Shaping sheet, resin decorative material and method of producing the same

• US 20070231583A1
• Filed: 09/29/2006
• Published: 10/04/2007
• Est. Priority Date: 09/30/2005
• Status: Active Grant

• Current Assignee: Dai Nippon Printing Company Limited
• Original Assignee: Dai Nippon Printing Company Limited
• Inventors: Tachihara, Kenichi, Hirota, Yoichi, Ilzuka, Takashi
• Granted Patent: US 8,187,695 B2
• Time in Patent Office: Days
• US Class Current: 428/423.700
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/4023 on the layer surface, e.g. ink
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/16 specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 29/00 : Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/252 : Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/2995 : Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31565 : Next to polyester [polyethylene terephthalate, etc.]

Abstract

The present invention provides a shaping sheet that includes a base material having at least an ink layer provided on the whole surface thereof and a surface shaping layer that is present on the ink layer, contacts the ink layer, and covers the whole surface of the ink layer, in which the surface shaping layer is a crosslinked and cured product of a curable resin composition and the surface shaping layer has a concavoconvex pattern on a surface thereof. There can be obtained: a shaping sheet that has a fine concavoconvex pattern, allows elaborated shaping with a high-grade feeling, and has excellent releasability; a shaping sheet having excellent design properties and releasability that can readily control a lustrous portion and a matted portion; and further a shaping sheet whose surface is free of contamination by impurities separated out of the base material even when it is repeatedly used.

Claims

1. A shaping sheet, comprising a base material having at least an ink layer provided on the whole surface thereof and a surface shaping layer that is present on the ink layer, contacts the ink layer, and covers the whole surface of the ink layer, wherein the surface shaping layer is a crosslinked and cured product of a curable resin composition and the surface shaping layer has a concavoconvex pattern on a surface thereof.

2. The shaping sheet according to claim 1, wherein the surface shaping layer contains fine particles therein, and the fine particles has an average particle size that is a plus-side approximation of a maximum thickness of the surface shaping layer positioned just above the ink layer.

3. The shaping sheet according to claim 1, wherein the curable resin composition is an ionizing radiation-curable resin composition.

4. The shaping sheet according to claim 3, wherein the ionizing radiation-curable resin composition is an electron beam-curable resin composition.

5. The shaping sheet according to claim 1, wherein the ink layer contains an ink containing a non-crosslinked urethane resin as a binder, and the curable resin composition contains a (meth)acrylate monomer.

6. The shaping sheet according to claim 5, wherein the ink that constitutes the ink layer contains as binders the non-crosslinked urethane resin and an unsaturated polyester resin.

9. The shaping sheet according to claim 1, wherein the curable resin composition is an ionizing radiation-curable resin composition.

10. The shaping sheet according to claim 9, wherein the ionizing radiation-curable resin composition is an electron beam-curable resin composition.

7. A shaping sheet, comprising a base material having thereon at least a transparent or translucent matted primer layer that is provided on the whole surface thereof and contains a releasing agent and a surface shaping layer partly provided on the primer layer, wherein the surface shaping layer is a crosslinked and cured product of a curable resin composition that contains a releasing agent and a matting agent.

8. The shaping sheet according to claim 7, wherein the releasing agent in the matted primer layer is a reactive silicone, and the releasing agent in the surface shaping layer is silicone (meth)acrylate.

11. A shaping sheet, comprising a base material made of a polyester film having thereon an ink layer provided at least partly and a surface shaping layer that is present above the ink layer, contacts the ink layer, and covers the whole surface over a region in which the ink layer is formed and a region in which the ink layer is not formed, wherein the surface shaping layer is a crosslinked and cured product of an ionizing radiation-curable resin composition and the base material shows a weight decrease of 1.0 mass % or less when immersed in xylene at 140°

C. for 24 hours.

12. The shaping sheet according to claim 11, wherein the surface of the surface shaping layer that is positioned just above the ink layer and above a portion in the vicinity thereof has a convex pattern.

13. The shaping sheet according to claim 11, wherein the ink layer contains an ink containing a non-crosslinked urethane resin as a binder and the ionizing radiation-curable resin composition contains a (meth)acrylate monomer.

14. A resin decorative board, that is formed by laminating an adhesive layer and a decorative sheet layer on a base material on the upper surface thereof in this order, applying a resin composition on the decorative sheet layer, abutting a shaping sheet on the coated resin composition, curing the resin composition and the shaping sheet integrally, and peeling the shaping sheet to form a resin layer, wherein

the shaping sheet comprises a base material having at least an ink layer provided on the whole surface thereof or partly provided on the surface thereof and a surface shaping layer that is present on the ink layer, contacts the ink layer, and covers over the whole surface of the ink layer, wherein the surface shaping layer is a crosslinked and cured product of an ionizing radiation-curable resin composition.

15. A resin decorative board, that is formed by laminating an adhesive layer and a decorative sheet layer on a base material on the upper surface thereof in this order, applying a resin composition on the decorative sheet layer, abutting a shaping sheet on the coated resin composition, curing the resin composition and the shaping sheet integrally, and peeling the shaping sheet to form a resin layer, wherein

the shaping sheet comprises a base material having thereon at least a transparent or translucent matted primer layer that is provided on the whole surface thereof and contains a releasing agent and a surface shaping layer partly provided on the primer layer, and wherein the surface shaping layer is a crosslinked and cured product of an ionizing radiation-curable resin composition that contains a releasing agent.

16. The resin decorative board according to claim 15, wherein the surface shaping layer is a crosslinked and cured product of the curable resin composition that further contains a matting agent.

17. A resin decorative board, that is formed by laminating an adhesive layer and a decorative sheet layer on a base material on the upper surface thereof in this order, applying a resin composition on the decorative sheet layer, abutting a shaping sheet on the coated resin composition, curing the resin composition and the shaping sheet integrally, and peeling the shaping sheet to form a resin layer, wherein

the shaping sheet comprises a shaping sheet obtained by forming a pattern layer on the base layer with an ink selected from the group consisting of (a) a repellent ink containing a binder that has repellency in itself, (b) a repellent ink that includes a binder having no repellency in itself to which is added an additive having repellency, and (c) a repellent ink that includes a binder having repellency in itself to which is added an additive having repellency, applying an ionizing radiation-curable resin composition containing a releasing agent on the pattern layer to form a coating layer, forming a concave portion on the coating layer formed above the pattern layer by repellent action between the resultant repellent pattern layer and the coating layer, and irradiating the coating layer with an ionizing radiation to cure the coating layer formed with concaves and convexes in conformity with the pattern layer.

18. A resin decorative board, that is formed by laminating an adhesive layer and a decorative sheet layer on a base material on the upper surface thereof in this order, applying a resin composition on the decorative sheet layer, abutting a shaping sheet on the coated resin composition, curing the resin composition and the shaping sheet integrally, and peeling the shaping sheet to form a resin layer, wherein

the shaping sheet comprises a shaping sheet obtained by forming an ink layer on the whole surface of the base layer with an ink selected from the group consisting of (a) a repellent ink containing a binder that has repellency in itself, (b) a repellent ink that includes a binder having no repellency in itself to which is added an additive having repellency, and (c) a repellent ink that includes a binder having repellency in itself to which is added an additive having repellency, applying a curable resin composition containing a releasing agent on the ink layer to form a coating layer, forming a convex portion on the coating layer formed above the ink layer by repellent action between the ink layer and the coating layer, and curing the coating layer formed with convexes.

19. A resin decorative board, that is formed by laminating an adhesive layer and a decorative sheet layer on a base material on the upper surface thereof in this order, applying a resin composition on the decorative sheet layer, abutting a shaping sheet on the coated resin composition, curing the resin composition and the shaping sheet integrally, and peeling the shaping sheet to form a resin layer, wherein

the shaping sheet comprises a base material, a surface shaping layer made of a crosslinked and cured product of an ionizing radiation-curable resin composition, and at least an ink layer and an interaction preventing layer laminated in this order from the side of the base material between the base material and the surface shaping layer, in which the ink layer is formed on a portion where the interaction region is to be developed or on the whole surface of the base material, and the interaction preventing layer is formed as having a shape such that the portion that develops the interaction region is cut out.

20. A method of producing a decorative board, comprising shaping an article to be shaped using a shaping sheet that has a base material and a surface shaping layer on the base material, wherein the article to be shaped contains a design property-imparting pigment and the surface shaping layer is made of a crosslinked and cured product of an ionizing radiation-curable resin composition containing a reactive silicone.

21. The method of producing a decorative board according to claim 20, wherein the design property-imparting pigment comprises one kind selected from a pearl pigment, a silver pigment, and a titanium pigment.

22. The method of producing a decorative board according to claim 20, wherein the surface shaping layer contains fine particles therein and the fine particles have an average particle size of 1 to 80 μ

m, and a content of 2 to 20 mass %.

23. The method of producing a decorative board according to claim 20, wherein the surface shaping layer contains calcined kaolin particles.

24. The method of producing a decorative board according to claim 20, wherein the ionizing radiation-curable resin composition is an electron beam-curable resin composition.