Method for producing decorative material

Patent metadata

Field	Value
Publication number	US-11969980-B2
Application number	US-202017764225-A
Country	US
Kind code	B2
Filing date	Sep 30, 2020
Priority date	Sep 30, 2019
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

Provided is a method for producing a decorative material, including: a preparation step of preparing sheet printed matters each including a substrate and a picture layer on one surface of the substrate and a roll of a transparent resin film having a first surface and a second surface opposing to each other, the first surface having a pattern of protrusions and depressions, the second surface having a pattern of protrusions and depressions that is shallower than the pattern of protrusions and depressions on the first surface; an application step of winding off the transparent resin film from the roll of a transparent resin film and applying an adhesive to the second surface of the transparent resin film; and a bonding step of bonding the second surface of the transparent resin film and the picture layer of each of the sheet printed matters with the adhesive.

First claim

The invention claimed is:

1. A method for producing a decorative material, comprising:
a preparation step of preparing sheet printed matters each comprising a substrate and a picture layer on one surface of the substrate and a roll of a transparent resin film having a first surface and a second surface opposing to each other, the first surface having a pattern of protrusions and depressions, the second surface having a pattern of protrusions and depressions that is shallower than the pattern of protrusions and depressions on the first surface;
an application step of winding off the transparent resin film from the roll of the transparent resin film and applying an adhesive to the second surface of the transparent resin film; and
a bonding step of bonding the second surface of the transparent resin film and the picture layer of each of the sheet printed matters with the adhesive and cutting the transparent resin film in front and at back of the sheet printed matters to obtain laminates; and
the transparent resin film protrudes outside an end portion of each of the sheet printed matters in the laminates, and
the method further comprises a removal step of stacking the laminates and removing portions of the transparent resin film that protrude from the laminates under application of pressure in a lamination direction.

2. The method for producing a decorative material according to claim 1 ,
wherein the transparent resin film of the roll prepared in the preparation step is wound in a manner that the second surface of the transparent resin film faces inside the roll.

3. The method for producing a decorative material according to claim 1 ,
wherein the application step involves reversing the transparent resin film after application of the adhesive to the second surface of the transparent resin film, prior to the bonding step.

4. The method for producing a decorative material according to claim 1 ,
wherein a second bonding step involves stacking the laminates in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate, and applying pressure to the laminates in a lamination direction.

5. The method for producing a decorative material according to claim 1 ,
wherein the removal step involves stacking the laminates in pairs in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate and removing portions of the transparent resin film that protrude from the laminates under application of pressure in a lamination direction of the laminates.

6. The method for producing a decorative material according to claim 1 ,
wherein the transparent resin film includes a surface protective layer on the first surface, and the surface protective layer contains an antibacterial antiviral agent.

7. The method for producing a decorative material according to claim 2 ,
wherein the application step involves reversing the transparent resin film after application of the adhesive to the second surface of the transparent resin film, prior to the bonding step.

8. The method for producing a decorative material according to claim 2 ,
wherein a second bonding step involves stacking the laminates in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate, and applying pressure to the laminates in a lamination direction.

9. The method for producing a decorative material according to claim 3 ,
wherein a second bonding step involves stacking the laminates in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate, and applying pressure to the laminates in a lamination direction.

10. The method for producing a decorative material according to claim 2 ,
wherein the removal step involves stacking the laminates in pairs in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate and removing portions of the transparent resin film that protrude from the laminates under application of pressure in a lamination direction of the laminates.

11. The method for producing a decorative material according to claim 3 ,
wherein the removal step involves stacking the laminates in pairs in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate and removing portions of the transparent resin film that protrude from the laminates under application of pressure in a lamination direction of the laminates.

12. The method for producing a decorative material according to claim 4 ,
wherein the removal step involves stacking the laminates in pairs in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate and removing portions of the transparent resin film that protrude from the laminates under application of pressure in a lamination direction of the laminates.

13. The method for producing a decorative material according to claim 2 ,
wherein the transparent resin film includes a surface protective layer on the first surface, and the surface protective layer contains an antibacterial antiviral agent.

14. The method for producing a decorative material according to claim 3 ,
wherein the transparent resin film includes a surface protective layer on the first surface, and the surface protective layer contains an antibacterial antiviral agent.

15. A method for producing a decorative material, comprising:
a preparation step of preparing sheet printed matters each comprising a substrate and a picture layer on one surface of the substrate and a roll of a transparent resin film having a first surface and a second surface opposing to each other, the first surface having a pattern of protrusions and depressions, the second surface having a pattern of protrusions and depressions that is shallower than the pattern of protrusions and depressions on the first surface;
an application step of winding off the transparent resin film from the roll of the transparent resin film and applying an adhesive to the second surface of the transparent resin film;
a bonding step of bonding the second surface of the transparent resin film and the picture layer of each of the sheet printed matters with the adhesive and cutting the transparent resin film in front and at back of the sheet printed matters to obtain laminates; and
the bonding step involves stacking the laminates in a manner that the transparent resin film of a first laminate is in contact with the transparent resin film of a second laminate or the substrate of a first laminate is in contact with the substrate of a second laminate, and applying pressure to the laminates in a lamination direction.

16. The method for producing a decorative material according to claim 15 ,
wherein the transparent resin film of the roll prepared in the preparation step is wound in a manner that the second surface of the transparent resin film faces inside the roll.

17. The metho

Assignees

• Dainippon Printing Co Ltd

Inventors

• Nakajima Tomomi
• Netsu Yoshiaki
• Kayahara Toshinaru
• Sumida Yosuke
• Wada Masataka

Classifications

• B32B37/02 Primary

  characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• B32B37/10

  characterised by the pressing technique, e.g. using action of vacuum or fluid pressure · CPC title