evaluation criteria.
The evaluation criteria are as follows.
A+: the concave-convex shape can be clearly recognized, and the stereoscopic impression can be strongly perceived by visual inspection.
A: the concave-convex shape can be recognized, and the stereoscopic impression can be perceived through visual inspection.
B: it is slightly difficult to recognize the concave-convex shape, but it is possible to confirm a design exhibiting a three-dimensional effect generated by the concave-convex shape.
C: the concave-convex shape cannot be confirmed.
TABLE 2
Symbol description
1: A transparent resin film layer; 1a: a convex portion; 1b: a concave portion; 2: a decorative layer; 3: supporting the film layer; 4: an adhesive layer; 5: molding a resin layer; 10: a decorative sheet; 20: and (3) decorating the resin molded product.
Claims (12)
1. A decorative sheet, comprising:
A transparent resin film layer having a concave-convex shape on one side surface; and
A decorative layer formed along the concave-convex shape of the transparent resin film layer,
The concave-convex shape has a plurality of convex parts protruding from the transparent resin film layer side to the decorative layer side,
The plurality of convex portions are each formed in a multi-stage shape.
2. The decorative sheet according to claim 1, wherein:
the decorative layer side is also provided with a supporting film layer.
3. The decorative sheet according to claim 2, wherein:
The support film layer is formed so as to bury the concave portion on the decorative layer side.
4. A decorative sheet as claimed in claim 2 or 3, wherein:
an adhesive layer is also provided between the decorative layer and the support film layer.
5. A decorative sheet according to any one of claims 1 to 3, wherein:
The surface of the transparent resin film layer on the side opposite to the decorative layer side is smooth.
6. A decorative resin molded article is characterized by comprising:
A transparent resin film layer having a concave-convex shape on one side surface;
a decorative layer formed along the concave-convex shape of the transparent resin film layer; and
The resin layer is formed by molding the resin layer,
The concave-convex shape has a plurality of convex parts protruding from the transparent resin film layer side to the decorative layer side,
The plurality of convex portions are each formed in a multi-stage shape.
7. A decorative sheet, comprising:
A transparent resin film layer having a concave-convex shape on one side surface; and
A decorative layer formed along the concave-convex shape of the transparent resin film layer,
The concave-convex shape has a plurality of convex portions with different heights protruding from the transparent resin film layer side to the decorative layer side,
The ratio (h/w) of the height h (μm) to the width w (μm) of the plurality of projections is 100% or less, respectively.
8. The decorative sheet of claim 7, wherein:
the decorative layer side is also provided with a supporting film layer.
9. The decorative sheet of claim 8, wherein:
The support film layer is formed so as to bury the concave portion on the decorative layer side.
10. The decorative sheet according to claim 8 or 9, wherein:
an adhesive layer is also provided between the decorative layer and the support film layer.
11. The decorative sheet according to any one of claims 7 to 9, wherein:
The surface of the transparent resin film layer on the side opposite to the decorative layer side is smooth.
12. A decorative resin molded article is characterized by comprising:
A transparent resin film layer having a concave-convex shape on one side surface;
a decorative layer formed along the concave-convex shape of the transparent resin film layer; and
The resin layer is formed by molding the resin layer,
The concave-convex shape has a plurality of convex portions with different heights protruding from the transparent resin film layer side to the decorative layer side,
The ratio (h/w) of the height h (μm) to the width w (μm) of the plurality of projections is 100% or less, respectively.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2021-162742 | 2021-10-01 | ||
| JP2021-162741 | 2021-10-01 | ||
| JP2021162742 | 2021-10-01 | ||
| PCT/JP2022/033702 WO2023053890A1 (en) | 2021-10-01 | 2022-09-08 | Decorative sheet |
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| CN118076479A true CN118076479A (en) | 2024-05-24 |
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| CN202280066640.5A Pending CN118076479A (en) | 2021-10-01 | 2022-09-08 | Decorative sheet |
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