Thermally expandable sheet and thermally expandable sheet production method

Abstract

A thermally expandable sheet in which a thermally expansive layer that contains a thermally expandable material is formed on one side of a base, and where the thermally expansive layer is distended, the base deforms following distension of the thermally expansive layer and the base deforms into an embossed shape.

What is claimed is: 
     
         1 . A method of manufacturing a thermally expandable sheet, the method comprising:
 providing a base arranged on a plane;   forming a thermally expansive layer on one side of the base facing a predetermined direction, the thermally expansive layer comprising a binder and particles of thermally expandable material configured to expand in response to heating of the thermally expandable material dispersed in binder; and   forming an anchor layer between the one side of the base and the thermally expansive layer to adhere the base to the thermally expansive layer,   wherein the base is provided, and the thermally expansive layer is formed such that a thickness of the base is equal to or less than a thickness of the thermally expansive layer to allow the thermally expandable material to expand, through heating, to cause:
 a portion of the thermally expansive layer to distend in the predetermined direction; and 
 a portion of the base to be deformed in the predetermined direction by the distension of the portion of the thermally expansive layer in the predetermined direction to form an embossed shape. 
   
     
     
         2 . The thermally expandable sheet according to  claim 1 , wherein the anchor layer comprises polyester/acryl/urethane composite resin. 
     
     
         3 . The thermally expandable sheet according to  claim 2 , further comprising: a first ink reception layer formed on the thermally expansive layer to be separated from the base by the thermally expansive layer, wherein the first ink reception layer is configured to receive ink. 
     
     
         4 . The thermally expandable sheet according to  claim 3 , further comprising: a second ink reception layer formed on another side of the base opposite to the one side of the base, wherein the second ink reception layer is configured to receive ink. 
     
     
         5 . The thermally expandable sheet according to  claim 4 , wherein the first ink reception layer and the second ink reception layer comprise the same material. 
     
     
         6 . The thermally expandable sheet according to  claim 1 , wherein the base comprises at least one resin among polyolefin-based resin, polyester based resin, polyamide-based resin, polyvinyl chloride-based resin, polyimide-based resin, and silicone-based resin. 
     
     
         7 . The thermally expandable sheet according to  claim 1 , wherein the base is a resin base. 
     
     
         8 . A method of manufacturing a thermally expandable sheet, the method comprising:
 providing a base arranged on a plane;   forming a thermally expansive layer on one side of the base facing a predetermined direction, the thermally expansive layer comprising a binder and particles of thermally expandable material configured to expand in response to heating of the thermally expandable material dispersed in the binder; and   forming a first ink reception layer on the thermally expansive layer to be separated from the base by the thermally expansive layer, wherein the first ink reception layer is configured to receive ink,   wherein the base is provided, and the thermally expansive layer is formed such that a thickness of the base is equal to or less than a thickness of the thermally expansive layer to allow the thermally expandable material to expand, through heating, to cause:
 a portion of the thermally expansive layer to distend in the predetermined direction; and 
 a portion of the base to be deformed in the predetermined direction by the distension of the portion of the thermally expansive layer in the predetermined direction to form an embossed shape. 
   
     
     
         9 . The thermally expandable sheet according to  claim 8 , further comprising:
 a second ink reception layer formed on another side of the base opposite to the one side of the base,   wherein the second ink reception layer is configured to receive ink.   
     
     
         10 . The thermally expandable sheet according to  claim 9 , wherein the first ink reception layer and the second ink reception layer comprise the same material. 
     
     
         11 . The thermally expandable sheet according to  claim 8 , wherein the base comprises at least one resin among polyolefin-based resin, polyester-based resin, polyamide-based resin, polyvinyl chloride-based resin, polyimide-based resin, and silicone-based resin. 
     
     
         12 . The thermally expandable sheet according to  claim 8 , wherein the base is a resin base. 
     
     
         13 . The thermally expandable sheet according to  claim 8 , further comprising: an anchor layer formed between the one side of the base and the thermally expansive layer, wherein the anchor layer is configured to adhere the base to the thermally expansive layer. 
     
     
         14 . The thermally expandable sheet according to  claim 13 , wherein the anchor layer comprises polyester/acryl/urethane composite resin.