JP7252178B2 - Method for manufacturing decorative sheet, and decorative sheet - Google Patents

Description

The present invention relates to a decorative sheet manufacturing method and a decorative sheet.

It is known to manufacture labels and packages by foil stamping onto paper or leather. For example, in Patent Document 1, a transfer film is supplied in a direction perpendicular to the supply direction of the belt-shaped plate material, the belt-shaped plate material is moved forward by the length of the product, and at the same time the transfer film is advanced by a predetermined length. A method (hereinafter referred to as a "batch method") is disclosed in which a die prints a pattern on a strip of plate material while it is moving and stationary. Although the batch method can stably print patterns, it has the problem that it is difficult to improve the production efficiency because the production line needs to be temporarily stopped.

On the other hand, in Patent Document 1, a pressure roll and a transfer roll cooperating with the pressure roll are provided, and a belt-shaped plate material and a transfer film are passed between the pressure roll and the transfer roll to obtain a belt-like shape. A method of transferring a pattern to the surface of a printing plate (hereinafter referred to as "rotary method") has been disclosed. Since the rotary method allows continuous transfer without stopping the production line, production efficiency can be improved compared to the batch method.

Japanese Patent Publication No. 2003-528777

However, although the above rotary method is suitable for transferring patterns to pieces of paper and leather materials, even if it is applied to nonwoven fabrics as it is, the pattern is not sufficiently fixed on the surface of the nonwoven fabric, and the pattern comes off. That's what I found out.

SUMMARY OF THE INVENTION An object of the present invention is to provide a decorative sheet manufacturing method and a decorative sheet that can efficiently and stably form a display layer showing a pattern on the surface of a nonwoven fabric.

The present invention provides a decorative sheet comprising a material sheet having a nonwoven fabric having a first surface and a second surface opposite to the first surface, and a display layer disposed on the first surface. A method, wherein a transfer film having a foil and the material sheet are overlapped and conveyed between a pattern roll having a pattern for foil stamping on the outer peripheral surface and an anvil roll arranged to face the pattern roll. a foil stamping step of pressing the foil corresponding to the pattern from the transfer film onto the first surface to form the display layer, wherein the compression energy WC value of the material sheet measured by KES measurement is A method for manufacturing a decorative sheet, wherein the surface area is 0.294 N·m/m ² or more and 1.960 N·m/m ² or less.

The decorative sheet manufacturing method according to the present invention can efficiently and stably form the display layer on the surface of the nonwoven fabric.

1 is a schematic diagram of a decorative sheet according to this embodiment; FIG. FIG. 3 is a partially enlarged cross-sectional view of the decorative sheet according to this embodiment; FIG. 5 is a partially enlarged cross-sectional view of a decorative sheet according to a modified example of the present embodiment; It is a schematic diagram showing an application example of the decorative sheet according to the present embodiment. FIG. 2 is a diagram schematically showing a foil stamping device used in the method for manufacturing a decorative sheet according to this embodiment; It is a schematic diagram (1) of the material sheet used for the manufacturing method of this embodiment. It is a schematic diagram (2) of the material sheet used for the manufacturing method of this embodiment. FIG. 2 is a partially enlarged view schematically showing a manufacturing apparatus used in the method for manufacturing a decorative sheet according to this embodiment; FIG. 7 is a diagram schematically showing a manufacturing apparatus used in a method for manufacturing a decorative sheet according to a modified example of the present embodiment;

This embodiment relates to the following aspects.
[Aspect 1]
A method for manufacturing a decorative sheet, comprising: a material sheet having a nonwoven fabric having a first surface and a second surface opposite to the first surface; and a display layer disposed on the first surface. , between a pattern roll having a pattern for foil stamping on the outer peripheral surface and an anvil roll arranged facing the pattern roll, the transfer film having foil and the material sheet are overlapped and conveyed, 1. A foil stamping step of forming the display layer by crimping the foil corresponding to the pattern from the transfer film on the surface, wherein the compression energy WC value of the material sheet is 0.294 N·m/m ² or more 1 .960 N·m/m ² or less, a method for manufacturing a decorative sheet.
The compression energy WC value of the material sheet is 0.294 N·m/m ² or more and 1.960 N·m/m ² or less. When the compression energy WC value is 0.294 N·m/m ² or more, the material sheet is pressed by the pattern and deformed more reliably. When the compression energy WC value is 1.960 N·m/m ² or less, the pattern can be prevented from sinking deeply into the material sheet, and the pattern can be more reliably pushed into the material sheet. Therefore, even with the rotary method, a display layer showing a pattern can be stably formed on the surface of the nonwoven fabric. Therefore, the manufacturing method of this decorative sheet can efficiently and stably form the display layer on the surface of the nonwoven fabric.

[Aspect 2]
The method for producing a decorative sheet according to aspect 1, wherein the foil stamping step conveys the material sheet between the pattern roll and the anvil roll while applying tension to the material sheet in the conveying direction.
The sheet of material expands due to tension and increases in thickness due to wavy undulations. A thicker sheet of material increases the contact time between the pattern roll and the anvil roll. Therefore, according to the manufacturing method of the present decorative sheet, the display layer can be formed more stably on the surface of the nonwoven fabric by improving the adhesiveness between the foil and the surface of the nonwoven fabric.

[Aspect 3]
The method for producing a decorative sheet according to aspect 1 or 2, wherein the material sheet has a density of 70 kg/m ³ or more and 350 kg/m ³ or less.
Since the density of the material sheet is 70 kg/m ³ or more and 350 kg/m ³ or less, there are few voids between the fibers of the nonwoven fabric, and the area that can come into contact with the transfer film increases. Therefore, according to the manufacturing method of the present decorative sheet, the adhesion between the foil and the surface of the nonwoven fabric is improved, so that the display layer can be formed more stably.

[Aspect 4]
The method for producing a decorative sheet according to aspect 2, wherein the orientation direction of the fibers of the nonwoven fabric is along the conveying direction.
The orientation direction of the fibers of the nonwoven fabric is along the conveying direction. Therefore, according to the manufacturing method of the present decorative sheet, the material sheet can be easily widened, so that the thickness of the material sheet can be increased more easily.

[Aspect 5]
The method for producing a decorative sheet according to any one of aspects 1 to 4, wherein the material sheet has a film laminated on the second surface.
By having a film laminated to the second surface of the material sheet, the compression energy WC value of the material sheet can be adjusted. Specifically, the compression energy WC value is set to 0.294 N·m/m ² or more by laminating a film on the second surface of the nonwoven fabric having a compression energy WC value of less than 0.294 N·m/m ² . can be done. Since the material sheet having the film laminated on the second surface in this way has increased rigidity as a whole and uniform cushioning properties, the adhesiveness between the surfaces of the foil and the non-woven fabric is further improved. Therefore, according to the manufacturing method of the present decorative sheet, the display layer can be efficiently and stably formed on the surface of the nonwoven fabric.

[Aspect 6]
The method for producing a decorative sheet according to any one of aspects 1 to 5, comprising a preheating step of preheating the material sheet before the foil stamping step.
By providing a preheating step for preheating the material sheet before the foil stamping step, the material sheet can be sufficiently heated. Therefore, this decorative sheet manufacturing method can improve the adhesion between the foil and the surface of the nonwoven fabric.

[Aspect 7]
The method for producing a decorative sheet according to aspect 6, wherein the preheating step heats the first surface to a temperature higher than that of the second surface.
A preheating step heats the first surface to a higher temperature than the second surface. That is, by heating the first surface forming the display layer to a higher temperature, the thermal influence on the second surface can be suppressed.

[Aspect 8]
The method for producing a decorative sheet according to any one of aspects 1 to 7, wherein the temperature of the first surface in the foil stamping step is equal to or higher than the softening point of the nonwoven fabric.
Since the temperature of the first surface in the foil stamping process is equal to or higher than the softening point of the nonwoven fabric, the fibers on the first surface melt when the pattern is pressed into the first surface, and the adhesion with the foil is improved. can be increased.

[Aspect 9]
A decorative sheet comprising: a material sheet having a nonwoven fabric including a first surface and a second surface opposite to the first surface; and a display layer disposed on the first surface, wherein the display The thickness of the decorative sheet in the first region located inside the layer in the direction crossing the orientation direction of the nonwoven fabric and away from the display layer in the direction parallel to the orientation direction is the thickness of the display layer thicker than the thickness of the decorative sheet in the second region located outside the direction intersecting the orientation direction.
Since the present decorative sheet has a height difference between the first area and the second area, the display layer can stand out more three-dimensionally.

[Decorative sheet]
Hereinafter, absorbent articles according to embodiments will be described with reference to the drawings. FIG. 1 is a schematic diagram of a decorative sheet according to this embodiment. FIG. 2 is a partially enlarged sectional view of the decorative sheet according to this embodiment. A decorative sheet 10A shown in FIG. Illustrations and explanations will be made below using an xyz coordinate system as necessary. The x-direction, y-direction, and z-direction are orthogonal to each other and include two directions opposite to each other.

The nonwoven fabric 12 is a tape-like member having a first surface 22 parallel to the xy plane and a second surface 24 opposite to the first surface 22, as shown in FIG. , an air-through nonwoven fabric, an SMS nonwoven fabric, or a spun lace nonwoven fabric can be used. The material of the nonwoven fabric 12 is not particularly limited, and examples thereof include synthetic resins such as polyethylene, polypropylene, and polyethylene terephthalate. The orientation direction of the fibers of the nonwoven fabric 12 is along the y direction. The orientation direction of fibers refers to the direction in which approximately 50% or more of the fibers forming the nonwoven fabric are oriented. The thickness of the nonwoven fabric 12 is, for example, 0.02 to 2 mm, preferably 0.05 to 1 mm. If the thickness is 0.02 mm or more, the material of the display layer 16 is less likely to come off the nonwoven fabric 12, so the display layer 16 can be formed satisfactorily. If the thickness is 2 mm or less, it is possible to suppress the display layer 16 from protruding from the surface of the product.

Each average basis weight of the nonwoven fabric 12 is preferably 30 to 250 g/m ² . Basis weight is measured according to the following measurement method. A sample having a size of 5 cm×5 cm is cut out in an atmosphere of normal temperature (20° C.±15° C. (5 to 35° C.): JIS Z 8703), and the mass is measured. The basis weight of the sample is then calculated by dividing the measured mass by the area of the sample. A value obtained by averaging the grammage of 10 samples is taken as the grammage of the sheet.

From the viewpoint of ensuring cushioning properties, the material sheet 14A has a compression energy WC value of 0.294 N·m/m ² or more and 1.960 N·m/m ² or less, preferably 0.343 N·m/m ² or more. 0.784 N·m/m ² or less, more preferably 0.381 N·m/m ² or more and 0.700 N·m/m ² or less. The compression energy WC value means that the greater the value, the easier the compression.

The compression energy WC value can be obtained by subjecting the sample to a compression characteristic evaluation test using an automated compression tester "KES FB-3A" (manufactured by Kato Tech Co., Ltd.). At this time, the center of the compressing element of the testing machine should be aligned with the central portion of the cushion in the width direction. In addition, the measurement conditions for the compression property evaluation test are as follows.

SENS: 2
Speed: 0.02mm/sec Stroke: 5mm/10V
Compressor area: ^2cm2
Capture interval: 0.1 second Upper limit load: 50 gf/cm ²
Number of repetitions: 1 time

The material sheet 14A has a surface 23 to be foil stamped and a base surface 25 opposite to the surface 23 to be foil stamped. In the case of FIG. 2, the surface to be hot stamped 23 is the first surface 22 of the nonwoven 12 and the base surface 25 is the second surface 24 of the nonwoven 12 . The density of the material sheet 14A is preferably 70 kg/m ³ or more and 350 kg/m ³ or less, more preferably 100 kg/m ³ or more and 300 kg/m ³ or less, and still more preferably 180 kg/m ³ or more and 200 kg/m ^{3 or} less. . In the case of FIG. 2, the density of the material sheet 14A is the density of the nonwoven fabric 12. In FIG. The density of the material sheet 12A is calculated by dividing the basis weight (g/m ² ) by the thickness (m).

First surface 22 of nonwoven fabric 12 includes recesses 26 that are concave toward second surface 24 and protrusions 28 positioned around recesses 26 . The concave portion 26 includes a main portion 30 positioned in the center of the concave portion 26 and an edge portion 32 positioned at the outer edge of the main portion 30 and in contact with the convex portion 28 in plan view. The display layer 16 is disposed on the main portion 30 and the edge portion 32 . The recesses 26 are formed on the first surface 22 of the nonwoven fabric 12 with a size that is slightly larger than the display layer 16 in the plane direction, rather than the recesses due to the unevenness of the surface inherent in the nonwoven fabric 12, for example, the recesses on the surface associated with fiber unevenness. It is the recessed part 26 which was made. The recesses 26 can be formed by heating and compressing the regions where the recesses 26 are to be formed, so that the fibers are fused to each other and the shape at the time of compression is generally maintained after compression. Due to the fusion bonding of the fibers, it is possible to suppress the unevenness of the surface caused by the unevenness of the fibers on the first surface 22 of the concave portion 26 to a certain extent.

In the planar direction, that is, the x-direction and the y-direction, the length of the recess 26 is more than 100% of the length of the display layer 16 in the x-direction and the y-direction from the viewpoint of fitting the display layer 16 in the recess 26, and preferably It is 104% or more, more preferably 108% or more. The lengths of the concave portions 26 in the x-direction and the y-direction are 140% or less, preferably 130% or less, of the lengths of the display layer 16 in the x-direction and the y-direction from the viewpoint of making the display layer 16 difficult to peel off. More preferably, it is 120% or less. For example, when the size of the display layer 16 in the y direction is approximately 20 mm, the size of the concave portion 26 in the y direction is approximately 22 mm. The convex portion 28 is a region surrounding the concave portion 26 and is a region of the nonwoven fabric 12 excluding the concave portion 26 .

The display layer 16 is placed directly in the recesses 26 of the nonwoven fabric 12 . The display layer 16 is a layer showing a pattern of letters, graphics, symbols and colors or a combination thereof. In this embodiment, a heart shape is used as the pattern. However, there are no particular restrictions on the types of patterns, i.e., characters, figures, symbols and colors, or combinations thereof. , or special characters. Examples of graphics include circles, ellipses, polygons, plant shapes, animal shapes, article shapes, character designs, national flags, and emblems. Examples of symbols include map symbols, clef symbols, guide map symbols (pictograms), and signs. The color may be, for example, a color having metallic luster such as gold or silver, a color exhibiting a predetermined degree of gloss, or a color having a predetermined color difference with respect to the color of the surroundings of the display layer 16 (example: material sheet). etc. A color having a metallic luster or a color exhibiting a predetermined degree of glossiness is easy to see even in a dark place, and thus has high visibility. A color having a predetermined color difference with respect to the surrounding color of the display layer 16 is highly identifiable with respect to materials surrounding the display layer 16, and thus has high visibility. Any number of patterns may be included in the display layer 16 . The size of one pattern is not particularly limited. 100 mm is mentioned.

The display layer 16 preferably has a high glossiness from the viewpoint of improving visibility. The high glossiness is, for example, 7 or more, preferably 10 or more, more preferably 20 or more, and still more preferably 30 or more. If the glossiness is too low, the visibility will be low, and it will be difficult to visually recognize the pattern of the display layer 16, especially in an environment where the brightness is not sufficient.

In this case, the color of the display layer 16 is not particularly limited as long as it can exhibit the above glossiness. Gold is particularly preferred. If it has a golden luster, it can give a more luxurious feel. However, it is not necessary to achieve gold or silver with gold or silver, and other materials may be used to achieve a pseudo gold or silver tint. Examples of colors capable of realizing a metallic luster exhibiting a predetermined degree of gloss or colors exhibiting a predetermined degree of gloss include, for example, PANTONE (registered trademark) Metallic Coated CHIPS colors in the 800s (C) and 8000s (C), An example is the 10000 series (C) color region.

The display layer 16 is formed of foil having a metal component. A foil is a thin flat layer containing a metallic component. The foil has a metal layer containing metal. The metal layer is formed by flattening a metal by beating it, or is a layer containing metal. Layered materials containing metal are, for example, coating films containing metallic powder pigments and vapor-deposited metal films. The foil may be used as a single metal layer, or as a laminate of a metal layer and an adhesive layer made of synthetic resin.

Foil has a fixed shape and thickness compared to liquid materials such as paint. Therefore, the display layer 16 can be formed relatively smoothly with a desired thickness without being affected by the irregularities and voids of the base on which the foil is formed, and the glossiness of the display layer 16 can be easily maintained at a desired value. The thickness of the display layer (foil) 16 is 1 to 1000 μm, preferably 10 to 500 μm. When the thickness of the display layer 16 is 1 μm or more, the glossiness can be maintained without being affected by the irregularities of the base. When the thickness of the display layer 6 is 1000 μm or less, the tactile sensation does not become too hard, and it is possible to suppress discomfort given to the wearer.

The thickness of the decorative sheet 10 differs between the first region 18 and the second region 20 shown in FIG. The first region 18 is located outside the display layer 16 parallel to the alignment direction (y-direction) with respect to the display layer 16 . The first region 18 is a region located inside the display layer 16 in a direction crossing the alignment direction, ie, inside in the x-direction, and away from the display layer 16 in a direction parallel to the alignment direction. The second region 20 is located outside the display layer 16 , crossing the display layer 16 in the alignment direction (y-direction). The second region 20 is a region outside the display layer 16 in a direction crossing the alignment direction, that is, outside in the x direction. The thickness of the decorative sheet 10 in the first region 18 is thicker than the thickness of the decorative sheet 10 in the second region 20 .

In this specification, unless otherwise specified, the thickness (mm) of an object is measured as follows. FS-60DS manufactured by Daiei Kagaku Seiki Co., Ltd. [measurement surface 44 mm (diameter), measurement pressure 3 g / cm ² ] was prepared, and the target was measured under standard conditions (temperature 23 ± 2 ° C., relative humidity 50 ± 5%). Press five different parts of the object, measure the thickness of each part after 10 seconds of pressurization, and take the average value of the five measured values as the thickness of the object.

FIG. 3 is a partially enlarged view of a decorative sheet 10B according to a modified example of this embodiment. A decorative sheet 10B shown in FIG. 3 includes a material sheet 14B and a display layer 16. As shown in FIG. Material sheet 14B includes nonwoven fabric 12 and film 34 laminated on second surface 24 of nonwoven fabric 12 . Film 34 has a front surface 33 and a back surface 35 and is bonded at surface 33 to second surface 24 of nonwoven fabric 12 . The material of the film 34 is not particularly limited, and examples thereof include synthetic resin. The thickness of the film 34 is, for example, 10 μm to 30 μm (or 0.010 mm to 0.030 mm in terms of conversion), preferably 14 μm to 20 μm (or 0.014 mm to 0.020 mm in terms of conversion). The foil-stamped surface 23 of the material sheet 14B is the first surface 22 of the nonwoven fabric 12 and the base surface 25 is the back surface 35 of the film 34 . In this modification, the compression energy WC value and density of the material sheet 14B including the nonwoven fabric 12 and the film 34 are the same as those of the material sheet 14A in the above embodiment.

In this specification, the decorative sheets 10A and 10B are the decorative sheets 10, and the material sheets 14A and 14B are the material sheets 14, unless the embodiment and the modification are particularly distinguished.

Next, an application example of the decorative sheet 10 will be described with reference to FIG. FIG. 4 is a schematic diagram showing an application example of the decorative sheet according to this embodiment. The x direction in FIG. 4 is called the width direction. A tape-type diaper 1 shown in FIG. 4 includes an abdominal portion 2 and a dorsal portion 3 . The dorsal portion 3 has a pair of engaging tapes 37 protruding outward from both ends in the width direction. The decorative sheet 10 can be applied to the target tape 36 in the tape-type diaper 1 . The target tape 36 is positioned in the widthwise central portion of the abdominal portion 2 on the non-skin side and extends in the widthwise direction. The target tape 36 includes a centrally arranged decorative sheet 10 and a pair of tape portions 38 integrally arranged on both sides of the decorative sheet 10 in the width direction. In the tape-type diaper 1, for example, after the abdomen part 2 is brought into contact with the wearer's abdomen, the pair of engaging tapes 37 of the back part 3 engages the pair of tape parts 38 of the abdomen part 2. It is worn by the wearer. Even in the tape-type diaper 1 after being worn, the display layer 16 of the decorative sheet 10 is not hidden by the pair of engaging tapes 37 and can be visually recognized from the outside.

[Decorative sheet manufacturing method]
Next, a method for manufacturing the decorative sheet 10 according to this embodiment will be described. First, the foil stamping device used in this manufacturing method will be described. However, in this specification, the "conveyance direction of the material or product" is "MD direction", the "direction perpendicular to the MD direction on the horizontal plane" (that is, the width direction of the production line) is "CD direction", "these MD A direction perpendicular to the direction and the CD direction” (that is, the vertical direction of the production line) is referred to as the “TD direction”. The MD, TD, and CD directions are orthogonal to each other and include two directions opposite to each other.

FIG. 5 is a schematic diagram showing the foil stamping device 40. As shown in FIG. The foil stamping device 40 includes a foil forming section 42 , a material supply section 44 and a foil supply section 46 . The foil forming section 42 has a pattern roll 48 and an anvil roll 50 facing the pattern roll 48 . The pattern roll 48 and the central axes of the pattern roll 48 are arranged parallel to each other and parallel to the CD direction. The pattern roll 48 has a plurality of foil stamping patterns (not shown) on its outer peripheral surface. The pattern roll 48 and the anvil roll 50 are in contact with each other at their outer peripheral surfaces, and are pressed so that a predetermined load (foil stamping load) acts on each other in the TD direction (radial direction) at the contact portion. . The pattern roll 48 and the anvil roll 50 rotate in opposite directions (arrow direction in FIG. 5) at the same peripheral speed.

The material supply unit 44 includes a supply roll 51 and a take-up roll 52 . The supply roll 51 is arranged on the upstream side of the foil forming section 42 , has a material sheet continuum 53 wound thereon, and supplies the material sheet continuum 53 . As shown in FIG. 6, the material sheet continuum 53 has the same configuration as the material sheet 14 except that it is strip-shaped. The take-up roll 52 is arranged on the downstream side of the foil forming section 42 and winds up the decorative sheet continuous body 54 on which the material sheet continuous body 53 is stamped with foil. The material supply unit 44 may apply tension in the MD direction to the material sheet continuum 53 . The tension may range, for example, from 6N to 60N. When tension is applied to the material sheet continuum 53 in the MD direction, the orientation direction of the nonwoven fabric 12 of the material sheet continuum 53 is preferably along the MD direction. That is, the orientation of the fibers of the nonwoven fabric 12 of the material sheet continuum 53 is relatively larger in the MD direction than in the CD direction.

The foil supply section 46 comprises a foil supply roll 55 and a foil take-up roll 56 . The foil supply roll 55 is arranged on the upstream side of the foil forming section 42 , has a transfer film 57 wound thereon, and supplies the transfer film 57 . The foil take-up roll 56 is arranged on the downstream side of the foil forming section 42 and winds up the transfer film 57 after transferring the foil corresponding to the pattern onto the material sheet continuous body 53 into a roll. The transfer film 57 is a strip-shaped member made of the foil, and has a metal layer containing metal and an adhesive layer containing a synthetic resin adhesive provided on one side surface of the metal layer.

The foil forming section 42 may have a heating section (not shown) that heats the material sheet continuous body 53 . For example, the heating section may be provided on at least one of the pattern roll 48 and the anvil roll 50 . A pattern roll 48 provided with a heating portion heats the material sheet continuous body 53 from the first surface 22 side. The anvil roll 50 provided with a heating portion heats the material sheet continuous body 53 from the base surface 25 side. An electric heater, for example, can be applied to the heating unit. The electric heater may be provided integrally inside the pattern roll 48 and the anvil roll 50 .

The heating unit preferably heats the material sheet continuous body 53 so that the temperature on the first surface 22 side, which is the side to be foil-stamped, is higher than that on the base surface 25 side. The temperature for heating the material sheet continuum 53 is preferably a temperature equal to or higher than the softening point of the nonwoven fabric 12 . As used herein, the term “softening point” means the “endothermic start temperature” when measuring the endothermic behavior of changing from a solid state to a liquid state with a differential scanning calorimeter at a heating rate of 10° C./min. .

The material sheet continuous body 53 is continuously supplied in the MD direction with the first surface 22 (foil stamping surface 23) facing the pattern roll 48 side. The transfer film 57 is continuously supplied in the MD direction between the pattern roll 48 and the first surface 22 of the continuous material sheet 53 . Thereby, the material sheet continuous body 53 is transported between the pattern roll 48 and the anvil roll 50 with the transfer film 57 superimposed on the first surface 22 . The material sheet continuum 53 contacts the anvil roll 50 at the base surface 25 .

When the material sheet continuous body 53 passes through the foil forming section 42, the pattern roll 48 and the anvil roll 50 are pressed against each other with a predetermined load. It is pushed into the continuum 53 . Next, the material sheet continuum 53 is separated from the first surface 22 by passing through the foil forming section 42 . By winding up the transfer film 57 with the foil take-up roll 56, the transfer film other than the adhered foil is separated from the first surface 22, and the adhered portion of the foil remains on the first surface 22, forming the display layer 16. be done. The decorative sheet continuous body 54 on which the display layer 16 is formed is wound up by the winding roll 52 . The decorative sheet 10 is obtained by cutting the decorative sheet continuous body 54 into a predetermined size. In this way, the display layer 16 is formed on the first surface 22 and the decorative sheet 10 is obtained by bringing the portion corresponding to the pattern into close contact with the material sheet continuous body 53 .

The material sheet continuum 53 has a compression energy WC value of 0.294 N·m/m ² or more and 1.960 N·m/m ^{2 or} less measured by the test method described above. Since the compression energy WC value is 0.294 N·m/m ² or more, the material sheet 14 has a sufficient cushioning property, and is pressed by the pattern, and is deformed more reliably. When the compression energy WC value is 1.960 N·m/m ² or less, the pattern can be prevented from sinking deeply into the material sheet 14 and the pattern can be more reliably pushed into the material sheet 14 . By using the nonwoven fabric 12 having the compression energy WC value within the above range, the nonwoven fabric 12 can be reliably deformed even by the rotary method, so that the display layer 16 can be brought into close contact with the first surface 22. . Therefore, even with the rotary method, the display layer 16 showing the pattern can be stably formed on the first surface 22 . Thus, the method for manufacturing the decorative sheet 10 can efficiently and stably form the display layer 16 on the first surface 22 . When the compression energy WC value is 0.343 N·m/m ² or more and 0.784 N·m/m ² or less, the nonwoven fabric 12 can be deformed more reliably, so that the display layer 16 adheres to the first surface 22. more improved.

When the density of the material sheet 14 is 70 kg/m ³ or more and 350 kg/m ³ or less, there are few voids between the fibers of the nonwoven fabric 12 and the area that can be in contact with the transfer film increases. Therefore, in the manufacturing method of the decorative sheet 10, when the density of the material sheet 14 is within the above range, the contact area between the foil and the nonwoven fabric 12 is increased, coupled with the effect obtained by the compression energy WC value being within the above range. Therefore, the adhesion between the display layer 16 and the first surface 22 is further improved. When the material sheet 14 has a compression energy WC value of 0.381 N·m/m ² or more and 0.700 N·m/m ² or less and a density of 180 kg/m ³ or more and 200 kg/m ³ or less, the foil and the nonwoven fabric Since the contact area between the display layer 12 and the first surface 22 is further increased, the effect of improving the adhesion between the display layer 16 and the first surface 22 can be obtained more reliably in combination with the effect obtained by setting the compression energy WC value within the above range.

By having the film 34 bonded to the second surface 24 of the nonwoven fabric 12 , the material sheet continuous body 53 can adjust the compression energy WC value of the material sheet continuous body 53 . Specifically, by bonding the film 34 to the second surface 24 of the nonwoven fabric 12 having a compression energy WC value of less than 0.294 N·m/m ² , the compression energy WC value is increased to 0.294 N·m/m ² or more. can be Since the material sheet continuum 53 having the film 34 bonded to the second surface 24 in this way has increased rigidity as a whole and uniform cushioning properties, the adhesiveness between the foil and the first surface 22 of the nonwoven fabric 12 is increased. improves. Therefore, according to the method for manufacturing the decorative sheet 10 , the display layer 16 can be efficiently and stably formed on the first surface 22 of the nonwoven fabric 12 .

Since the material sheet 14B includes the film 34 on the second surface 24 of the nonwoven fabric 12, it is possible to further suppress the smoothness of the display layer 16 from being affected by the unevenness of the base below the material sheet 14B. Therefore, the display layer 16 can be evenly joined onto the nonwoven fabric 12, and the visibility can be improved, and it can be made difficult to peel off. Since the thickness of the material sheet 14B is increased by the amount of the laminated film 34, pressure is easily applied between the foil and the material sheet 14B during the foil stamping process of the display layer 16, and the foil is attached to the material sheet 14B. Easier to load.

When the heating unit heats the material sheet continuous body 53 , the heat melts the adhesive layer of the transfer film 57 , and the first surface 22 more securely adheres. Therefore, by heating the material sheet continuous body 53 with the pattern roll 48 or the anvil roll 50, the display layer 16 can be formed on the first surface 22 more stably.

When the heating unit heats the material sheet continuum 53 above the softening point of the nonwoven fabric 12, the material sheet continuum 53 pushed by the pattern roll 48 melts. At the same time, the adhesive layer of the transfer film 57 corresponding to the pattern melts and adheres to the first surface 22 . Next, the material sheet continuum 53 is separated from the first surface 22 by passing through the foil forming section 42 . The continuous material sheet 53 is cooled by leaving the surfaces of the pattern roll 48 and the anvil roll 50 , and the molten adhesive layer adheres to the first surface 22 . The fibers of the nonwoven fabric 12 heated above the softening point change from solid to liquid. Although the nonwoven fabric 12 has greater variations in basis weight and surface irregularities than paper or leather, it is smoothed by heat. The liquefied portion of the nonwoven fabric 12 and the melted adhesive layer of the transfer film 57 adhere to each other, so that the display layer 16 is more firmly attached to the first surface 22 .

When the material supply unit 44 applies tension in the MD direction to the material sheet continuum 53, as shown in FIG. The thickness increases due to the occurrence of wavy undulations. That is, when no tension is generated, the thickness of the material sheet 14 is the thickness T1 of the nonwoven fabric (the total if the film 34 is included) 12 itself (FIG. 6). When tension in the MD direction is applied to the material sheet 14, portions of the material sheet 14 with low fiber basis weight and low strength become peaks 39 or valleys 41, and a plurality of undulations occur in the direction (CD direction) crossing the direction of tension (MD direction). occurs. Therefore, the thickness of the material sheet 14 when there are wavy undulations is the height difference of the undulations. As a result, the apparent thickness of the material sheet 14, that is, the volume increases by the undulations, and the distance between the fibers in the CD direction is reduced, so that the basis weight of the fibers is made more uniform.

The vertically bulked sheet of material 14, as shown in FIG. and make contact. As a result, the contact time between the pattern roll 48 and the anvil roll 50 in the material sheet continuum 53 increases, so the amount of heat transferred from the pattern roll 48 and the anvil roll 50 increases. Since the material sheet continuous body 53 and the transfer film 57 are heated more reliably, the adhesiveness between the foil and the first surface 22 of the nonwoven fabric 12 is improved. Therefore, the method for manufacturing the decorative sheet 10 can more stably form the display layer 16 on the first surface 22 . In this case, if the orientation direction of the fibers of the nonwoven fabric 12 is along the MD direction, the material sheet 14 can be easily stretched by applying tension in the MD direction. Therefore, the vertical bulk of the material sheet 14 can be increased more easily, and as a result, the adhesion between the foil and the first surface 22 of the nonwoven fabric 12 can be further improved.

The heating unit efficiently heats the transfer film 57 by heating the material sheet continuous body 53 so that the temperature of the first surface 22 side, which is the side to be foil-stamped, is higher than that of the base surface 25 side. be able to. By efficiently heating the transfer film 57, the adhesive layer of the transfer film 57 can be reliably melted, so that the adhesion of the display layer 16 can be further enhanced. When using the material sheet continuous body 53 having the film 34 on the second surface 24 of the nonwoven fabric 12, the temperature on the side of the base surface 25 is lower than the temperature on the side of the first surface 22, so that the heat shrinkage is less than that of the nonwoven fabric 12. It is possible to avoid heat shrinkage of the film 34 which is prone to shrinkage.

The method for manufacturing the decorative sheet 10 may include a step (preheating step) of preheating the material sheet continuous body 53 before the step of forming foil in the foil forming section 42 (foil stamping step). The preheating step is not particularly limited, and for example, the material sheet continuous body 53 may be heated by applying gas heated to a predetermined temperature to the material sheet continuous body 53 on the upstream side of the foil forming section 42. . Alternatively, as shown in FIG. 9, the material sheet continuous body 53 may be wrapped around the anvil roll 50 so as to be folded back and preheated. In this case, the material sheet continuous body 53 is supplied to the foil forming section 42 from the upstream side, wound around the anvil roll 50 from the lower side in the TD direction, and transported from the upper side of the anvil roll 50 in the TD direction to the upstream side. be done. The base surface 25 of the material sheet continuum 53 is in contact with the outer peripheral surface of the anvil roll 50 over half the circumference. In this way, by lengthening the contact time of the material sheet continuous body 53 with the anvil roll 50, the material sheet continuous body 53 can be preheated. The preheated material sheet continuous body 53 is subjected to foil stamping by the pattern roll 48 on the upper side of the anvil roll 50 in the TD direction. By preheating the material sheet continuous body 53 , the adhesive layer of the transfer film 57 is sufficiently melted in the foil stamping process, so that the adhesive permeates the first surface 22 . Therefore, the adhesion between the foil and the first surface 22 can be improved.

When the material sheet continuous body 53 is preheated, it is possible to lower the heating temperature of the pattern roll 48 and the anvil roll 50 as compared with the case where the material sheet continuous body 53 is not preheated. Therefore, thermal damage to the material sheet continuous body 53 can be suppressed. . By preheating, even if the speed of passing through the foil forming part 42 is increased, a predetermined amount of heat can be transferred to the material sheet continuous body 53, and the display layer 16 can be stably formed on the first surface 22. Production efficiency can be improved.

The preheating temperature is preferably lower than the softening point of the nonwoven fabric 12 and closer to the softening point. Assuming that the preheating temperature is tp and the softening point is t, the preheating temperature tp is preferably in the range of (t−10)≦tp<t. By preheating to a temperature closer to the softening point of the nonwoven fabric 12 , the softening point of the nonwoven fabric 12 can be reached in a shorter time in the foil-forming portion 42 , so that the display layer 16 can be applied more efficiently to the first surface 22 . can be adhered to.

(decorative sheet)
Conventional foil-stamped pieces of paper, leather, and the like have concave portions in the foil-stamped portions, but the portions other than the foil-stamped portions are flat, giving a simple impression.

On the other hand, the decorative sheet 10 manufactured by the manufacturing method of the present embodiment has a difference in height between the first region 18 and the second region 20, so that the display layer 16 can stand out more three-dimensionally. Therefore, the decorative sheet 10 can further improve the visibility of the display layer 16, and can give a high-class feeling. Furthermore, since the decorative sheet 10 is manufactured by the manufacturing method of the above embodiment, the display layer 16 showing the pattern is stably formed on the surface of the nonwoven fabric 12 .

In the decorative sheet 10 , the display layer 16 is formed not only on the main portion 30 of the concave portion 26 but also on the edge portion 32 . Here, the surface of the edge portion 32 is an inclined surface that is inclined with respect to the surface of the main portion 30 . Therefore, the reflection direction of the light incident on the display layer 16 differs between the main portion 30 and the edge portion 32 . Further, if the edge 32 surrounds the main portion 30, the position of the edge 32 relative to the main portion 30 will cause the slopes to face in different directions. In that case, the reflection direction of the light incident on the display layer 16 is directed in various directions depending on the position of the edge portion 32 . By forming the display layer 16 also on the edge portion 32 in this manner, the display layer 16 can be visually recognized from various directions, and the visibility of the display layer 16 can be improved.

[Modification]
The nonwoven fabric 12 may be thermally compressed (pressed). In this case, the fibers of the nonwoven fabric 12 are heat-sealed or heat-pressed to improve the smoothness. Therefore, it is possible to further suppress the smoothness of the display layer 16 from being affected by the unevenness of the base below the material sheet 14 . Therefore, the display layer 16 can be evenly joined onto the nonwoven fabric 12, and the visibility can be improved, and it can be made difficult to peel off. In addition, when the decorative sheet 10 is smoothed by heat pressing or the like (including the case where the material sheet 14 is originally smooth), the entire display layer 16 including the display layer 16 becomes very smooth, so that it is tactile. Also, the display layer 16 can be more easily confirmed.

A base coat layer (not shown) may also be provided between the nonwoven fabric 12 and the display layer 16 . In that case, the first surface 22 of the nonwoven fabric 12 can be covered with a base coat to improve smoothness. Therefore, it is possible to further suppress the smoothness of the display layer 16 from being affected by the unevenness of the base below the material sheet 14 . Therefore, the visibility of the display layer 16 can be improved, and it can be made difficult to peel off.

A topcoat layer (not shown) may also be provided over the display layer 16 on the nonwoven fabric 12 . In that case, since the top coat layer is provided on the display layer 16, deformation of the display layer 16 is suppressed, and unevenness and wrinkles can be suppressed. Therefore, since the smoothness of the surface of the display layer 16 is maintained, the visibility of the display layer 16 can be improved and the peeling of the display layer 16 can be prevented.

EXAMPLES The present invention will be described below with reference to Examples, but the present invention is not limited to these Examples.
(A) Sample A nonwoven fabric continuous body made of a plurality of nonwoven fabrics with different types and basis weights, and a film continuous body made of films with different thicknesses (PP: polypropylene) are prepared, and the nonwoven fabric continuous body is used alone, or A film continuous body was laminated on the nonwoven fabric continuous body as needed to prepare a plurality of types of material sheet continuous bodies. A transfer film having a thickness of 0.017 mm and comprising a base film, a release layer, a colored layer, a deposition layer, and an adhesive layer was prepared. Using the continuous material sheet and the transfer film, a decorative sheet was manufactured according to the procedure described in the above manufacturing method. The heating temperature of the pattern roll was 140°C, and the heating temperature of the anvil roll was 80°C. The material sheet continuum was conveyed between the pattern roll and the anvil roll at a tension of 30 N and a conveying speed of 20 m/min with a foil stamping pressure of 0.3 MPa.

(B) Evaluation Adhesion was evaluated for the decorative sheets of Examples 1 to 10 and Comparative Examples 1 to 9. Table 1 shows the evaluation results. Adhesion was evaluated by observing the appearance and performing a peeling test on the display layer of the obtained decorative sheet. When the display layer was not in close contact with the external appearance, the adhesion was evaluated as poor. A peeling test was performed on the display layer in which no chipping occurred in the appearance observation. In the peeling test, Cellotape (registered trademark) manufactured by Nichiban Co., Ltd. was attached so as to cover the display layer, finger pressure was applied, and the display layer was slowly peeled off from one end in a direction of 90 degrees to the surface of the display layer. As a result, in the peeling test, the adhesive tape was evaluated to have good adhesion when a small amount of metal powder was peeled off from the adhesive tape, and the adhesive tape was evaluated to have excellent adhesion when no peeling occurred in the peeling test. It was evaluated as ⊚. Table 1 shows the results.

In Examples 1 to 10, the compression energy WC value of the material sheet was 0.294 N·m/m ² or more and 1.960 N·m/m ² or less, and good adhesion was obtained.
In Examples 1 to 10, the density of the material sheet was 70 kg/m ³ or more and 350 kg/m ³ or less, and good adhesion was obtained.
In Examples 1 to 4, the compression energy WC value of the material sheet is 0.343 N·m/m ² or more and 0.784 N·m/m ² or less, and the density of the material sheet is 180 kg/m ³ or more and 200 kg/m ³ or less. and the adhesion was superior.
On the other hand, in Comparative Examples 1 to 9, since the compression energy WC value of the material sheet was outside the range of 0.294 N·m/m ² or more and 1.960 N·m/m ² or less, good adhesion was obtained. I couldn't.

For 10 samples of the decorative sheets according to the above examples, the thickness of the decorative sheet was measured in the first region outside the display layer parallel to the orientation direction with respect to the display layer. Next, the thickness of the decorative sheet was measured in a second region outside the display layer, which intersects the display layer in the alignment direction. As a result, the thickness of the first region was 134% on average with respect to the thickness of the second region. Therefore, it was confirmed that the manufacturing method of the present embodiment can obtain a decorative sheet in which the first region is thicker than the second region and the display layer appears to stand out three-dimensionally.

10 Decorative sheet 12 Nonwoven fabric 14 Material sheet 16 Display layer 22 First surface 24 Second surface 34 Film 48 Pattern roll 50 Anvil roll 53 Material sheet continuum 54 Decorating sheet continuum 57 Transfer film

Claims (7)

a sheet of material having a nonwoven fabric comprising a first surface and a second surface opposite the first surface;
a display layer disposed on the first surface;
A method for manufacturing a decorative sheet comprising
A transfer film having a foil and the material sheet are overlapped and conveyed between a pattern roll having a pattern for foil stamping on the outer peripheral surface and an anvil roll arranged to face the pattern roll, and the first A foil stamping step of forming the display layer by crimping the foil corresponding to the pattern from the transfer film on the surface,
The compression energy WC value of the material sheet is 0.294 N·m/m ² or more and 1.960 N·m/m ² or less,
The density of the material sheet is 70 kg/m ³ or more and 350 kg/m ³ or less.
A method for manufacturing a decorative sheet. 2. The method of manufacturing a decorative sheet according to claim 1, wherein said foil stamping step conveys said material sheet between said pattern roll and said anvil roll while applying tension to said material sheet in the conveying direction. 3. The method for manufacturing a decorative sheet according to claim 2, wherein the orientation direction of fibers of said nonwoven fabric is along said conveying direction. The method for producing a decorative sheet according to any one of claims 1 to 3 , wherein the material sheet has a film laminated on the second surface. The method for producing a decorative sheet according to any one of claims 1 to 4 , comprising a preheating step of preheating the material sheet before the foil stamping step. The method of manufacturing a decorative sheet according to claim 5 , wherein the preheating step heats the first surface to a temperature higher than that of the second surface. The method for producing a decorative sheet according to any one of claims 1 to 6 , wherein the temperature of the first surface in the foil stamping step is equal to or higher than the softening point of the nonwoven fabric.

Images