Decorative sheet

Patent metadata

Field	Value
Publication number	US-11203177-B2
Application number	US-201615559547-A
Country	US
Kind code	B2
Filing date	Mar 30, 2016
Priority date	Mar 30, 2015
Publication date	Dec 21, 2021
Grant date	Dec 21, 2021

Abstract

Provided is a decorative sheet which can impart, to molded resin articles, excellent design attractiveness and an excellent touch both due to a rugged shape. The decorative sheet comprises, superposed in the following order, a base layer, a surface layer which is constituted of a cured object obtained from a curable resin composition and has the rugged shape, and a removable thermoplastic resin film.

First claim

The invention claimed is:

1. A decorative sheet in which at least a base material layer, a surface layer formed of a cured product of a curable resin composition and having an irregular shape, and a releasable thermoplastic resin film layer are laminated in this order, wherein
a pattern layer is laminated between the base material layer and the surface layer,
at least a portion of the recesses in the irregular shape formed by the surface layer reach the base material layer,
the thermoplastic resin film layer fills recesses in the irregular shape of the surface layer,
the thermoplastic resin film layer is a single layer, and
the thermoplastic resin film layer is directly laminated on the surface layer to fill the recesses in the irregular shape.

2. The decorative sheet according to claim 1 , wherein the surface layer is formed of a cured product of an ionizing radiation curable resin composition.

3. The decorative sheet according to claim 2 , wherein the thermoplastic resin film layer is laminated on the irregular shape of the surface layer by extrusion molding or heat lamination.

4. The decorative sheet according to claim 1 , wherein the thermoplastic resin film layer contains a noncrystalline polyester resin.

5. The decorative sheet according to claim 1 , wherein the thermoplastic resin film layer is laminated on the irregular shape of the surface layer by extrusion molding or heat lamination.

6. The decorative sheet according to claim 1 , wherein a primer layer is laminated immediately below the surface layer.

7. The decorative sheet according to claim 1 , wherein the thickness of the surface layer is 0.01 to 30 μm.

8. A method for producing the decorative sheet according to claim 1 , the method including:
a first step of forming a laminated body in which a surface layer having an irregular shape and formed of a cured product of a curable resin composition is laminated on a base material layer; and
a second step of laminating a releasable thermoplastic resin film layer on the surface layer of the laminated body obtained in the first step.

9. The method for producing a decorative sheet according to claim 8 , wherein the thermoplastic resin film layer contains a noncrystalline polyester resin.

10. The method for producing a decorative sheet according to claim 8 , wherein the second step includes the steps of:
laminating the releasable thermoplastic resin film layer on the surface layer by extrusion molding or heat lamination so as to fill recesses in the irregular shape of the surface layer.

11. A method for producing a decorative resin molded article with a thermoplastic resin film layer, the method including the step of laminating a molded resin layer on the base material layer of the decorative sheet according to claim 1 by injecting a resin.

12. The decorative sheet according to claim 1 , wherein the surface of the thermoplastic resin film layer on a side opposite to the surface layer is flat.

13. The decorative sheet according to claim 1 , wherein the thermoplastic resin film layer is formed by a thermoplastic resin consisting of a group selected from acrylonitrile-butadiene-styrene resins, acrylonitrile-styrene-acrylic acid ester resins, acrylic resins, polyolefin-based resins and polyester resins.

14. A decorative resin molded article with a thermoplastic resin film layer in which at least a molded resin layer, a base material layer, a surface layer formed of a cured product of a curable resin composition and having an irregular shape, and a releasable thermoplastic resin film layer are laminated in this order, wherein
a pattern layer is laminated between the base material layer and the surface layer,
at least a portion of the recesses in the irregular shape formed by the surface layer reach the base material layer,
the thermoplastic resin film layer fills recesses in the irregular shape of the surface layer,
the thermoplastic resin film layer is a single layer, and
the thermoplastic resin film layer is directly laminated on the surface layer to fill the recesses in the irregular shape.

15. A method for producing a decorative resin molded article, the method including the step of separating the thermoplastic resin film layer from the decorative resin molded article with the thermoplastic resin film layer according to claim 14 .

Assignees

• Dainippon Printing Co Ltd

Inventors

• Sutou Masatoshi
• Meiki Yoshiyuki
• Kataoka Sakie
• Takano Yoko

Classifications

• B32B38/06

  Embossing · CPC title

• B32B27/40

  comprising polyurethanes · CPC title

• B29C48/21

  the layers being joined at their surfaces · CPC title

• B32B27/308

  comprising acrylic (co)polymers · CPC title

• B44C1/1712

  Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive · CPC title