# US 11,440,299 B2 · Decorative sheet, decorative material, and method of producing decorative sheet

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- Number: US 11,440,299 B2
- Document ID: US11440299B2
- Status: Granted
- Kind: B2
- Application number: 16/884,504
- Filed: 2020-05-27
- Published: 2020-09-10
- Granted: 2022-09-13
- Earliest claimed: 2018-01-17
- Assignees: Toppan Printing Co., Ltd.
- Applicants: Toppan Printing Co., Ltd.
- Inventors: Kazuki Kinoshita
- Web page: https://patentgrep.com/patent/US11440299B2

## CPC

- B32B 27/08: of synthetic resin
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/08: of synthetic resin
- B32B 21/14: comprising wood board or veneer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 38/145: {Printing}
- D06N 7/00: Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material (paper-based or board-based structures for surface covering D21H27/20)
- B32B 37/0007: {involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality}
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2307/402: Coloured
- B32B 2307/4023: on the layer surface, e.g. ink
- B32B 2307/412: Transparent
- B32B 2307/538: Roughness
- B32B 2307/584: Scratch resistance
- B32B 2307/732: Dimensional properties
- B32B 2307/75: Printability
- B32B 2323/10: Polypropylene
- B32B 2398/20: Thermoplastics
- B32B 2419/00: Buildings or parts thereof
- B32B 2451/00: Decorative or ornamental articles
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- E04F 15/16: Flooring, e.g. parquet on flexible web, laid as flexible webs; Webs specially adapted for use as flooring; {Parquet on flexible web}(resiliently-mounted floors, e.g. sprung floors, E04F15/22; linoleum D06N; {carpets A47G27/00})
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

A decorative sheet that includes at least a thermoplastic resin substrate layer, a transparent thermoplastic resin layer and a surface protective layer in this order. The surface protective layer is formed by laminating at least two layers. At least a second surface protective layer, which constitutes an outermost layer that is a layer located furthest from the transparent thermoplastic resin layer among layers constituting the surface protective layer contains an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer at a weight ratio of 60% or more. The arithmetic mean height of a profile curve measured from the second surface protective layer in accordance with JIS B 0601 is 15 μm or more, and the maximum height of the profile curve is 38 μm or more.

## Claims

### Claim 1

A decorative sheet, comprising:
at least a thermoplastic resin substrate layer, a transparent thermoplastic resin layer, and a surface protective layer in this order,
wherein the surface protective layer is formed by laminating at least two layers;
wherein at least an outermost layer that is a layer located furthest from the transparent thermoplastic resin layer among layers constituting the surface protective layer contains an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer at a weight ratio of 60% or more, and,
wherein the arithmetic mean height of a profile curve measured from the outermost layer in accordance with JIS B 0601 is 15 μm or more, and the maximum height of the profile curve is 38 μm or more.

### Claim 2 (depends on 1)

The decorative sheet of claim 1, further comprising a pattern layer interposed between the thermoplastic resin substrate layer and the transparent thermoplastic resin layer.

### Claim 3 (depends on 1)

The decorative sheet of claim 1, wherein the thermoplastic resin substrate layer is formed with a polyolefin-based resin or a polyester-based resin each having a thickness in the range of 10 μm or more and 200 μm or less.

### Claim 4 (depends on 1)

The decorative sheet of claim 1, wherein the transparent thermoplastic resin layer is formed with a polyolefin-based resin or a polyester-based resin each having a thickness in the range of 30 μm or more and 200 μm or less.

### Claim 5 (depends on 1)

The decorative sheet of claim 1, wherein
the surface protective layer is formed by laminating at least one of a first surface protective layer which is laminated to the transparent thermoplastic resin layer, and the outermost layer, and
the thickness of the first surface protective layer is in the range of equal to or more than 1 μm and less than 30 μm.

### Claim 6 (depends on 1)

A decorative material, comprising:
the decorative sheet of claim 1;
an adhesive layer that is provided on a surface of the thermoplastic resin substrate layer on a side facing a surface closer to the transparent thermoplastic resin layer, and contains an adhesive; and
a substrate that is bonded to the thermoplastic resin substrate layer through the adhesive contained in the adhesive layer.

### Claim 7

A method of producing a decorative sheet, comprising:
a transparent thermoplastic resin layer forming process of forming a transparent thermoplastic resin layer on one surface of a thermoplastic resin substrate layer; and
a surface protective layer forming process of forming a surface protective layer formed by laminating at least two layers on the transparent thermoplastic resin layer,
characterized in that the surface protective layer forming process includes forming at least an outermost layer that is a layer located furthest from the transparent thermoplastic resin layer among layers constituting the surface protective layer, such that
the outermost layer contains an ionizing radiation-curable resin containing a multifunctional hexamethylene diisocyanate oligomer at a weight ratio of 60% or more, and
the arithmetic mean height of a profile curve measured from the outermost layer in accordance with JIS B 0601 is 15 μm or more, and the maximum height of the profile curve is 38 μm or more.

### Claim 8 (depends on 1)

The decorative sheet of claim 1, wherein the arithmetic mean height of a profile curve measured from the outermost layer in accordance with JIS B 0601 is 15 μm or more and 30 μm or less, and the maximum height of the profile curve is 38 μm or more and 80 μm or less.

### Claim 9 (depends on 1)

The decorative sheet of claim 1, wherein the maximum height of the profile curve is equal to or more than 2.4 times and equal to or less than 2.7 times the arithmetic mean height of the profile curve.

### Claim 10 (depends on 8)

The decorative sheet of claim 8, wherein the maximum height of the profile curve is equal to or more than 2.4 times and equal to or less than 2.7 times the arithmetic mean height of the profile curve.

### Claim 11 (depends on 7)

The method of claim 7, wherein the arithmetic mean height of a profile curve measured from the outermost layer in accordance with JIS B 0601 is 15 μm or more and 30 μm or less, and the maximum height of the profile curve is 38 μm or more and 80 μm or less.

### Claim 12 (depends on 7)

The method of claim 7, wherein the maximum height of the profile curve is equal to or more than 2.4 times and equal to or less than 2.7 times the arithmetic mean height of the profile curve.

### Claim 13 (depends on 9)

The method of claim 9, wherein the maximum height of the profile curve is equal to or more than 2.4 times and equal to or less than 2.7 times the arithmetic mean height of the profile curve.