Shaping sheet, resin decorative plate and method for manufacturing the same

Abstract

A shaping sheet which has a delicate and daring concave-convex shape, is capable of realizing minute shaping with excellent design and touch feeling and having an air of luxuriousness and is excellent in release properties; a resin decorative plate obtained by using the shaping sheet; and a method for manufacturing a resin decorative plate capable of shaping a body to be shaped using the shaping sheet are provided. The shaping sheet is a sheet including a base material having thereon at least an ink layer provided partially or entirely and a surface shaping layer existing on the ink layer, coming into contact therewith and covering over the whole surface including a region where the ink layer is formed and a region where the ink layer is not formed, wherein the surface shaping layer is a layer obtained through crosslinking and curing of a curable resin composition, and in the surface shaping layer, the surface of the surface shaping layer which is located just above the ink layer and in an upper part in the vicinity thereof has a convex shape and further has a concave pattern.

1 . A shaping sheet comprising a base material having thereon at least a partially or entirely provided ink layer and a surface shaping layer existing on the ink layer, coming into contact therewith and covering over the whole surface including a region where the ink layer is formed and a region where the ink layer is not formed, wherein the surface shaping layer is a layer obtained through crosslinking and curing of a curable resin composition, and in the surface shaping layer, the surface of the surface shaping layer which is located just above the ink layer and in an upper part in the vicinity thereof has a convex shape and additionally has a concave pattern. 
     
     
         2 . The shaping sheet according to  claim 1 , wherein the surface shaping layer contains a fine particle, and an average particle size of the fine particle is a neighborhood value on a plus side of a maximum thickness of the surface shaping layer which is located just above the foregoing ink layer. 
     
     
         3 . The shaping sheet according to  claim 1 , wherein the curable resin composition is an ionizing radiation curable resin composition. 
     
     
         4 . The shaping sheet according to  claim 3 , wherein the ionizing radiation curable resin composition is an electron beam curable resin composition. 
     
     
         5 . The shaping sheet according to  claim 3 , wherein an ink constituting the ink layer contains a non-crosslinking urethane resin as a binder, and the ionizing radiation curable resin composition contains a (meth)acrylate monomer. 
     
     
         6 . The shaping sheet according to  claim 5 , wherein the ink constituting the ink layer contains a non-crosslinking urethane resin and an unsaturated polyester resin as a binder. 
     
     
         7 . A resin decorative plate prepared by laminating an adhesive layer and a decorative sheet layer in this order on an upper surface of a substrate, coating a resin composition on the decorative sheet layer, subsequently bringing a shaping sheet into contact therewith and integrally curing and then peeling the shaping sheet to form a resin layer, wherein the shaping sheet is the shaping sheet according to  claim 1 . 
     
     
         8 . The resin decorative plate according to  claim 7 , wherein a resin in the resin composition is an unsaturated polyester resin. 
     
     
         9 . A resin decorative plate comprising a substrate having a resin decorative sheet stuck thereto via an adhesive layer, said decorative sheet prepared by inserting the shaping sheet according to  claim 1  between a molded article to be press molded between hot press plates and a press plate and molding and then peeling the shaping sheet. 
     
     
         10 . The resin decorative plate according to  claim 9 , wherein the resin decorative sheet is a melamine resin decorative plate. 
     
     
         11 . The resin decorative plate according to  claim 9 , wherein the resin decorative sheet is a diallyl phthalate (DAP) resin decorative plate. 
     
     
         12 . A method for manufacturing a resin decorative plate comprising laminating an adhesive layer and a decorative sheet layer in this order on an upper surface of a substrate, coating a resin composition on the decorative sheet layer, subsequently bringing the shaping sheet according to  claim 1  into contact therewith and integrally curing and then peeling the shaping sheet to form a resin layer. 
     
     
         13 . A method for manufacturing a resin decorative plate comprising sticking onto a substrate via an adhesive layer a resin decorative sheet prepared by inserting the shaping sheet according to  claim 1  between a molded article to be press molded between hot press plates and a press plate and molding and then peeling the shaping sheet.