JP7559443B2 - Decorative sheet, display device with decorative sheet, manufacturing method for decorative sheet, and manufacturing method for display device with decorative sheet - Google Patents

Description

The present invention relates to a decorative sheet, a display device with a decorative sheet, a method for manufacturing a decorative sheet, and a method for manufacturing a display device with a decorative sheet.

Conventionally, as disclosed in Patent Document 1, for example, a decorative sheet (screen) that is used by being overlaid on a display device has been publicly known. This decorative sheet has a picture section that displays a picture, and a transparent section consisting of an opening provided in the picture section. The transparent section passes image light from a display device arranged behind the decorative sheet, making it possible to observe the image formed by the display device. The picture section displays a picture when the display device is stopped displaying. In other words, the decorative sheet allows the display device to display the desired image, while concealing the display device that is not displaying, and by displaying a picture, it is possible to add design to the installation area of the display device.

JP 2001-331132 A

The display surface of the display device is located behind the decorative sheet that displays the design. Of the image light emitted from the display surface of the display device, the image light that passes through the transparent portion of the decorative sheet forms the image observed by the observer. For this reason, in a display device with a decorative sheet that includes a decorative sheet and a display device, the angle range at which an image can be observed, i.e., the viewing angle, tends to be narrow.

To widen the viewing angle, it is possible to place a light diffusion sheet on the observer side of the decorative sheet. However, when a light diffusion sheet is placed on the observer side of the decorative sheet, the clarity of the image displayed by the picture portion decreases. The decrease in clarity of the image can be said to be a fatal defect that undermines the purpose of installing the decorative sheet, which is to improve the design in the area where the display device is placed.

The present invention was made in consideration of the above points, and aims to expand the viewing angle of an image while maintaining the clarity of the image on a display device with a decorative sheet.

The decorative sheet according to the present invention is
a base member having a first surface and a second surface opposed to each other;
A pattern portion is provided on the first surface side of the base portion and located only on the first region of the base portion,
The first surface of the base member has an uneven surface at least in a second region other than the first region.

In the decorative sheet according to the present invention, the first surface of the base material may have the uneven surface only in the second region.

In the decorative sheet according to the present invention, the picture portion may have a design layer that displays the picture, and a light-shielding layer provided on the side of the design layer opposite the base portion.

In the decorative sheet according to the present invention, the first surface of the base material may have a recess, and the uneven surface may be provided within the recess.

In the decorative sheet according to the present invention, the depth of the recess may be smaller than the thickness of the pattern portion.

In the decorative sheet according to the present invention, the light-shielding layer includes a first light-shielding layer and a second light-shielding layer stacked on each other,
The first and second light blocking layers may have different colors.

In the decorative sheet according to the present invention, the first light-shielding layer and the second light-shielding layer may have different thicknesses.

In the decorative sheet according to the present invention, the pattern portion may have an uneven surface on the side opposite to the base portion.

The display device with a decorative sheet according to the present invention comprises:
Any of the decorative sheets according to the present invention described above;
and a display device on which the decorative sheet is overlaid.

The method for producing a decorative sheet according to the present invention includes the steps of:
A step of providing a blast mask on the side of the pattern film of a laminate having a base film and a pattern film laminated on the base film;
and a step of blasting the laminate through the blast mask to pattern the pattern film to form a pattern portion.

In the blasting process of the method for producing a decorative sheet of the present invention, recesses may be formed in areas of the base film that are not covered by the blast mask.

In the method for manufacturing a decorative sheet of the present invention, the thickness of the blast mask may be greater than the thickness of the pattern film.

In the method for manufacturing a decorative sheet of the present invention, the thickness of the blast mask may be less than twice the thickness of the pattern film.

In the decorative sheet of the present invention, the picture film may have a design film that displays a picture and a light-shielding film provided on the opposite side of the design film from the substrate.

In the decorative sheet of the present invention, the blast mask may have a color different from that of the light-shielding film.

In the decorative sheet of the present invention, the blast mask after the blasting process may have a thickness different from that of the light-shielding film.

In the method for manufacturing a decorative sheet of the present invention, in the step of providing the blast mask, the blast mask may be provided on the laminate by screen printing.

In the method for producing a decorative sheet of the present invention, the pattern film includes a design film having a pattern formed thereon,
In the step of providing the blast mask, the blast mask may be provided on the laminate by screen printing so as to be adjacent to the decorative film.

In the decorative sheet of the present invention, the step of providing the blast mask may include a step of providing a resist layer on the laminate and a step of patterning the resist layer to form the blast mask.

The decorative sheet of the present invention may further include a step of removing the blast mask after the step of performing the blast processing.

In the decorative sheet of the present invention, the blast mask may be used as part of the pattern portion.

The method for manufacturing a display device with a decorative sheet according to the present invention includes the steps of:
The manufacturing method of the decorative sheet described above;
and laminating the decorative sheet on a display device.

The present invention makes it possible to expand the viewing angle of an image while maintaining the clarity of the image.

FIG. 1 is a diagram for explaining one embodiment, and is an exploded perspective view that shows a schematic example of a display device with a decorative sheet. FIG. 2 is a cross-sectional view of the display device with the decorative sheet of FIG. FIG. 3 is a plan view showing the display device with the decorative sheet of FIG. 1, showing the display device in a display state. FIG. 4 is a plan view showing a light-shielding sheet included in the display device with the decorative sheet of FIG. FIG. 5 is a partially enlarged plan view showing an example of the decorative sheet included in the display device with the decorative sheet of FIG. FIG. 6 is a cross-sectional view of the decorative sheet. FIG. 7 is a diagram for explaining an example of a method for manufacturing the decorative sheet of FIG. FIG. 8 is a diagram for explaining an example of a method for manufacturing the decorative sheet of FIG. FIG. 9 is a diagram for explaining an example of a method for manufacturing the decorative sheet of FIG. FIG. 10 is a diagram for explaining an example of a method for manufacturing the decorative sheet of FIG. FIG. 11 is a diagram for explaining an example of a method for manufacturing the decorative sheet of FIG. FIG. 12 is a cross-sectional view corresponding to FIG. 2, showing another example of a display device with a decorative sheet. FIG. 13 is a cross-sectional view corresponding to FIG. 6, showing another example of the decorative sheet. FIG. 14 is a cross-sectional view corresponding to FIG. 6, showing still another example of the decorative sheet. FIG. 15 corresponds to FIG. 9 and is a diagram for explaining another example of the method for producing the decorative sheet. FIG. 16 corresponds to FIG. 11 and is a diagram for explaining another example of the method for producing the decorative sheet. FIG. 17 is a view corresponding to FIG. 5 and is a partially enlarged plan view showing still another example of the decorative sheet. FIG. 18 is a view corresponding to FIG. 5 and is a partially enlarged plan view showing still another example of the decorative sheet. FIG. 19 is a plan view showing a pixel array of a display device included in a display device with a decorative sheet.

One embodiment of the present invention will be described below with reference to the drawings, with reference to the illustrated specific example. Note that in the drawings attached to this specification, the scale and aspect ratios have been appropriately altered and exaggerated from those of the actual objects for the convenience of illustration and ease of understanding.

In this specification, the terms "layer," "sheet," and "film" are not distinguished from one another solely on the basis of differences in name. For example, the term "layer" is a concept that includes members that may be called sheets or films.

In addition, terms used in this specification that specify shapes, geometric conditions, and the extent of those conditions, such as "parallel," "perpendicular," and "same," as well as values of lengths and angles, are to be interpreted without being bound by strict meanings, but rather to include the range within which similar functions can be expected.

Figure 1 is an exploded perspective view that shows a schematic diagram of a display device with a decorative sheet 1 according to an embodiment of the present invention. As shown in Figure 1, the display device with a decorative sheet 1 has a display device 10 having a display surface 11, and a decorative sheet 20 arranged opposite the display surface 11. In the illustrated example, the display device with a decorative sheet 1 is shown as a flat plate, but each component of the display device with a decorative sheet 1 may be curved so that the display device with a decorative sheet 1 has a curved shape. For example, only the decorative sheet 20 may be curved, or the decorative sheet 20 and at least the display surface 11 of the display device 10 may be curved.

This display device 1 with decorative sheet can be in a non-display state shown in FIG. 1 and a display state shown in FIG. 3. In the non-display state shown in FIG. 1, a pattern formed on the pattern portion 24 of the decorative sheet 20 can be displayed. In the display state shown in FIG. 3, an image formed by the display device 10 can be displayed. In the display device 1 with decorative sheet and the decorative sheet 20 according to this embodiment, a design has been made to realize a wide viewing angle of the image displayed by the display device 10 while ensuring sufficient clarity of the pattern displayed on the decorative sheet.

First, the configuration of the display device 1 with decorative sheet will be explained with reference to the illustrated specific example.

Various devices for displaying images can be used as the display device 10. Typically, the display device 10 can be a device that displays an image by emitting image light from the display surface 11.

In the example shown in FIG. 2, the display device 10 has a surface light source device 12 and a light-shielding sheet 14. The surface light source device 12 is a device that emits light in a planar manner. The surface light source device 12 has a light-emitting surface 13 that emits light. The surface light source device 12 is not particularly limited, and various types of devices, such as edge-light type and direct type devices, can be used.

The light-shielding sheet 14 is disposed on the light-emitting surface 13 of the surface light source device 12. The light-shielding sheet 14 forms the display surface 11 of the display device 10. As shown in FIG. 4, which is a plan view of the light-shielding sheet 14, the light-shielding sheet 14 is divided into an opening region 14a having the same pattern as the pattern of the image to be displayed, and a light-shielding region 14b adjacent to the opening region 14a. The light-shielding region 14b has visible light absorption properties and blocks the light emitted by the surface light source device 12. The light-shielding region 14b can be made using a resin material containing a black pigment or the like. More specifically, it can be made using a material similar to the light-shielding layer 32 of the pattern portion 24 described later. The opening region 14a is a transparent or open region that transmits the light emitted by the surface light source device 12. In other words, the light-shielding sheet 14 functions as a light-shielding mask that transmits light in a desired pattern. In one example of the light-shielding sheet 14 shown in FIG. 5, the opening region 14a has the shape of the alphabet "D".

As used herein, "transparent" means that the visible light transmittance, specified as the average value of the transmittance at each wavelength when measured using a spectrophotometer (Shimadzu Corporation's "UV-3100PC", compliant with JIS K 0115) in the measurement wavelength range of 380 nm to 780 nm, is 70% or more, and preferably 80% or more.

The illustrated display device 10 configured as described above can display the letter "D" as a still image when the surface light source device 12 emits light. In addition, by changing the light-shielding sheet 14, i.e., by using a different light-shielding sheet 14, various images can be displayed inside the outer contour of the light-emitting surface 13. From this point of view, the display surface 11 of the illustrated display device 10 can be said to be the area facing the light-emitting surface 13.

However, the display device 10 is not limited to the example shown in FIG. 2. For example, the light-emitting surface 13 of the surface light source device 12 may have the same pattern as the pattern of the displayed image, and the light-shielding sheet 14 may be omitted. In addition, a device that displays moving images, for example, may be used as the display device 10. Specifically, as will be described later, a dot-matrix display device 10 may be used. In the dot-matrix display device 10, the desired image can be formed by individually controlling the light-emitting state of the pixels that form the dots.

Next, the decorative sheet 20 will be described. As shown in FIG. 1 and FIG. 2, the decorative sheet 20 is disposed facing the display surface 11 of the display device 10, and covers at least the entire display surface 11 so that the display surface 11 is not directly observed from the outside. The decorative sheet 20 has dimensions equal to or larger than the dimensions of the display surface 11 so as to cover the entire display surface 11 of the display device 10. The illustrated decorative sheet 20 has dimensions covering the entire area of the front surface of the display device 10, including the display surface 11 and the peripheral area 11a located around the display surface 11. In other words, the decorative sheet 20 conceals the entire display device 10. In the example shown in FIG. 1, the decorative sheet 20 is a flat plate-shaped member that extends in the same direction as the display surface 11 of the display device 10 as a whole. The thickness of the decorative sheet 20 can be, for example, 20 μm or more and 550 μm or less.

In the illustrated example, the decorative sheet 20 has a rectangular shape in a plan view. As shown in FIG. 1, the decorative sheet 20 includes a first end side 20a and a second end side 20b that extend parallel to each other as long sides, and a third end side 20c and a fourth end side 20d that extend parallel to each other as short sides. As shown in FIG. 1, the first end side 20a and the second end side 20b extend linearly in a first direction DS1, and the third end side 20c and the fourth end side 20d extend linearly in a second direction DS2 perpendicular to the first direction DS1.

In order to clarify the directional relationships between the drawings, some of the drawings show the first direction DS1 and the second direction DS2, as well as the normal direction ND perpendicular to both the first direction DS1 and the second direction DS2, as directions common to the drawings. Also, an arrow pointing into the paper in a direction perpendicular to the paper surface of the drawing is shown by a symbol with an X in a circle, as shown in Figure 2, for example. An arrow pointing out from the paper in a direction perpendicular to the paper surface of the drawing is shown by a symbol with a dot in a circle, as shown in Figure 4, for example.

The decorative sheet 20 displays a pattern and imparts design to the display device 1 with the decorative sheet. As shown in FIG. 2, the decorative sheet 20 has a base portion 21, a pattern portion 24, and a transmissive portion 26 provided as an opening of the pattern portion 24. The pattern portion 24 further includes a design layer 31 that displays the pattern, and a light-shielding layer 32. In the illustrated example, the transmissive portion 26 transmits image light from the display device 10. That is, the image formed by the display device 10 can be observed through the transmissive portion 26. The illustrated decorative sheet 20 has a base portion 21 at a position facing the pattern portion 24 and the transmissive portion 26 in the normal direction ND. Each component of the decorative sheet 20 will be described below.

First, the substrate 21 that supports the pattern portion 24 will be described. As shown in FIG. 2 and FIG. 6, the substrate 21 has a first surface 21a and a second surface 21b that face each other. The substrate 21 is a transparent film-like member, and the first surface 21a and the second surface 21b form a pair of main surfaces. In the example shown in FIG. 2, the substrate 21 is located on the side of the display device 1 with the decorative sheet that is farthest from the display device 10. In other words, the pattern portion 24 is supported by the substrate 21 on the side of the display device 10. A resin film can be used as the substrate 21. The substrate 21 may be any material that transmits visible light and can properly support the pattern portion 24, and examples of such materials include polymethylmethacrylate, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polystyrene, cyclic polyolefin, and ABS (acrylonitrile butadiene styrene copolymer). Considering visible light transmittance and appropriate support for the pattern portion 24 and the transparent portion 26, it is preferable that the substrate portion 21 has a thickness of 10 μm or more and 500 μm or less.

Next, the pattern portion 24 and the transmissive portion 26 will be described in order. As shown in FIG. 2 and FIG. 6, the pattern portion 24 is provided on the display device 10 side of the substrate 21. The pattern portion 24 is provided so as to contact the first surface 21a of the substrate 21. That is, the pattern portion 24 is directly disposed on the first surface 21a of the substrate 21. The illustrated pattern portion 24 has a design layer 31 and a light-shielding layer 32 that are laminated in order on the substrate 21 in the normal direction ND of the decorative sheet 20. Of these, the light-shielding layer 32 is close to the display device 10 along the normal direction ND of the decorative sheet 20, and the design layer 31 is separated from the display device 10 along the normal direction ND. In the illustrated example, the design layer 31 forms the layer in the pattern portion 24 closest to the viewer.

The design layer 31 forms the design displayed by the decorative sheet 20. The design layer 31 can form designs such as figures, patterns, designs, colors, pictures, photographs, characters, marks, pictograms, letters, and numbers. The design layer 31 can also express a design that displays a background. For example, the design layer 31 may display a wood grain or marble pattern or a geometric pattern as a design that can harmonize with the surrounding environment in which the display device 1 with the decorative sheet is installed. The design layer 31 can be formed, for example, by printing or transfer. The thickness of the design layer 31 can be, for example, 1 μm or more and 20 μm or less.

The light-shielding layer 32 is provided so as to cover the design layer 31 from the side facing the display device 10. In the illustrated example, the light-shielding layer 32 is located between the display device 10 and the design layer 31. The light-shielding layer 32 has a visible light-shielding property so that visible light from the display device 10 does not enter the design layer 31. Therefore, it is preferable that the visible light transmittance of the light-shielding layer 32 is lower than the visible light transmittance of the design layer 31. The light-shielding layer 32 may contain, for example, light-absorbing particles in a binder resin. Examples of light-absorbing particles include black pigments such as carbon black and titanium black. By covering the design layer 31 with a light-shielding layer 32 of sufficient thickness, the design formed by the design layer 31 can be displayed thickly and clearly. As a specific example, the thickness of the light-shielding layer 32 can be set to 1 μm or more and 20 μm or less.

In addition to the design layer 31 and the light-shielding layer 32, the picture portion 24 may further have a base layer between the design layer 31 and the light-shielding layer 32. The base layer is configured as a layer of various colors. By providing the base layer, the color of the back surface of the design layer 31 can be selected without being restricted by the light-shielding layer 32. From the viewpoint of preventing the presence of the light-shielding layer 32 from affecting the design expression of the design layer 31, it is preferable that the base layer is white. A white design layer 31 also increases the reflectance (especially the scattered reflectance), allowing the design to be displayed clearly.

Next, the transparent portion 26 will be described. The transparent portion 26 is a portion of the decorative sheet 20 through which the image light from the display device 10 passes. Therefore, the transparent portion 26 is a portion that has high visible light transmittance. The transparent portion 26 is configured as an opening provided in the picture portion 24. In other words, the transparent portion 26 is configured as a non-formed portion of the picture portion 24. In the example shown in FIG. 2, the transparent portion 26 opens toward the display device 10.

As shown in FIG. 5, the decorative sheet 20 in plan view is divided into a pattern portion 24 and a transparent portion 26. In particular, in the illustrated example, a plurality of transparent portions 26 are dispersed within the pattern portion 24. In the illustrated decorative sheet 20, the plurality of transparent portions 26 are arranged in the first direction DS1 and the second direction DS2. The plurality of transparent portions 26 are arranged regularly. More specifically, the plurality of transparent portions 26 are arranged in a lattice array. That is, in the illustrated example, the plurality of transparent portions 26 are arranged at a constant pitch in the first direction DS1, and are also arranged at a constant pitch in the second direction DS2. The illustrated transparent portion 26 has a circular shape in plan view.

However, the arrangement of the transparent portions 26 and the pattern portions 24 is not limited to the illustrated example, and can be changed in various ways. The transparent portions 26 may have a shape other than a circle in a plan view, for example, an ellipse, a triangle, a rectangle, a pentagon, etc. Furthermore, the arrangement of the multiple transparent portions 26 is not limited to the lattice arrangement illustrated, and may be a honeycomb arrangement or an irregular arrangement. Furthermore, the multiple transparent portions 26 may be arranged in one direction, and each transparent portion 26 may extend linearly in another direction that is not parallel to the one direction. In other words, the multiple transparent portions 26 may be arranged in a stripe pattern.

The ratio of the area of the transparent portion 26 to the area of the decorative sheet 20 in a plan view (hereinafter referred to as the "aperture ratio") is preferably 5% or more, more preferably 10% or more, and even more preferably 20% or more, so that the observer can observe the image light from the display device 10 to a practical level. On the other hand, when no image is displayed on the display surface 11 of the display device 10, the decorative sheet 20 displays the design of the picture portion 24. The aperture ratio of the decorative sheet 20 is preferably 30% or less, more preferably 20% or less, and even more preferably 15% or less, so that the observer can clearly observe the design of the decorative sheet 20 to a practical level.

In the present embodiment, as shown in FIG. 6, the base material 21 has an uneven surface 21S, in other words a rough surface, on the first surface 21a, which is the surface on which the pattern portion 24 is provided. In the illustrated example, only the first surface 21a of the base material 21 has the uneven surface 21S. The second surface 21b of the base material is formed as a smooth surface. Therefore, the roughness of the uneven surface 21S included in the first surface 21a is rougher than the roughness of the second surface 21b. In this specification, roughness refers to the roughness evaluated by the arithmetic mean roughness measured in accordance with JIS B 0601-2001.

The substrate 21 has a first region 22 in which a pattern portion 24 is provided, and a second region 23 different from the first region 22. In the illustrated example, the pattern portion 24 is provided only on the first region 22, and the pattern portion 24 is not provided on the second region 23. That is, a transparent portion 26 is formed on the second region 23. The illustrated substrate 21 is composed of a first region 22 and a second region 23. In other words, the illustrated substrate 21 is planarly divided into either the first region 22 or the second region 23. As shown in FIG. 6, the first surface 21a of the substrate 21 includes an uneven surface 21S at least in the second region 23. In the illustrated example, the first surface 21a of the substrate 21 includes an uneven surface 21S only in the second region 23. In particular, the uneven surface 21S is provided in each of the multiple second regions 23 that are distributed. The uneven surface 21S may be formed over the entire area of each second region 23, or the uneven surface 21S may be formed on the portion excluding the peripheral edge of each second region 23. In the illustrated example, the roughness of the uneven surface 21S provided on the first surface 21a of the substrate 21 in the second region 23 is rougher than the roughness of the first surface 21a of the substrate 21 in the first region 22.

As will be described in detail later, the uneven surface 21S is intended to diffuse light passing through the transmission portion 26 to expand the viewing angle of the image displayed by the display device 10. Therefore, the pitch of the convex portions of the uneven surface 21S formed on the first surface 21a of the substrate portion 21 is longer than the wavelength of visible light (380 nm or more and 780 nm or less), for example, 1 μm or more. From the viewpoint of expanding the viewing angle of the image, the arithmetic mean roughness of the uneven surface 21S measured in accordance with JIS B 0601-2001 is preferably 0.7 μm or more and 10 μm or less, more preferably 1 μm or more and 7 μm or less, and even more preferably 2 μm or more and 5 μm or less.

As shown in FIG. 6, the first surface 21a of the substrate 21 has a recess 21c formed thereon. The first surface 21a of the substrate 21 has the recess 21c formed at least in the second region 23. In the illustrated example, the first surface 21a of the substrate 21 has the recess 21c formed only in the second region 23. In particular, the recess 21c is provided in each of the multiple second regions 23 that are dispersedly arranged. The recess 21c may be formed over the entire area of each second region 23, or the recess 21c may be formed in a portion of each second region 23 excluding the peripheral portion.

In the illustrated example, the uneven surface 21S is formed in the recess 21c. In particular, the uneven surface 21S is formed only in the recess 21c. The uneven surface 21S may be formed over the entire area of each recess 21c, or the uneven surface 21S may be formed in a portion excluding the peripheral portion of each recess 21c. Alternatively, the recess 21c may be formed in the area in which the uneven surface 21S is formed. In particular, the recess 21c may be formed only in the area in which the uneven surface 21S is formed. The recess 21c may be formed over the entire area in which each uneven surface 21S is formed, or the recess 21c may be formed in a portion excluding the peripheral portion of the area in which each uneven surface 21S is formed. As shown in FIG. 6, the depth T1 of the recess 21c (the length along the normal direction ND of the recess 21c) is preferably smaller than the thickness T2 of the pattern portion 24 in order to maintain the clarity of the pattern as described later.

Note that some components such as the uneven surface 21S and the recessed portion 21c are omitted in some of the drawings.

In addition, the illustrated decorative sheet 20 has, in addition to the substrate 21 and the pattern portion 24, a cover layer 27 on the side closest to the display device 10 along the normal direction ND. The pattern portion 24 is covered by the substrate 21 from one side in the normal direction ND, and by the cover layer 27 from the other side in the normal direction ND. That is, the pattern portion 24 is located between the substrate 21 and the cover layer 27. The cover layer 27 also extends to the non-formed portion of the pattern portion 24 on the substrate 21. That is, the cover layer 27 forms the translucent portion 26. This cover layer 27 protects the pattern portion 24 and can effectively prevent foreign matter such as dust from entering the translucent portion 26.

It is preferable that the cover layer 27 has a predetermined refractive index difference with the substrate 21. The cover layer 27 is provided adjacent to the uneven surface 21S. The uneven surface 21S functions as a light diffusing surface as described later, and diffuses the image light. Therefore, it is preferable that the refractive index difference between the cover layer 27 and the substrate 21 is 0.1 or more and 0.6 or less. For example, when an acrylic resin having a refractive index of 1.53 to 1.57 is used as the substrate 21 of the decorative sheet 20, a preferable material for the cover layer 27 can be a polymethyl methacrylate resin, a fluorine resin, a silicone resin, a polypropylene, a urethane resin, a polyethylene, a nylon, a polyvinyl chloride, an epoxy, a polycarbonate, a polystyrene, or the like having a refractive index of 1.33 to 1.77. Hollow silica may be mixed into these resins to reduce the refractive index.

Next, an example of a method for manufacturing the decorative sheet 20 having the above configuration will be described.

First, a base film 21A (see FIG. 7) that will form the base part 21 is prepared. As such a base film 21A, a film material made of a transparent resin material used for the base part 21 described above can be used. As shown in FIG. 7, a design film 31A that will form the design layer 31 is formed on this base film 21A. The design film 31A is obtained by providing halftone dots of a predetermined pattern and size distribution on the base film 21A by gravure printing, for example. In this way, the design film 31A is formed on the base film 21A. Next, a light-shielding film 32A that will form the light-shielding layer 32 is provided. The light-shielding film 32A can be formed on the design film 31A by, for example, coating a resin composition containing a material that will form the light-shielding layer 32. In this way, the light-shielding film 32A is formed on the design film 31A. Through the above procedure, a laminate 35 is obtained in which the design film 31A and the light-shielding film 32A are laminated in this order on the base film 21A, as shown in FIG. 8. The thickness of the design film 31A can be 1 μm or more and 20 μm or less, similar to the thickness of the design layer 31 described above. The thickness of the light-shielding film 32A can be 1 μm or more and 20 μm or less, similar to the thickness of the light-shielding layer 32 described above.

Next, a resist layer 36A is formed on the light-shielding film 32A of the laminate 35 (see FIG. 8). The resist layer 36A can be formed, for example, by laminating dry film resist. As a material for the dry film resist, for example, MS7050 manufactured by Mitsubishi Paper Mills Co., Ltd. can be selected. In this manner, the resist layer 36A is formed on the laminate 35. The thickness of the resist layer 36A, i.e., the length of the resist layer 36A along the normal direction ND of the decorative sheet 20, can be, for example, 50 μm or more and 100 μm or less.

Here, the thickness of the resist layer 36A (the length along the normal direction ND of the resist layer 36A) can be greater than the combined thickness of the decorative film 31A (the length along the normal direction ND of the decorative film 31A) and the light-shielding film 32A (the length along the normal direction ND of the light-shielding film 32A). In addition, the thickness of the resist layer 36A can be greater than the combined thickness of the decorative film 31A and the light-shielding film 32A, and less than twice the thickness of the decorative film 31A and the light-shielding film 32A.

Next, the resist layer 36A is exposed from above the pattern mask with the pattern mask placed on it. For example, a first resist region that is exposed and hardened, and a second resist region that is not exposed and hardened by the pattern mask are generated in the resist layer 36A. The first resist region is located in a region that will be on the first region 22 of the substrate of the decorative sheet to be produced, and the second resist region is located in a region that will be on the second region 23 of the substrate of the decorative sheet to be produced. Then, the resist layer 36A is developed with a developer, and the resist layer 36A dissolves in the developer in the second resist region. By the above procedure, a resist pattern 36 is obtained from the resist layer 36A on the laminate 35 as shown in FIG. 9. In the produced resist pattern 36, the remaining portion of the resist layer 36A is located in the area that will be on the first region 22 of the base material 21 of the decorative sheet 20 to be produced, and the dissolved portion of the resist layer 36A is located in the area that will be on the second region 23 of the base material 21 of the decorative sheet 20 to be produced.

Next, as shown in FIG. 10, the laminate 35 is blasted through the resist pattern 36. In this process, the resist pattern 36 is used as a blast mask 37. A blasting material is sprayed from a blasting device M toward the laminate 35 from the side where the blast mask 37 made of the resist pattern 36 is provided. In FIG. 10 and FIG. 11 and FIG. 16, which will be referred to later, the movement of the blasting material is shown by a thick arrow. The blasting material is sprayed from the opening of the blast mask 37 to the laminate 35. The blasting material collides with the pattern film 24A located on the blast mask 37 side of the laminate 35, and erodes the pattern film 24A. That is, the part of the pattern film 24A that is not covered by the blast mask 37, in the illustrated example, the part of the pattern film 24A exposed to the opening of the blast mask 37 is removed. In this way, the light-shielding film 32A and the design film 31A that constitute the pattern film 24A are eroded in order by the blasting process. As a result, the blasting process patterns the pattern film 24A to have a pattern similar to that of the blast mask 37. The patterned pattern film 24A forms the pattern portion 24. In the illustrated example, the light-shielding layer 32 of the pattern portion 24 is formed by the light-shielding film 32A of the patterned pattern film 24A, and the design layer 31 of the pattern portion 24 is formed by the design film 31A of the patterned pattern film 24A.

As a result, the first surface 21a of the base film 21A is exposed in the opening of the blast mask 37 as shown in FIG. 10. The blast process is continued on the laminate of FIG. 10. As a result, the first surface 21a of the base film 21A is eroded as shown in FIG. 11, and a recess 21c is formed in the first surface 21a of the base film 21A. The depth of the recess 21c can be adjusted by the time of T1 blast process. In this way, the blast process is completed. The base film 21A forms the base portion 21. The portion of the base portion 21 covered by the blast mask 37 forms the first region 22, and the pattern portion 24 is provided on this first region 22. In addition, the portion of the base portion 21 exposed in the opening of the blast mask 37 forms the second region 23, and the transparent portion 26 is formed in this second region 23. The recess 21c formed in the base film 21A is located in the second region 23 of the first surface 21a of the base portion 21.

Furthermore, as shown in Figures 10 and 11, the first surface 21a in the second region 23 of the base material 21 becomes the surface to be processed by the blasting process, and therefore becomes the uneven surface 21S. Similarly, the surface of the blast mask 37 opposite the laminate 35 also becomes the surface to be processed, to which the blasting material is sprayed. Therefore, the surface of the blast mask 37 opposite the laminate 35 also becomes the uneven surface 21S. The roughness of these uneven surfaces 21S can be adjusted, for example, by the type and size of the blasting material, the spraying speed of the blasting material, etc. Note that, for example, sand, glass, etc. can be used as the blasting material.

However, as the pattern film 24A is eroded by the blast process, the blast mask 37 is also eroded. Normally, when commonly used materials are used and typical blast process conditions are adopted, the erosion rate of the pattern film containing resin, coloring material, etc. due to the blast process is the same as or slightly faster than the erosion rate of the blast mask 37 containing resin during the blast process. In other words, when the erosion of the pattern film 24A due to the blast process progresses by the thickness of the pattern film 24A, the erosion of the blast mask 37 may also progress by an amount equal to or slightly smaller than the thickness of the pattern film 24A.

Therefore, before the removal of the pattern film 24A in the area forming the transparent portion 26 is completed, the blast mask 37 may be eroded by its thickness. If the blast mask 37 on the laminate 35 is removed before the blast process is completed, the portion of the pattern portion 24 that is not intended to be removed will be removed by the blast process. In order to prevent such a problem from occurring, in the above example, as shown in FIG. 9, the thickness T3A of the blast mask 37 before the blast process is made thicker than the thickness T2A of the pattern film 24A. According to this example, even if the removal speed of the pattern film 24A during the blast process is approximately the same as the removal speed of the blast mask 37 during the blast process, the blast mask 37 will remain on the laminate 35 without being removed until a predetermined area of the pattern film 24A is removed. As a result, the thickness T2 of the pattern portion 24 becomes equal to the thickness T2A of the pattern film 24A.

In addition, in the illustrated example, the thickness T3A of the blast mask 37 before the blast process is thinner than twice the thickness T2A of the pattern film 24A. According to this example, by performing the blast process while checking that the blast mask 37 remains, the depth T1 (see FIG. 6) of the recess 21c formed on the first surface 21a in the second region 23 of the substrate 21 does not become too deep, and for example, the depth T1 of the recess 21c can be made less than the thickness T2 of the pattern portion 24.

After the blasting process is completed as described above, a process of removing the blast mask 37 is carried out. For example, the blast mask 37 remaining on the laminate 35 can be removed from the laminate 35 using a resist remover.

Next, the resin composition that will form the cover layer 27 is applied onto the laminate 35 from the side of the created pattern portion 24. The resin composition is cured on the applied film to form the cover layer 27.

By the above steps, the decorative sheet 20 shown in Figures 2 and 6 is manufactured. The resulting decorative sheet 20 is laminated onto the display device 10 to obtain the display device 1 with the decorative sheet.

Next, we will explain the operation of the display device 1 with decorative sheet of this embodiment.

When the display device 10 is in a non-display state and image light is not emitted from the display surface 11, as shown in FIG. 1, the decorative sheet 20 arranged on the display surface 11 of the display device 10 is visible. Then, the design layer 31 located on the observer side of the light-shielding layer 32 in the decorative sheet 20 is observed. The design layer 31 can provide excellent design by displaying a pattern. In other words, when the image is not displayed, the display device 10, which is usually observed as black, can be concealed, and the display device 10 can be installed while ensuring harmony and uniformity of the design with the surrounding environment. In addition, the range of application of the display device 10 has been rapidly expanding in recent years, and by using the decorative sheet 20, it is possible to apply the display device 10 to the surface components of automobiles, furniture, and building materials for which design is important.

On the other hand, when the display surface 11 is in a display state, image light is emitted from the display surface 11. The image light emitted from the display surface 11 travels toward the pattern portion 24 or the transmission portion 26 of the decorative sheet 20. The image light incident on the transmission portion 26 then passes through the base material portion 21 and is emitted from the decorative sheet 20 to the viewer side. The image light that has passed through the transmission portion 26 forms an image that is observed on the display surface 11, as shown in FIG. 3.

The image light directed toward the pattern portion 24 is absorbed by the light-shielding layer 32 located on the side of the pattern portion 24 closest to the display device 10. That is, the image light from the display device 10 does not pass through the pattern portion 24. Therefore, the image light does not illuminate the design layer 31 from the back side. This effectively prevents the image displayed by the display device 10 from mixing with the design formed in the pattern portion 24 of the decorative sheet 20. It also effectively prevents the design of the pattern portion 24 from being conspicuous when an image is displayed by the display device 10. This allows the image displayed by the display device 10 to be clearly observed when the display device 10 is in a display state.

The display surface 11 of the display device 10 is located behind the decorative sheet 20 that displays the design. Of the image light emitted from the display surface 11 of the display device 10, the image light that passes through the transmissive portion 26 of the decorative sheet 20 forms the image observed by the observer. In particular, the transmissive portion 26 has a constant thickness (a constant length along the normal direction ND). For this reason, a display device 1 with a decorative sheet, which includes the decorative sheet 20 and the display device 10, has a problem in that the angle range at which an image can be observed, i.e., the viewing angle, tends to become narrow.

In general, the viewing angle of a displayed image is increased by diffusing the image light. Typically, a light diffusion sheet is placed on the observer side of the decorative sheet. However, when a light diffusion sheet is placed on the observer side of the decorative sheet 20, the light that allows the pattern portion 24 to be observed is also diffused, resulting in a problem of reduced clarity of the displayed pattern. In particular, the reflected light from the pattern portion 24 that allows the pattern portion 24 to be observed passes through the light diffusion sheet twice, before and after reflection, and is more diffused than the image light from the display device 10. The reduction in clarity of the pattern displayed by the pattern portion 24 is a fatal defect that undermines the purpose of installing the decorative sheet 20, such as improving the design in the area where the display device 10 is placed.

In this regard, in the present embodiment, as shown in FIG. 6, the first surface 21a of the substrate 21 has an uneven surface 21S at least in the second region 23 other than the first region 22. A transmission section 26 through which the image light travels is provided on the second region 23 of the substrate 21. Therefore, the image light passing through the transmission section 26 is diffused by the uneven surface 21S, so that the viewing angle at which the image can be observed can be expanded. That is, the viewing angle of the image light emitted from the display surface 11 of the display device 10 can be expanded without disposing a light diffusion sheet on the viewer side of the decorative sheet 20. At the same time, the light traveling from the picture portion 24 to the viewer can be effectively prevented from being diffused by the light diffusion sheet. Therefore, the uneven surface 21S for expanding the viewing angle of the image displayed by the display device 10 can effectively avoid the image displayed by the picture portion 24 from being destroyed, and the clarity of the image can be maintained.

In particular, in the illustrated example, the decorative sheet 20 has the uneven surface 21S only in the second region 23. This example makes it possible to more reliably prevent the image from being distorted due to diffusion on the uneven surface 21S. In other words, the viewing angle of the image can be effectively expanded while stably maintaining the clarity of the image.

The uneven surface 21S is provided on the first surface 21a, which is the side on which the pattern portion 24 of the substrate 21 is superimposed. Therefore, as shown in FIG. 6, the second surface 21b, which is the opposite side of the pattern portion 24 of the substrate 21, can be formed as a flat surface. According to this decorative sheet 20, when the flat second surface 21b is bonded to other members or devices, such as the display device 10, a bonding layer selected from various materials can be used. In other words, since the second surface 21b is not shaped in the expectation of some support, the second surface 21b can be covered with a bonding layer. When the decorative sheet 20 is bonded to other members or devices using a bonding layer, it is possible to avoid the presence of an air layer between the decorative sheet 20 and the other members or devices. This effectively prevents reflection at the interface between the decorative sheet 20 and the air layer or the interface between the air layer and the other members or devices. Therefore, it is possible to effectively prevent the generation of stray light caused by reflection at these interfaces, and defects such as Newton's rings.

Furthermore, by diffusing the image light displayed by the display device 10 with the uneven surface 21S provided on the base material portion 21 of the decorative sheet 20, the image is observed as if the image was formed at a position closer to the uneven surface 21S side than the actual position of the display surface of the display device 10. That is, the pattern displayed by the pattern portion 24 and the image displayed by the display device 10 are viewed at a closer position in the normal direction ND of the decorative sheet 20. In particular, since the uneven surface 21S is formed on the first surface 21a of the base material portion on the pattern portion side, the pattern and the image are viewed at a very close position in the normal direction ND. In contrast, if the pattern and the image are observed at positions that are significantly different in the normal direction ND, the viewer may feel a strange sensation when the image starts to be displayed. Therefore, by using the decorative sheet 20 according to this embodiment, this strange sensation can be effectively alleviated.

6, the first surface 21a of the base material 21 has a recess 21c, and the uneven surface 21S is formed within the recess 21c. In this decorative sheet 20, the uneven surface 21S is located slightly closer to the viewer than the design layer 31 of the pattern portion 24 in the normal direction ND of the decorative sheet 20. In this example, the image light after passing through the transparent portion 26 can be diffused by the uneven surface 21S. Therefore, the viewing angle at which the image can be observed can be adjusted with a high degree of freedom without being restricted by the cross-sectional shape of the transparent portion 26 (the area of the transparent portion 26, the thickness of the pattern portion 24, etc.). In addition, according to this example, the position of the image observed by the viewer and the position at which the pattern of the pattern portion 24 is observed from the position of the display surface 11 of the display device 10 can be made closer in the normal direction ND. In particular, this example makes it possible to align the position of the observed pattern and the position of the image in the normal direction ND more than when the uneven surface 21S is disposed in the same position as the design layer 31 along the normal direction ND. Therefore, the viewer can naturally view the image displayed by the display device 10 without feeling uncomfortable, especially when the image starts to be displayed.

Furthermore, as shown in FIG. 6, the depth T1 of the recess 21c is smaller than the thickness T2 of the pattern portion 24. In this decorative sheet 20, it is possible to effectively prevent the light reflected by the design layer 31 of the pattern portion 24 from passing through the uneven surface 21S located in the recess 21c and heading toward the viewer's eye. Alternatively, it is possible to effectively prevent external light from passing through the uneven surface 21S, being diffused, and then being reflected by the design layer 31. In other words, it is possible to effectively prevent the light reflected by the design layer 31 of the pattern portion 24 that is heading toward the viewer's eye from being diffused by the uneven surface 21S. This makes it possible to effectively widen the viewing angle of the image displayed by the display device 10 while more stably maintaining the clarity of the pattern displayed by the pattern portion 24.

On the other hand, it is preferable that the depth of the recess 21c is at least 0.7 μm or more. In a display device 1 with a decorative sheet in which the display device 10 is disposed on the back surface of the decorative sheet 20, as described above, it may be possible to align the position of the observed pattern and the position of the image in the normal direction ND more than when the uneven surface 21S is disposed in the same position as the design layer 31 along the normal direction ND. In particular, making the depth T1 of the recess 21c at least 1 μm or more is advantageous in aligning the position of the observed pattern and the position of the image in the normal direction ND. According to this example, the viewer can naturally view the image displayed by the display device 10 without any sense of discomfort, especially when the image starts to be displayed.

In the embodiment described above, the decorative sheet 20 has a substrate 21 having a first surface 21a and a second surface 21b facing each other, and a pattern portion 24 provided on the first surface 21a side of the substrate 21 and located only on the first region 22 of the substrate 21. The first surface 21a of the substrate 21 has an uneven surface 21S at least in the second region 23 other than the first region 22. According to the decorative sheet 20 of this embodiment, the uneven surface 21S of the substrate 21 located in the second region 23 can diffuse the image light from the display device 10 and widen the viewing angle. On the other hand, by providing the uneven surface 21S only in the second region 23 of the decorative sheet 20 where the pattern portion 24 is not overlapped, or by using the decorative sheet 20 so that the opposite side of the substrate 21 with respect to the pattern portion 24 is the observer side as in the above specific example, it is possible to effectively prevent the uneven surface 21S from destroying the pattern displayed by the pattern portion 24. This allows the uneven surface 21S to widen the viewing angle of the image while maintaining the clarity of the image.

In the specific example of the embodiment described above, the pattern portion 24 has a design layer 31 that displays a pattern, and a light-shielding layer 32 that is provided on the opposite side of the design layer 31 to the substrate. This decorative sheet 20 can be arranged so that the opposite side of the pattern portion 24 is the observer side, with the substrate portion 21 as a reference. In this case, the design layer 31 of the pattern portion 24 can be effectively protected by the substrate portion 21. In addition, the image light from the display device 10 is diffused after passing between the two adjacent pattern portions 24. Therefore, the viewing angle at which the image can be observed can be greatly expanded without being restricted by the cross-sectional shape of the transmission portion 26 (the area of the transmission portion 26, the thickness of the pattern portion 24, etc.). Furthermore, the position of the image observed by the observer can be made to approach the position where the pattern of the pattern portion 24 is observed from the position of the display surface 11 of the display device 10 in the normal direction ND. Therefore, the observer can naturally observe the image displayed by the display device 10 without feeling strange, especially when the image starts to be displayed.

In the embodiment described above, the manufacturing method of the decorative sheet 20 includes a step of providing a blast mask 37 on the side of the pattern film 24A of the laminate 35 having the base film 21A and the pattern film 24A laminated on the base film 21A, and a step of blasting the laminate 35 through the blast mask 37 and patterning the pattern film 24A to form the pattern portion 24. According to the manufacturing method of this embodiment, the second region 23 of the first surface 21a of the base portion 21 on which the pattern film 24A is laminated, which is the non-forming portion of the pattern portion 24, can be roughened to form the uneven surface 21S. That is, the decorative sheet 20 having a diffusion surface consisting of the uneven surface 21S in the second region 23 of the first surface 21a of the base portion 21 can be easily manufactured. This decorative sheet 20 can achieve the excellent effects described above. In particular, as a specific example of one embodiment, in the blasting process, recesses 21c can be easily and stably formed only in the second region 23 of the first surface 21a of the base material 21.

In the specific example of the embodiment described above, the thickness T3A of the blast mask 37 before the blast process was thicker than the thickness T2A of the pattern film 24A. Usually, the removal of the pattern film 24A made of resin and color material by the blast process proceeds more easily or to the same extent as the removal of the blast mask 37 during the blast process. Therefore, by making the thickness T3A of the blast mask 37 before the blast process thicker than the thickness T2A of the pattern film 24A, the surface of the base film 21A is exposed in the region that is to become the second region 23 where the transparent portion 26 is to be formed before the blast film 37A is completely removed in the region that is to become the first region 22 of the base material portion 21 where the pattern portion 24 is to be formed. Therefore, the pattern portion 24 having the planned thickness T2 can be formed on the first region 22 of the first surface 21a of the base material portion 21. It is also possible to stably form recesses 21c only in the second region 23 of the first surface 21a of the base material portion 21, which is made of the base material film 21A.

In addition, in the specific example of the embodiment described above, the thickness T3A of the blast mask 37 before the blast process is thinner than twice the thickness T2A of the pattern film 24A. According to this example, by performing the blast process while checking that the blast mask 37 remains, it is possible to prevent the depth T1 of the recess 21c formed on the first surface 21a in the second region 23 of the substrate portion 21 from becoming too deep. More specifically, the depth T1 of the recess 21c can be made less than the thickness T2 of the pattern portion 24.

Furthermore, in the specific example of the embodiment described above, the pattern film 24A has a design film 31A and a light-shielding film 32A provided on the side of the design film 31A opposite the substrate film 21A. According to this example, in the obtained decorative sheet 20, the pattern portion 24 can have a design layer 31 that displays the pattern and a light-shielding layer 32 provided on the side of the design layer 31 opposite the substrate.

Furthermore, in the specific example of the embodiment described above, the step of providing the blast mask 37 includes the steps of providing a resist layer 36A on the laminate 35 and patterning the resist layer 36A to form the blast mask 37. In this example, the blast mask 37 can be formed from the resist layer 36A by patterning using a photolithography technique. In other words, by patterning the resist layer 36A, a highly accurate blast mask 37 can be easily formed.

Although one embodiment has been described using a number of specific examples, these specific examples are not intended to limit the one embodiment. The one embodiment described above can be implemented using various other specific examples, and various omissions, substitutions, modifications, additions, etc. can be made without departing from the spirit of the embodiment.

Below, an example of a modification will be described with reference to the drawings. In the following description and the drawings used in the following description, parts that can be configured similarly to the above-mentioned specific example will be designated by the same reference numerals as those used for the corresponding parts in the above-mentioned specific example, and duplicated descriptions will be omitted.

In the above-mentioned specific example, the pattern portion 24 of the decorative sheet 20 has a substrate portion 21, a design layer 31 and a light-shielding layer 32 laminated in order on the substrate portion 21, but this is not limited to this example. As shown in FIG. 12, the decorative sheet 20 may have a substrate portion 21, a light-shielding layer 32 laminated on the substrate portion 21, and a design layer 31 laminated on the side of the light-shielding layer 32 opposite the substrate portion 21. In this example, the decorative sheet 20 can be arranged so that the side opposite the substrate portion 21 with respect to the pattern portion 24 is the observer side. Also, in the example shown in FIG. 12, the position of the image observed by the observer can be moved closer to the position where the pattern of the pattern portion 24 is observed from the position of the display surface 11 of the actual display device 10 along the normal direction ND. Therefore, the sense of incongruity felt by the observer when observing an image, especially when the image starts to be displayed, can be effectively alleviated.

In the example shown in FIG. 12, the decorative sheet 20 also has a transparent cover layer 27 laminated on the side where the pattern portion 24 is formed on the base material portion 21. The cover layer 27 covers the pattern portion 24 from the observer side. The cover layer 27 can protect the pattern portion 24, and in particular the design layer 31 of the pattern portion 24. However, the cover layer 27 is not an essential layer for the decorative sheet 20 to perform the function of displaying a pattern or image. In the specific examples described above with reference to FIG. 2 and FIG. 6, and the example described with reference to FIG. 12, the cover layer 27 can be omitted.

In the above-mentioned specific example, the pattern portion 24 of the decorative sheet 20 is formed by laminating one design layer 31 and one light-shielding layer 32, but this is not limited to the example. As in the example shown in FIG. 13, the light-shielding layer 32 may include a first light-shielding layer 33 and a second light-shielding layer 34 laminated together.

In the example shown in FIG. 13, the first light-shielding layer 33 and the second light-shielding layer 34 may have different colors. By having the first light-shielding layer 33 and the second light-shielding layer 34 have different colors, the absorption spectrum of the first light-shielding layer 33 and the absorption spectrum of the second light-shielding layer 34 can be made different. Therefore, the absorption spectrum of the light-shielding layer 32 can be adjusted with a high degree of freedom in response to the spectral distribution of the image light. This allows the image light incident on the picture portion 24 to be stably absorbed by the light-shielding layer 32, and the image can be displayed in the desired color by effectively suppressing color mixing between the images and the patterns.

Furthermore, in the example shown in FIG. 13, the first light-shielding layer 33 and the second light-shielding layer 34 may have different thicknesses T3 and T4. By having the first light-shielding layer 33 and the second light-shielding layer 34 have different thicknesses T3 and T4, the absorption spectrum of the light-shielding layer 32 can be adjusted with a higher degree of freedom.

Furthermore, as shown in Figs. 13 and 14, the surface of the pattern portion 24 opposite to the surface facing the substrate 21, i.e., the surface of the pattern portion 24 opposite to the substrate 21, may be an uneven surface 21K. According to this example, it is possible to effectively suppress the image light toward the pattern portion 24 from the opposite side of the substrate 21 in the normal direction ND from being reflected, particularly from the surface of the pattern portion 24, from the surface of the pattern portion 24. This effectively suppresses the occurrence of double images, also called ghosts. In particular, when the uneven surface 21K of the pattern portion 24 facing the display device 10 is formed by the light-shielding layer 32, the image light toward the pattern portion 24 can be absorbed with a higher absorption rate. This effectively suppresses the occurrence of stray light. As a result, according to this example, it is also possible to display images observed at a wide viewing angle more clearly. In order to achieve such an effect, the arithmetic mean roughness of the uneven surface 21K of the picture portion 24 measured in accordance with JIS B 0601-2001 is preferably 0.7 μm or more and 10 μm or less, more preferably 1 μm or more and 7 μm or less, and even more preferably 2 μm or more and 5 μm or less.

In addition, in the decorative sheet 20 shown in FIG. 14, the picture portion 24 has one design layer 31 and one light-shielding layer 32 laminated in this order on the base material portion 21. The surface of the light-shielding layer 32 opposite the design layer 31 is the uneven surface 21K.

As yet another modified example, the manufacturing method of the decorative sheet 20 described above is merely one example. For example, in the specific example described above, the manufacturing method of the decorative sheet 20 includes a step of removing the blast mask 37. However, the blast mask 37 produced during the manufacturing of the decorative sheet 20 can be used as part of the picture portion 24 without being removed from the laminate 35. For example, the blast mask 37 remaining on the laminate 35 can be used as the light-shielding layer 32.

As an example, the decorative sheet 20 shown in FIG. 13 already mentioned can be produced by producing a first light-shielding layer 33 from the light-shielding film 32A of the laminate 35 and producing a second light-shielding layer 34 from the blast mask 37 remaining on the laminate 35.

In this example, the blast mask 37 may have a different color from the light-shielding film 32A of the pattern film 24A. In this case, the first light-shielding layer 33 and the second light-shielding layer 34 will have different colors. Also, as shown in FIG. 13, the blast mask 37 after the blasting process may have a thickness T3 that is different from the thickness T4 between the blast mask 37 and the light-shielding film 32A of the pattern film 24A. In this case, the first light-shielding layer 33 and the second light-shielding layer 34 will have different thicknesses.

As another example, the light-shielding film 32A may be omitted from the pattern film 24A of the laminate 35, and the light-shielding layer 32 may be formed only by the remaining blast mask 37. In this example, the decorative sheet 20 shown in FIG. 14 can be produced. According to this example, it is possible to reduce manufacturing costs by omitting the light-shielding film 32A from the pattern film 24A.

Another example of the manufacturing method of the decorative sheet 20 will be further described with reference to Figures 15 and 16. First, the manufacturing method of the blast mask 37 described above can be changed. In this example, a laminate 35 having a base film 21A and a pattern film 24A is prepared in the same manner as in the above-mentioned specific example. The pattern film 24A of this laminate 35 may have a design film 31A and a light-shielding film 32A laminated in order on the base film 21A, as in the above-mentioned specific example. However, in the example shown in Figures 15 and 16, the pattern film 24A provided on the base film 21A includes only the design film 31A. Next, a blast mask 37 is formed on the surface of the pattern film 24A facing the base film 21A. In the example described here, the blast mask 37 is formed on the laminate 35 by screen printing. That is, as shown in Figure 15, a printing layer 38 is formed adjacent to the design film 31A on the design film 31A of the pattern film 24A of the laminate 35 by screen printing. This printing layer 38 has a pattern similar to that of the blast mask 37 to be produced, and further a pattern corresponding to the pattern of the picture portion 24 to be formed through blast processing. Next, the printing layer 38 on the laminate 35 is dried or cured to obtain the blast mask 37 from the printing layer 38. The process after producing the blast mask 37 includes the blast processing process shown in FIG. 16, and can be the same as the manufacturing method of the decorative sheet 20 described above. As in this example, by using screen printing to produce the blast mask 37, the blast mask 37 can be formed easily and inexpensively. The manufacturing method shown in FIG. 15 and FIG. 16 can produce the decorative sheet 20 shown in FIG. 14.

In the above-mentioned specific example, as an example of the arrangement of the transparent portion 26 and the pattern portion 24 of the decorative sheet 20 on a plane, the decorative sheet 20 in which the transparent portion 26 is formed in a circular shape and the pattern portion 24 is arranged around it is shown in FIG. 5, but as already mentioned, this example is not limited to this example. For example, as shown in the example of FIG. 17, the decorative sheet 20 can be formed such that the pattern portion 24 is formed in a circular shape in a plan view and the transparent portion 26 is arranged around it. In addition, the transparent portion 26 can have a shape other than a circle in a plan view. For example, as shown in the example of FIG. 18, a plurality of transparent portions 26 may be arranged in one direction, and each transparent portion 26 may extend linearly in another direction that is not parallel to the one direction. In particular, in the example shown in FIG. 18, a plurality of transparent portions 26 are arranged in one direction, and each transparent portion 26 extends linearly in the other direction perpendicular to the one direction. That is, a plurality of transparent portions 26 may be arranged in a stripe shape.

In the above-mentioned specific example, the display device 10 has a surface light source device 12 and a light-shielding sheet 14, but as already mentioned, this is not limited to this example. For example, the light-emitting surface 13 of the surface light source device 12 may have the same pattern as the pattern of the displayed image, and the light-shielding sheet 14 may be omitted. In addition, as the display device 10, a dot-matrix display device 10, such as a liquid crystal display device or an organic EL display device, may be used together with the decorative sheet 20. With the dot-matrix display device 10, the light-emitting state of each pixel can be controlled to display the desired video or still image.

As a specific example, FIG. 19 shows an example of a pixel arrangement in a dot-matrix display device 10. In this example, the display device 10 includes a first pixel 51, a second pixel 52, and a third pixel 53 that emit different colors. The first pixels 51, the second pixels 52, and the third pixels 53 are each regularly arranged.

However, it is assumed that moire occurs on the decorative sheet 20 due to interference between the regularity of the pixel arrangement of the display device 10 and the regularity of the arrangement of the transmissive portion 26. When moire occurs, a striped pattern is observed on the decorative sheet 20 along with the image displayed by the display device 10. Such an appearance defect may be fatal in light of the use of the decorative sheet 20. In general, it is considered effective to weaken the regularity of the two elements that cause interference in order to make the striped pattern caused by moire less noticeable. In this regard, according to the decorative sheet 20 of this embodiment, the first surface 21a of the base material portion 21 has an uneven surface 21S in the second region 23 facing the transmissive portion 26. Moire can be effectively suppressed by diffusion on this uneven surface 21S. Therefore, the decorative sheet 20 of this embodiment is suitable for a dot-matrix type display device 10.

Although several variations on the above embodiment have been described, it is of course possible to combine multiple variations as appropriate.

DS1 First direction DS2 Second direction ND Normal direction T1 Depth of recess T2 Thickness of pattern portion T2A Thickness of pattern film T3 Thickness of blast mask 37 after blast processing T3A Thickness of blast mask 37 before blast processing T4 Thickness of first light-shielding layer 1 Display device with decorative sheet 10 Display device 11 Display surface 11a Surrounding area 12 Surface light source device 13 Light-emitting surface 14 Light-shielding sheet 14a Opening area 14b Light-shielding area 20 Decorative sheet 20a First edge 20b Second edge 20c Third edge 20d Fourth edge 21 Base material portion 21a First surface 21b Second surface 21c Recess 21A Base material film 21S Uneven surface 21K Uneven surface 22 First area 23 Second area 24 Pattern portion 24A Pattern film 26 Transmitting portion 27 Cover layer 31 Design layer 31A Design film 32 Light-shielding layer 32A Light-shielding film 33 First light-shielding layer 34 Second light-shielding layer 35 Laminate 36 Resist pattern 36A Resist layer 37 Blast mask 38 Print layer 51 First pixel 52 Second pixel 53 Third pixel

Claims (19)

a base member having a first surface and a second surface opposed to each other;
A pattern portion is provided on the first surface side of the base portion and located only on the first region of the base portion,
The first surface of the base member has an uneven surface only in a second region other than the first region ,
A decorative sheet , wherein the first surface of the base material has a recess, and the uneven surface is provided within the recess . The decorative sheet according to claim 1 , wherein the picture portion has a design layer and a light-shielding layer provided on a side of the design layer opposite to the base portion. The decorative sheet according to claim 1 or 2 , wherein a depth of the recess is smaller than a thickness of the picture portion. the light-shielding layer includes a first light-shielding layer and a second light-shielding layer stacked on each other,
The decorative sheet according to claim 2 , wherein the first light-shielding layer and the second light-shielding layer have different colors. The decorative sheet according to claim 4 , wherein the first light-shielding layer and the second light-shielding layer have different thicknesses. The decorative sheet according to any one of claims 1 to 5 , wherein the picture portion has an uneven surface on the side opposite to the base portion. a base member having a first surface and a second surface opposed to each other;
A pattern portion is provided on the first surface side of the base portion and located only on the first region of the base portion,
The first surface of the base member has an uneven surface only in a second region other than the first region,
The decorative sheet, wherein the pattern portion has an uneven surface on the side opposite to the base portion. A decorative sheet according to any one of claims 1 to 7 ,
A display device with a decorative sheet, comprising: a display device on which the decorative sheet is overlaid. A method for producing the decorative sheet according to claim 1 or 7, comprising the steps of:
A step of providing a blast mask on a side of the pattern film of a laminate having a base film constituting the base portion and a pattern film laminated on the base film and constituting the pattern portion ;
blasting the laminate through the blast mask to pattern the pattern film to form the pattern portion. The method for producing a decorative sheet according to claim 9 , wherein in the blasting step, recesses are formed in areas of the base film that are not covered by the blast mask. The method for manufacturing a decorative sheet according to claim 9 or 10 , wherein the blast mask has a thickness greater than a thickness of the pattern film. The method for manufacturing a decorative sheet according to any one of claims 9 to 11 , wherein the pattern film has a design film and a light-shielding film provided on the opposite side of the design film to the base film. The method for producing a decorative sheet according to claim 12 , wherein the blast mask has a color different from that of the light-shielding film. The method for producing a decorative sheet according to claim 12 or 13 , wherein the blast mask after the blasting process has a thickness different from that of the light-shielding film. The method for producing a decorative sheet according to any one of claims 9 to 14 , wherein in the step of providing the blast mask, the blast mask is provided on the laminate by screen printing. The pattern film includes a design film having a pattern formed thereon,
The method for manufacturing a decorative sheet according to any one of claims 9 to 11 , wherein in the step of providing a blast mask, the blast mask is provided on the laminate by screen printing so as to be adjacent to the decorative film. The method for producing a decorative sheet according to any one of claims 9 to 14 , wherein the step of providing a blast mask includes a step of providing a resist layer on the laminate, and a step of patterning the resist layer to form the blast mask. The method for producing a decorative sheet according to any one of claims 9 to 17 , wherein the blast mask is used as a part of the picture portion. A step of producing a decorative sheet by the production method according to any one of claims 9 to 18 ;
and laminating the decorative sheet on a display device.