Transfer sheet and method for manufacturing decorative molded article

Abstract

Provided is a transfer sheet which is capable of imparting a design having a poor gloss to a decorative molded article and which has good transferability. Also provided is a method for producing a decorative molded article, which can impart a design having a poor gloss to a decorative molded article by using the transfer sheet, and which can suppress the occurrence of transfer defects. A transfer sheet (10) having a transfer layer (30) on a release sheet (20), the release sheet (20) comprising: a base material (22); an uneven layer (24) that is provided on a part of one surface of the base material (22) and contains a binder resin and a roughening agent, the binder resin including a thermoplastic resin; and a release layer (26) provided on the uneven layer (24) and on the substrate (22) on which the uneven layer is not formed.

Description

[0001] This case is filed on March 26, 2020 、Application number is 202080023957.1 (PCT / JP2020 / 013711) , divisional application for the invention titled "Method for manufacturing transfer sheet and decorative molded article." Technical Field

[0002] The present invention relates to a transfer sheet and a method for manufacturing a decorative molded product using the transfer sheet. Background Art

[0003] At present, in the fields of household electrical products, automobile interior products, and sundries, high functionality and design are demonstrated by decorating the surface of the products with text or patterns. As a method for decorating the surface of a product, a transfer method is known. The so-called transfer method refers to a method of using a transfer sheet having a transfer layer composed of a peeling layer, a pattern layer, a bonding layer, etc. formed on a substrate, heating and pressurizing the transfer sheet to make it close to the transfer object, then peeling off the substrate, and transferring only the transfer layer to the surface of the transfer object to decorate.

[0004] For products that require a matte feel as a design, a transfer sheet having a rough layer with fine irregularities is used for decoration. Patent Documents 1 and 2 disclose methods for producing molded products having a partially different matte feel on the surface using a transfer sheet having a rough layer on a portion of a substrate.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent No. 3017175

[0008] Patent Document 2: Japanese Patent No. 4885281 Summary of the invention

[0009] Technical problem to be solved by the invention

[0010] In the methods described in Patent Documents 1 and 2, a thermosetting resin is used in the rough layer. If the degree of curing of the rough layer is insufficient, the adhesion between the rough layer and the release layer decreases, and the release layer partially remains on the protective layer after peeling (transfer failure) which becomes a problem.

[0011] The present invention is made in view of such a situation, and its object is to provide a transfer sheet that can give a design with a gloss difference to a decorative molded product and has good transferability. In addition, it is also an object to provide a method for manufacturing a decorative molded product that can give a design with a gloss difference to a decorative molded product by using the transfer sheet of the present invention and can suppress the occurrence of transfer defects.

[0012] Technical solutions for solving technical problems

[0013] In order to solve the above-mentioned technical problems, the present invention provides the following [1] to [7].

[0014] [1] A transfer sheet having a transfer layer on a release sheet, wherein the release sheet comprises: a substrate; a concave-convex layer provided on a portion of one surface of the substrate and containing an adhesive resin and a roughening agent, the adhesive resin containing a thermoplastic resin; and a release layer provided on the concave-convex layer and on the substrate where the concave-convex layer is not formed.

[0015] [2] The transfer sheet according to [1], wherein the release layer is in contact with the transfer layer.

[0016] [3] The transfer sheet according to [1] or [2], wherein the average particle size of the roughening agent is 0.5 μm or more and 20 μm or less.

[0017] [4] The transfer sheet according to any one of [1] to [3], wherein the release layer has a thickness of 0.5 μm to 50 μm.

[0018] [5] The transfer sheet according to any one of [1] to [4], wherein the release layer comprises at least one of a cured product of a thermosetting resin composition and a cured product of an ionizing radiation-curable resin composition.

[0019] [6] The transfer sheet according to any one of [1] to [5], wherein the concavo-convex layer contains 50 parts by mass or more and 180 parts by mass or less of the roughening agent relative to 100 parts by mass of the binder resin.

[0020] [7] A method for manufacturing a decorative molded product, comprising: a step of joining the transfer layer of the transfer sheet described in any one of [1] to [6] to an adherend and laminating the transfer sheet on the adherend; and a step of peeling off the release sheet of the transfer sheet and transferring the transfer layer to the adherend.

[0021] Effects of the Invention

[0022] The transfer sheet of the present invention can make the release layer and the concavo-convex layer have good adhesion, and can give the decorative molded product a design with a gloss difference. By using the transfer sheet of the present invention, when the release sheet is peeled off during the manufacturing process of the decorative molded product, the peeling between the release layer and the concavo-convex layer can be suppressed. As a result, the occurrence of transfer failure can be suppressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1This is a schematic cross-sectional view showing one embodiment of the transfer sheet of the present invention.

[0024] Figure 2 This is a schematic cross-sectional view of a decorative molded article produced using the transfer sheet of the present invention.

[0025] Explanation of symbols

[0026] 10 transfer sheet; 20 release sheet; 22 substrate; 24 concavo-convex layer; 26 release layer; 30 transfer layer; 32 protective layer; 34 primer layer; 36 printing layer; 38 bonding layer; 40 decorative molded product; 42 adherend. DETAILED DESCRIPTION

[0027] [Transfer sheet]

[0028] The present invention is a transfer sheet having a transfer layer on a release sheet, wherein the release sheet comprises: a substrate; a concave-convex layer, which is arranged on a portion of one surface of the substrate and contains an adhesive resin and a roughening agent, wherein the adhesive resin contains a thermoplastic resin; and a release layer, which is arranged on the concave-convex layer and on the substrate where the concave-convex layer is not formed.

[0029] Figure 1 This is a schematic cross-sectional view showing one embodiment of the transfer sheet of the present invention. Figure 1 The transfer sheet 10 includes a release sheet 20 and a transfer layer 30 .

[0030] exist Figure 1 In the embodiment, the release sheet 20 includes a concavo-convex layer 24 provided on one surface of a substrate 22 , and a release layer 26 formed on the substrate 22 and the concavo-convex layer 24 .

[0031] exist Figure 1 In the transfer layer 30, the protective layer 32, the printing layer 36 and the bonding layer 38 are sequentially provided from the side of the release sheet 20. The protective layer 32 is in contact with the release layer 26. The transfer layer 30 may further include a primer layer 34 between the protective layer 32 and the printing layer 36.

[0032] like Figure 1 As shown in FIG. 1 , the concavoconvex layer 24 is formed in a predetermined pattern on a portion of one surface of the substrate 22. That is, the transfer sheet 10 has a region ( Figure 1 In the figure, the symbol A) and the area without the concavoconvex layer ( Figure 1 , symbol B). It is preferred that a plurality of regions A are formed in the surface of the substrate 22. Patterns are formed on the release layer 26 and the protective layer 32 corresponding to the pattern of the concavo-convex layer 24.

[0033] Each layer of the transfer sheet will be described in detail below. In addition, the expression of the numerical range "AA to BB" in this specification means "AA or more and BB or less".

[0034] 〔Release sheet〕

[0035] <Base material>

[0036] The substrate may be in the form of a sheet or a film.

[0037] Examples of the substrate include plastic films containing resins such as polyolefin resins such as polyethylene and polypropylene, vinyl resins such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymers, and ethylene-vinyl alcohol copolymers, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate, acrylic resins such as polymethyl (meth)acrylate and polyethyl (meth)acrylate, styrene resins such as polystyrene, and polyamide resins represented by nylon 6 or nylon 66.

[0038] Among these plastic films, biaxially stretched polyester films having excellent heat resistance and dimensional stability are preferred.

[0039] The thickness of the substrate is preferably 12 to 150 μm, more preferably 25 to 100 μm.

[0040] The surface of the substrate may be subjected to physical treatment such as corona discharge treatment or oxidation treatment, or coated with a coating called a thickener or primer, in order to improve adhesion with the concavo-convex layer and the release layer.

[0041] <Concave-convex layer>

[0042] The concavoconvex layer is provided on at least a portion of one surface of the substrate. By partially forming the concavoconvex layer, the surface of the protective layer (the interface between the protective layer and the release layer) can be given a concavoconvex shape brought by the concavoconvex layer. By using the transfer sheet of the present invention, a decorative molded product having a pattern design with a gloss difference given to the surface of the protective layer can be manufactured.

[0043] In the present invention, the concavo-convex layer is required to contain a binder resin and a roughening agent, and the binder resin is required to contain a thermoplastic resin.

[0044] When the concavoconvex layer is formed by a thermosetting resin, the release layer is formed after the concavoconvex layer is cured, and the close contact between the concavoconvex layer and the release layer is deteriorated. Therefore, when transferring to the adherend, peeling occurs between the concavoconvex layer and the release layer, and sometimes the release layer remains on the decorative molded product. In addition, due to the shrinkage during curing, the shape of the concavoconvex layer is disturbed, and there is a concern that the design of the matte part will deteriorate when the decorative molded product is made.

[0045] In addition, when the release layer is formed on the concave-convex layer without completely curing the thermosetting resin during the formation of the concave-convex layer, the concave-convex layer may swell due to the solvent contained in the coating liquid for forming the release layer, depending on the degree of curing. As a result, there is a concern that the design of the matte portion may be deteriorated when a decorative molded article is made.

[0046] In the present invention, by forming a concavo-convex layer with a thermoplastic resin as the main component of the binder resin, the adhesion between the release layer and the concavo-convex layer can be improved. As a result, when the transfer sheet of the present invention is used for transfer, the difference in peel strength between the release layer and the transfer layer (protective layer) is difficult to occur, and the peelability can be improved. In addition, when a thermoplastic resin is used, there is no influence of solidification shrinkage or swelling caused by a solvent, so the concavo-convex shape becomes smooth, and the appearance of the decorative molded product can be improved. In the present invention, it is preferred that the binder resin is substantially composed of a thermoplastic resin. In the present invention, "substantially" means that the proportion of the thermoplastic resin in the binder resin is 95% or more, preferably 98% or more, and more preferably 100%.

[0047] The thickness of the concavoconvex layer after drying is preferably 0.5 μm to 50 μm, more preferably 0.5 μm to 25 μm, and further preferably 0.5 μm to 10 μm. The thickness of the concavoconvex layer is an average value obtained by measuring the thickness of any 20 locations of the concavoconvex layer using a scanning electron microscope (SEM).

[0048] The area ratio of the concavoconvex layer in the substrate surface is preferably 1% or more, more preferably 5% or more, and further preferably 10% or more. In addition, the area ratio is preferably 99% or less, more preferably 95% or less, and further preferably 90% or less.

[0049] As thermoplastic resins, for example, polyolefin resins such as polypropylene and polyethylene, polyester resins, polycarbonate resins, acrylonitrile-butadiene-styrene resins (hereinafter also referred to as "ABS resin"), acrylic resins, vinyl chloride resins, cellulose resins, etc. In the present invention, the above-mentioned resins can be used alone or in combination of two or more.

[0050] Among these, acrylic resin and cellulose resin are preferred from the viewpoint of the dispersibility of the roughening agent and the adhesion to the release layer. In addition, when ionizing radiation is used to form the protective layer described later, acrylic resin and cellulose resin are also suitable for use because they are stable against ionizing radiation. As acrylic resin, there is no particular limitation, and examples thereof include homopolymers of (meth)acrylate, copolymers of two or more different (meth)acrylate monomers, or copolymers of (meth)acrylate and other monomers. As (meth)acrylate resin, more specifically, polymethyl (meth)acrylate, polyethyl (meth)acrylate, polypropyl (meth)acrylate, polybutyl (meth)acrylate, methyl (meth)acrylate-butyl (meth)acrylate copolymer, ethyl (meth)acrylate-butyl (meth)acrylate copolymer, ethylene-methyl (meth)acrylate copolymer, styrene-methyl (meth)acrylate copolymer and other (meth)acrylates. As cellulose resin, nitrocellulose resin and the like can be cited.

[0051] The thermoplastic resin preferably has a weight average molecular weight of 10,000 to 200,000, more preferably 30,000 to 150,000. By setting the molecular weight range, it is easy to adjust the coating liquid for forming the concave-convex layer, and the shape stability of the concave-convex layer can be improved. In addition, the "weight average molecular weight" here is the weight average molecular weight of polystyrene conversion measured by gel permeation chromatography (GPC).

[0052] The roughening agent contained in the concavoconvex layer preferably has an average particle size of 0.5 μm or more. By making the average particle size of the roughening agent be 0.5 μm or more, it is easy to form a concavoconvex shape caused by the concavoconvex layer on the protective layer. In order to give the protective layer a concavoconvex shape of sufficient size, the average particle size of the roughening agent is preferably 1.0 μm or more, more preferably 3.0 μm or more, and further preferably 5.0 μm or more. In addition, when considering the visibility of the printed layer in the area of ​​the concavoconvex shape brought by the concavoconvex layer when making a decorative molded product, and the ease of forming the concavoconvex layer, the average particle size of the roughening agent is preferably 20 μm or less, more preferably 15 μm or less, and further preferably 10 μm or less.

[0053] The ratio of the average particle size of the roughening agent to the thickness of the concavo-convex layer is preferably 1 or more, more preferably 1.2 or more, and further preferably 1.4 or more. By making the ratio satisfy the above numerical value, a sufficient matte effect can be given to the decorative molded product. On the other hand, when the concavo-convex layer is thin relative to the average particle size of the roughening agent, there is a situation where the roughening agent falls off from the concavo-convex layer. Therefore, when considering the retention of the roughening agent, the ratio is preferably 10 or less, more preferably 8 or less, and further preferably 6 or less.

[0054] In this specification, the average particle size is the average value (arithmetic mean diameter) of the particle sizes of 100 randomly selected non-agglomerated particles measured by observing a cross section in the thickness direction of a layer using a scanning electron microscope (SEM) at an acceleration voltage of 3.0 kV and a magnification of 50,000 times.

[0055] The roughening agent may be inorganic particles or organic particles.

[0056] As inorganic particles, for example, silicon dioxide, aluminum oxide, clay, talc, diatomaceous earth, zeolite, calcium carbonate, barium sulfate, zinc oxide, titanium oxide, glass beads, etc. can be cited. In addition, as organic particles, various synthetic resin particles, such as melamine resin, benzoguanamine resin, benzoguanamine / melamine / formaldehyde condensate, acrylic resin, polyurethane resin, styrene resin, etc. can be cited, and these can be used alone or in combination. The shape of the particles can be spherical or amorphous.

[0057] In particular, silica particles are preferred because they have the advantages of improving the roughness of the surface of the decorative molded article and reducing the production cost.

[0058] Relative to 100 parts by mass of binder resin (solid content), preferably containing 50 parts by mass or more and 180 parts by mass or less (solid content) of roughening agent. By setting it to more than 50 parts by mass, it is possible to form a moderate fine concave-convex shape on the surface of the concave-convex layer and the surface of the release layer on the concave-convex layer. As a result, the desired matte design can be given to the decorative molding. In the case of forming a concave-convex layer containing a thermosetting resin and a roughening agent, due to the low flexibility of the layer, there is a concern that the concave-convex layer generates cracks during the manufacture of the decorative molding, the shape is disturbed, and the design of the matte part when the decorative molding is made is deteriorated. For this reason, there is a problem that the amount of roughening agent added cannot be increased when using a thermosetting resin. In the present invention, by forming a concave-convex layer from a thermoplastic resin, it is believed that even if the roughening agent is made in the above-mentioned amount, the concave-convex layer also has flexibility, and the shape of the concave-convex layer can be maintained during the manufacture of the decorative molding.

[0059] When considering the formatibility of the concavo-convex shape, the content of the roughening agent is more preferably 75 parts by mass or more, and more preferably 90 parts by mass or more. By setting it to less than 180 parts by mass, the film strength of the concavo-convex layer can be suppressed from decreasing, and the concavo-convex shape can be maintained in the manufacturing process of the transfer sheet and the manufacturing process of the decorative molding. In addition, when the release sheet is peeled off, the peel strength is made roughly uniform, and poor transfer can be suppressed. Moreover, when the decorative molding is made, the visibility of the printing layer is good. The content of the roughening agent is more preferably less than 160 parts by mass, and more preferably less than 140 parts by mass.

[0060] The formation pattern of the concavoconvex layer is preferably appropriately selected according to the pattern of the printing layer described later. Examples of the pattern include wood grain, stone grain, cloth grain, sand grain, circle, quadrangle, polygon, geometric pattern, and text.

[0061] When forming the concavoconvex layer, first, additives are added to the thermoplastic resin as the binder resin and the roughening agent as needed to prepare a coating liquid for forming the concavoconvex layer to which a suitable solvent is added. The coating liquid is applied to the substrate by a known method such as gravure printing, screen printing, etc., and dried to form the concavoconvex layer.

[0062] <Mold release layer>

[0063] The release layer is disposed on the concavo-convex layer and on the substrate. Figure 1 As shown, the release sheet is composed of a substrate, a concavo-convex layer, and a release layer in this order in the thickness direction. In contrast, in a region where the concavo-convex layer is not provided, the release sheet is composed of a substrate and a release layer in this order in the thickness direction.

[0064] The surface of the release layer opposite to the substrate is in the region formed on the concavo-convex layer ( Figure 1 In the figure, the symbol A) and the area without the concavoconvex layer ( Figure 1 In other words, the surface of the release layer opposite to the substrate is formed with a pattern corresponding to the pattern of the concavo-convex layer.

[0065] The resin component of the release layer is not particularly limited as long as it has a low bonding force with the protective layer and can easily peel the transfer layer from the substrate. For example, a cured product of a thermosetting resin composition and a cured product of an ionizing radiation curable resin composition can be cited. Specifically, fluorine resins, silicone resins, acrylic resins, polyester resins, polycarbonate resins, polyolefin resins, polystyrene resins, polyurethane resins, vinyl chloride-vinyl acetate copolymer resins, etc. can be cited. Among these resin components, a cured product of an ionizing radiation curable resin composition that has excellent strength and can be given a correct and precise shape due to instant curing is preferred, and a cured product of an electron beam curable resin composition is more preferred.

[0066] The so-called ionizing radiation curable resin refers to a resin that is crosslinked and cured by irradiating ionizing radiation, and is a resin with ionizing radiation curable functional groups. Among them, the so-called ionizing radiation curable functional group refers to a group that is crosslinked and cured by irradiating ionizing radiation, and preferably, functional groups with olefinic double bonds such as (meth) acryloyl, vinyl, and allyl can be listed. In addition, the so-called ionizing radiation refers to a ray with an energy quantum that can polymerize or crosslink molecules in electromagnetic waves or charged particle rays, usually ultraviolet rays (UV) or electron rays (EB), in addition, electromagnetic waves such as X-rays and gamma rays, alpha rays, ion rays and other charged particle rays. Among these, the cured product of the electron beam curable resin composition is more preferred.

[0067] Specifically, the ionizing radiation curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers commonly used as conventional ionizing radiation curable resins.

[0068] As the polymerizable monomer, a (meth)acrylate monomer having a radical polymerizable unsaturated group in the molecule is preferred, and among them, a polyfunctional (meth)acrylate monomer is preferred.

[0069] Examples of the polyfunctional (meth)acrylate monomer include a (meth)acrylate monomer having two or more ionizing radiation-curable functional groups in a molecule and having at least a (meth)acryloyl group as the functional group.

[0070] From the viewpoint of heat resistance and formability, the number of functional groups is preferably 2 or more and 8 or less, more preferably 2 or more and 6 or less, further preferably 2 or more and 4 or less, and particularly preferably 2 or more and 3 or less. These multifunctional (meth) acrylate monomers can be used alone or in combination. In addition, they can also be used in the form of a composition obtained by mixing one or more of these multifunctional (meth) acrylate monomers and one or more of the polymerizable oligomers described later. By making a composition obtained by mixing the two, the crosslinking density of the cured product, the molecular weight between crosslinks, etc. can be adjusted, and the various physical properties of the cured product can be adjusted.

[0071] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule and at least a (meth)acryloyl group as the functional group. Examples include polyurethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers.

[0072] The number of functional groups of these polymerizable oligomers is preferably 2 or more and 8 or less from the viewpoint of heat resistance and moldability, and the upper limit is more preferably 6 or less, further preferably 4 or less, and particularly preferably 3 or less.

[0073] In particular, when considering the adhesion with the concave-convex layer, acrylic (meth) acrylate compounds and polyurethane (meth) acrylate compounds are preferred as resin components. Here, the so-called "(meth) acrylate" refers to "acrylate or methacrylate". The resin component can be any type of acrylic (meth) acrylate compound and polyurethane (meth) acrylate compound, or a mixture thereof. Acrylic (meth) acrylate compounds and polyurethane (meth) acrylate compounds can be monomers, oligomers, or mixtures of monomers and oligomers.

[0074] From the viewpoint of heat resistance and moldability, the weight average molecular weight of the monomers and oligomers used in the release layer is preferably 250 to 30,000, more preferably 250 to 20,000, and even more preferably 250 to 15,000. The weight average molecular weight is an average molecular weight measured by GPC analysis and converted to standard polystyrene.

[0075] To the resin composition, additives such as a curing agent and a polymerization initiator may be added as necessary.

[0076] The release layer may contain a release agent in order to improve the releasability from the protective layer.

[0077] As the release agent, waxes such as synthetic wax or natural wax can be cited. As the synthetic wax, polyolefin waxes such as polyethylene wax and polypropylene wax can be cited. In addition, from the viewpoints of improving the hardness of the release layer, inhibiting the oozing of the release agent, and the dispersibility of the particles, as the release agent, it is preferred to use a release component that can be crosslinked and cured, such as reactive silicone.

[0078] The mass ratio of the release agent to the total solid content of the release layer is preferably 0.3 to 10 mass %, more preferably 0.5 to 5 mass %.

[0079] The release layer preferably has a thickness that allows the uneven shape formed on the surface of the release layer to follow the shape of the uneven layer well, and is easy to form and has good releasability from the protective layer. Specifically, the thickness of the release layer is preferably 0.5 μm to 50 μm, and more preferably 0.5 μm to 10 μm.

[0080] The demoulding layer may also contain a roughening agent. Thus, when the decorative molded product is made, it can have a matte feeling as a whole, and the gloss difference of each region can also be made obvious. As a roughening agent, the same substance as that used in the concavoconvex layer can be used. In particular, from the viewpoint of cost, it is preferred to contain silica particles.

[0081] In the case where the demoulding layer includes a roughening agent, the amount of the roughening agent added is preferably less than the amount added in the concavo-convex layer. Specifically, relative to 100 parts by mass (solid content) of the resin component of the demoulding layer, the amount of the roughening agent added preferably contains 0.1 parts by mass or more and 10 parts by mass or less (solid content), and more preferably contains 1.0 parts by mass or more and 5 parts by mass or less. By making the addition amount within the above range, the desired matte design can be given to the decorative molded product.

[0082] The average particle size of the roughening agent contained in the release layer is preferably 0.5 μm or more, more preferably 0.7 μm or more. When the average particle size of the roughening agent is 0.5 μm or more, it is easy to form a concavo-convex shape caused by the release layer on the protective layer. When considering the visibility of the printed layer when the decorative molded article is made, the average particle size of the roughening agent contained in the release layer is preferably 60 μm or less, more preferably 25 μm or less.

[0083] The ratio of the average particle size of the roughening agent to the thickness of the release layer is preferably 1 or more, more preferably 1.2 or more, and further preferably 1.4 or more. By satisfying the above numerical value with this ratio, a sufficient matte effect can be given to the decorative molded product. On the other hand, when the release layer is thin relative to the average particle size of the roughening agent, there is a situation where the roughening agent falls off from the concavo-convex layer. Therefore, when considering the retention of the roughening agent, the ratio is preferably 10 or less, more preferably 8 or less, and further preferably 6 or less.

[0084] In order to design a gloss difference between the portion corresponding to the concave-convex layer and its surroundings (the portion where the concave-convex layer is not provided) when a decorative molded product is made, it is preferred to make the average particle size, added amount, and ratio of the average particle size of the roughening agent contained in the concave-convex layer and the release layer different from each other, and a design in which the concave-convex layer is rougher than the release layer is more preferred.

[0085] The release layer can be formed by a known printing method such as a gravure printing method, an offset printing method, a relief printing method, or a screen printing method.

[0086] <Other layers>

[0087] A resin layer (anti-blocking resin layer) containing a filler may be formed between the substrate and the pattern layer. By forming this resin layer, blocking can be prevented when a roll-shaped transfer film is produced.

[0088] An antistatic layer may be provided on the substrate on the side opposite to the release layer. Preferably, the antistatic layer is provided between the substrate and the pattern layer. By providing the antistatic layer, static electricity on the transfer sheet can be suppressed, thereby suppressing the attachment of foreign matter, etc. Therefore, the transfer workability can be improved.

[0089] The antistatic layer may be in contact with the substrate, or the above-mentioned anti-adhesive layer, primer layer, etc. may be provided between the antistatic layer and the substrate.

[0090] 〔Transfer layer〕

[0091] <Protective layer>

[0092] The protective layer is disposed on the release sheet side of the transfer layer. The protective layer is formed on the region ( Figure 1 In the figure, the symbol A) and the area without the concavoconvex layer ( Figure 1 In the embodiment, symbol B) has different surface irregularities. It is preferred that the protective layer is in contact with the release layer, and the surface on the substrate side has a shape complementary to the surface of the release layer.

[0093] The protective layer preferably contains a cured product of a curable resin composition. As the cured product of the curable resin composition, a cured product of a thermosetting resin composition, a cured product of an ionizing radiation curable resin composition, and a cured product of a mixture thereof can be cited. Among these, from the viewpoint of the scratch resistance of the protective layer, a cured product of an ionizing radiation curable resin composition is preferred. In addition, among the cured products of the ionizing radiation curable resin composition, from the viewpoint of easily completing the crosslinking curing at the moment of forming the protective layer, a cured product of an electron beam curable resin composition is preferred.

[0094] Thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that is cured by heating. Examples of thermosetting resins include acrylic resins, polyurethane resins, phenolic resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In the thermosetting resin composition, a curing agent is added to these curable resins as required.

[0095] Specifically, the ionizing radiation curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers commonly used as conventional ionizing radiation curable resins.

[0096] As the polymerizable monomer, a (meth)acrylate monomer having a radical polymerizable unsaturated group in the molecule is preferred, and among them, a polyfunctional (meth)acrylate monomer is preferred.

[0097] Examples of the multifunctional (meth)acrylate monomer include a (meth)acrylate monomer having two or more ionizing radiation curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group, preferably an acrylate monomer having an acryloyl group. These polymerizable oligomers may be used alone or in combination of two or more.

[0098] The number of functional groups of the polymerizable monomer is preferably 2 or more and 8 or less, more preferably 2 or more and 6 or less, further preferably 2 or more and 4 or less, particularly preferably 2 or more and 3 or less.

[0099] Examples of polymerizable oligomers include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule and having at least a (meth)acryloyl group as the functional group. Examples include polyurethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers.

[0100] These polymerizable oligomers may be used alone or in combination of two or more.

[0101] Among the polymerizable oligomers, polycarbonate (meth) acrylate oligomers are preferred. The polycarbonate (meth) acrylate oligomer is not particularly limited as long as it has a carbonate bond in the main chain and a (meth) acrylate group at the end or in the side chain, and may be a polycarbonate-based polyurethane (meth) acrylate oligomer that is a polyurethane (meth) acrylate oligomer having a polycarbonate skeleton.

[0102] The number of functional groups of these polymerizable oligomers is preferably 2 or more and 8 or less from the viewpoint of heat resistance and moldability, and the upper limit is more preferably 6 or less, further preferably 4 or less, and particularly preferably 3 or less.

[0103] The ionizing radiation curable resin may be appropriately used in combination with the above-mentioned multifunctional (meth)acrylates, etc., for the purpose of reducing the viscosity thereof, etc. These monofunctional (meth)acrylates may be used alone or in combination of two or more.

[0104] From the viewpoint of heat resistance and moldability, the weight average molecular weight of the monomers and oligomers used in the protective layer is preferably 250 to 30,000, more preferably 250 to 20,000, and even more preferably 250 to 15,000.

[0105] It is preferred that the protective layer does not substantially contain particles such as organic particles and inorganic particles. By not containing particles in the protective layer, the pattern of the printed layer serving as the underlying layer can be easily visible.

[0106] The phrase "the protective layer does not substantially contain particles" means that the particles are 1% by mass or less, preferably 0.1% by mass or less, more preferably 0.01% by mass or less, and even more preferably 0% by mass, of the total solid content of the protective layer.

[0107] The protective layer may contain a thermoplastic resin as a resin component other than the cured product of the curable resin composition. By containing a thermoplastic resin in the protective layer, cracks during molding can be suppressed and moldability can be improved. The thermoplastic resin may be a commonly used resin such as an acrylic resin, a polyester resin, or a polyurethane resin.

[0108] The content of the thermoplastic resin is preferably 0.1 to 20% by mass, more preferably 0.5 to 10% by mass, and even more preferably 1 to 5% by mass, based on the total solid content of the protective layer.

[0109] From the viewpoint of the balance between surface hardness and moldability, the thickness of the protective layer is preferably 0.5 to 30 μm, more preferably 1 to 20 μm, and even more preferably 1 to 10 μm.

[0110] The protective layer can be formed by a known printing method such as a gravure printing method, an offset printing method, a letterpress printing method, or a screen printing method.

[0111] In addition, the thermosetting resin composition and / or the ionizing radiation curable resin composition can be completely cured at the time of forming the protective layer, but from the viewpoint of moldability, the thermosetting resin composition and / or the ionizing radiation curable resin composition can also be in an uncured or semi-cured state at the time of forming the protective layer, and after transfer to the adherend, the thermosetting resin composition and / or the ionizing radiation curable resin composition is cured to make it completely cured.

[0112] <Printing layer>

[0113] The printed layer is a layer for imparting a desired design to the decorative molded article.

[0114] The pattern of the printed layer is arbitrary, and examples thereof include wood grain, stone grain, cloth grain, sand grain, circle, quadrangle, polygon, geometric pattern, text, and full-coat printing.

[0115] The print layer preferably contains a binder resin such as a polyvinyl resin, a polyester resin, an acrylic resin, a polyvinyl acetal resin, or a cellulose resin, and a pigment and / or a dye.

[0116] From the viewpoint of designability, the thickness of the printed layer is preferably 0.5 to 40 μm, more preferably 1 to 30 μm.

[0117] The printed layer can be formed by a known printing method such as a gravure printing method, an offset printing method, a letterpress printing method, or a screen printing method.

[0118] <Joint layer>

[0119] The bonding layer has a function of improving the bonding between the adherend such as a resin molded body and the transfer layer. In addition, when the bonding between the protective layer and the adherend is good, the bonding layer may not be provided.

[0120] The bonding layer preferably uses a resin having bonding properties suitable for the raw materials of the adherend. For example, when the material of the adherend is an acrylic resin, it is preferred to use an acrylic resin. Furthermore, when the material of the adherend is a polyphenylene ether-polystyrene resin, a polycarbonate resin, or a styrene resin, it is preferred to use an acrylic resin, a polystyrene resin, a polyamide resin, etc. that have affinity with these resins. In addition, when the material of the adherend is a polypropylene resin, it is preferred to use a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone-indene resin.

[0121] The bonding layer may contain additives such as ultraviolet absorbers and infrared absorbers.

[0122] The thickness of the bonding layer is preferably 0.1 to 10 μm, more preferably 0.5 to 5 μm.

[0123] The bonding layer can be formed by a known printing method such as a gravure printing method, an offset printing method, a letterpress printing method, or a screen printing method.

[0124] <Base coating>

[0125] The primer layer is a layer provided as necessary in order to improve the adhesion between the protective layer and the printed layer.

[0126] The primer layer preferably mainly contains a resin component. In addition, in consideration of imparting heat resistance in a high temperature environment such as in-mold molding, the resin component of the primer layer preferably contains a cured product of a curable resin composition.

[0127] Examples of the curable resin composition include thermosetting resin compositions and ionizing radiation curable resin compositions. The thermosetting resin composition and ionizing radiation curable resin composition of the undercoat layer may be the same as those exemplified for the thermosetting resin composition and ionizing radiation curable resin composition of the protective layer.

[0128] It is particularly preferred that the primer layer contains a cured product of a thermosetting resin composition. Examples of the thermosetting resin composition include two-component curing polyurethane resins containing various polyol compounds such as polyether polyol, polyester polyol, and acrylic polyol, and a curing agent such as an isocyanate compound.

[0129] The thickness of the primer layer is preferably 0.1 to 6 μm, more preferably 0.5 to 5 μm.

[0130] The primer layer may be composed of a single layer or a laminate of two or more layers in consideration of interlayer adhesion and the like.

[0131] The primer layer can be formed by a known printing method such as gravure printing, offset printing, letterpress printing, or screen printing.

[0132] [Decorative moldings]

[0133] use Figure 2 A decorative molded article produced using the transfer sheet of the present invention will be described. Figure 2 4 is a schematic cross-sectional view of a decorative molded article. The decorative molded article 40 includes an adherend 42 and a transfer layer 30 covering the adherend. Figure 2 In the embodiment, the transfer layer 30 includes a bonding layer 38, a printing layer 36, a primer layer 34, and a protective layer 32 in order from the adherend side. The protective layer 32 is located on the outermost surface layer of the decorative molded article 40.

[0134] <Attachment>

[0135] The adherend is a resin molded body made of resin. The shape of the adherend can be a flat plate or a three-dimensional shape with a curved surface. Furthermore, the adherend can also have a color.

[0136] The resin molded body may be formed of a thermoplastic resin or a thermosetting resin.

[0137] When the decorative molded article is manufactured by in-mold molding, a thermoplastic resin is preferably used as the resin molded body. Examples of such thermoplastic resins include polystyrene resins, polyolefin resins, ABS resins (including heat-resistant ABS resins), AS resins, PC / ABS resins, PC / AS resins, AN resins, polyphenylene ether resins, polycarbonate resins, polyacetal resins, acrylic resins, polyethylene terephthalate resins, polybutylene terephthalate resins, polysulfone resins, and polyphenylene sulfide resins.

[0138] <Protective layer>

[0139] The protective layer in the decorative molded article of the present invention preferably has a concavoconvex shape that is substantially complementary to the surface shape of the release layer of the release sheet. The concavoconvex shape becomes a shape corresponding to the pattern of the concavoconvex layer. For example, the surface of the protective layer has a portion corresponding to the concavoconvex layer ( Figure 2 In the figure, the symbol A') has a small concave-convex shape. Therefore, the part corresponding to the concave-convex layer ( Figure 2 In the symbol A') becomes relative to its surrounding ( Figure 2 In the embodiment of the present invention, the region with symbol B') has a rough and low glossy area. That is, the decorative molded article of the present invention has a pattern with different gloss differences within the surface. In the present invention, the region with symbol B' does not necessarily have gloss. As long as the region with symbol B' has high gloss and a significant gloss difference compared to the region with symbol A', the region B' may also have a rough feeling.

[0140] [Method for producing decorative molded article]

[0141] The decorative molded article of the present invention comprises: (1) a step of bonding the transfer layer of the transfer sheet to an adherend via a bonding layer to laminate the transfer sheet on the adherend; and (2) a step of peeling off a release sheet of the transfer sheet to transfer the transfer layer to the adherend.

[0142] The transfer sheet of the present invention is particularly suitable for producing a decorated molded product by in-mold molding (injection molding and simultaneous transfer decoration method). According to the present invention, a pattern with gloss difference can be transferred to the surface of a resin molded body having a complex surface shape such as a three-dimensional curved surface.

[0143] One embodiment of a method for producing a decorative molded article by in-mold molding includes the following steps.

[0144] (S1) a step of placing the transfer layer side of the transfer sheet toward the inner side of the in-mold molding mold;

[0145] (S2) a step of injecting a resin for an adherend into the above-mentioned in-mold molding mold;

[0146] (S3) a step of integrating the transfer sheet with the resin to form a laminated body in which the transfer sheet is laminated on the surface of the resin molded body (adhered body);

[0147] (S4) A step of peeling off the release sheet of the transfer sheet after the laminate is taken out of the mold or simultaneously with the resin molded body being taken out of the mold.

[0148] In the present invention, since the binder resin of the concavo-convex layer is a thermoplastic resin, the release layer and the concavo-convex layer have excellent adhesion. Therefore, when the release sheet is peeled off in the manufacture of the decorative molded product, peeling at the interface between the concavo-convex layer and the release layer can be prevented, and the peeling strength can be made substantially uniform. As a result, the occurrence of transfer failure can be suppressed.

[0149] Example

[0150] Next, the present invention will be described in further detail with reference to Examples, but the present invention is not limited to these Examples in any way.

[0151] The following measurement and evaluation were performed at a temperature of 23°C ± 5°C and a humidity of 40 to 65%. The target samples were exposed to the above atmosphere for 30 minutes or more before measurement and evaluation.

[0152] 1. Evaluation and measurement

[0153] 1-1. Design evaluation

[0154] The decorative molded articles produced in Examples and Comparative Examples were evaluated based on the following criteria to determine whether there was a difference in gloss between the region having the concavo-convex layer and the region not having the concavo-convex layer.

[0155] 2 points: obvious gloss difference;

[0156] 1 point: Although there is a gloss difference, the gloss difference is less obvious than in the evaluation of "2 points";

[0157] 0 points: no difference in gloss is felt;

[0158] Evaluation was performed by 20 test subjects, and the average score was calculated. The design of each decorative molded article was evaluated according to the following criteria.

[0159] A: The average score is above 1.8;

[0160] B + : The average score is above 1.4 and below 1.8;

[0161] B: The average score is above 1.0 and below 1.4;

[0162] C: The average score is less than 1.0.

[0163] 1-2. Evaluation of peelability

[0164] For the transfer sheets of the examples and comparative examples, the release sheet was peeled off from each transfer sheet. The case where the release sheet was easily peeled off and no release layer remained on the transfer layer side was rated as 2 points; the case where the release sheet was difficult to peel off but no release layer remained on the transfer layer side was rated as 1 point; the case where the release sheet was difficult to peel off and the release layer remained on the transfer layer was rated as 0 points. The peelability of 10 release sheets was evaluated and the average score was calculated. The peelability of each transfer sheet was evaluated according to the following criteria.

[0165] A: The average score is 1.5 or above;

[0166] B: The average score is above 1.0 and below 1.5;

[0167] C: The average score is less than 1.0.

[0168] 2. Adjustment of coating liquid

[0169] 2-1. Adjustment of the coating liquid for the concavo-convex layer

[0170] A coating liquid for a concavo-convex layer having the following formulation was prepared.

[0171] (1) Coating liquid for concavoconvex layer 1

[0172] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 5.0 μm) 100 parts by mass

[0173] Solvent (ethyl acetate) appropriate amount

[0174] (2) Coating liquid 2 for concavoconvex layer

[0175] Acrylic resin (thermoplastic resin, weight average molecular weight: 100,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 5.0 μm) 100 parts by mass

[0176] Solvent (ethyl acetate) appropriate amount

[0177] (3) Coating liquid 3 for concavoconvex layer

[0178] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 1.0 μm) 100 parts by mass

[0179] Solvent (ethyl acetate) appropriate amount

[0180] (4) Coating liquid for concavoconvex layer 4

[0181] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 0.5 μm) 100 parts by mass

[0182] Solvent (ethyl acetate) appropriate amount

[0183] (5) Coating liquid for concavoconvex layer 5

[0184] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 20 μm) 100 parts by mass

[0185] Solvent (ethyl acetate) appropriate amount

[0186] (6) Coating liquid for concavoconvex layer 6

[0187] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 5.0 μm) 50 parts by mass

[0188] Solvent (ethyl acetate) appropriate amount

[0189] (7) Coating liquid for concavoconvex layer 7

[0190] Nitrocellulose resin (thermoplastic resin, weight average molecular weight: 50,000) 100 parts by mass Roughening agent (amorphous silica, average particle size 5.0 μm) 180 parts by mass

[0191] Solvent (ethyl acetate) appropriate amount

[0192] 2-2. Preparation of coating liquid for release layer

[0193] A release layer coating liquid having the following formulation was prepared.

[0194] (1) Coating liquid for release layer 1

[0195] Bifunctional urethane acrylate (weight average molecular weight: 8,000) 85 parts by mass

[0196] Trifunctional acrylate (weight average molecular weight: 300) 15 parts by mass

[0197] 1 part by mass of electron beam curable silicone compound

[0198] Solvent (methyl ethyl ketone) appropriate amount

[0199] (2) Coating liquid 2 for release layer

[0200] 100 parts by mass of tetrafunctional acrylic acrylate (weight average molecular weight: 10,000)

[0201] 1 part by mass of electron beam curable silicone compound

[0202] Solvent (methyl ethyl ketone) appropriate amount

[0203] (3) Coating liquid for release layer 3

[0204] Bifunctional urethane acrylate (weight average molecular weight: 8,000) 85 parts by mass

[0205] Trifunctional acrylate (weight average molecular weight: 300) 15 parts by mass

[0206] Roughening agent (amorphous silica, average particle size 2.0 μm) 10 parts by mass

[0207] Solvent (methyl ethyl ketone) appropriate amount

[0208] 2-3. Adjustment of the coating liquid for the protective layer

[0209] A protective layer coating liquid having the following formulation was prepared.

[0210] Bifunctional urethane acrylate (weight average molecular weight: 10,000) 95 parts by mass

[0211] 5 parts by mass of trifunctional acrylate monomer (weight average molecular weight: 300)

[0212] Solvent (methyl ethyl ketone) appropriate amount

[0213] 2-4. Adjustment of the coating liquid for the primer layer

[0214] A coating liquid for an undercoat layer having the following formulation was prepared.

[0215] <Coating liquid for primer layer>

[0216] Acrylic polyol (hydroxyl value: 80 mgKOH / g, Tg: 90°C) 100 parts by mass XDI (meta-xylylene diisocyanate) 10 parts by mass

[0217] Solvent (methyl ethyl ketone) appropriate amount

[0218] 3. Preparation of transfer sheet (Example 1)

[0219] The coating liquid 1 for the concavoconvex layer was applied to one side of a substrate (a biaxially stretched polyethylene terephthalate film having a thickness of 75 μm) and dried to form a concavoconvex layer having a thickness of 2 μm. The concavoconvex layer had a wood-grain duct pattern.

[0220] Next, the release layer coating liquid 1 was applied on the substrate and the concavo-convex layer, and electron beams were irradiated under the conditions of 165 KeV and 7 Mrad (70 kGy) to form a release layer having a thickness of 3 μm.

[0221] Next, a protective layer coating liquid was applied onto the release layer, and electron beams were irradiated under the conditions of 165 KeV and 5 Mrad (50 kGy) to form a protective layer having a thickness of 3 μm.

[0222] Next, the undercoat layer coating liquid 1 was applied on the protective layer and dried to form an undercoat layer having a thickness of 2 μm.

[0223] Next, a brown ink (acrylic resin composition) was applied on the primer layer by gravure printing and dried to form a printed layer having a wood grain pattern with a thickness of 6 μm.

[0224] Next, an adhesive layer coating liquid prepared by diluting a thermoplastic resin (acrylic resin) with a solvent was applied onto the printed layer and dried to form a heat-sealable adhesive layer having a thickness of 2 μm. The transfer sheet of Example 1 was obtained through the above steps.

[0225] (Example 2)

[0226] A transfer sheet of Example 2 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 2 was used.

[0227] (Example 3)

[0228] A transfer sheet of Example 3 was produced by the same procedure as in Example 1 except that the release layer coating liquid 2 was used.

[0229] (Example 4)

[0230] A transfer sheet of Example 4 was prepared by the same procedure as in Example 1 except that the release layer coating liquid 3 was used.

[0231] (Example 5)

[0232] A transfer sheet of Example 5 was produced by the same procedure as in Example 1 except that the thickness of the release layer was changed to 0.5 μm.

[0233] (Example 6)

[0234] A transfer sheet of Example 6 was produced by the same procedure as in Example 1 except that the thickness of the release layer was set to 20 μm.

[0235] (Example 7)

[0236] A transfer sheet of Example 7 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 3 was used.

[0237] (Example 8)

[0238] A transfer sheet of Example 8 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 4 was used.

[0239] (Example 9)

[0240] A transfer sheet of Example 9 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 5 was used.

[0241] (Example 10)

[0242] A transfer sheet of Example 10 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 6 was used.

[0243] (Example 11)

[0244] A transfer sheet of Example 11 was prepared by the same procedure as in Example 1 except that the concavo-convex layer coating liquid 7 was used.

[0245] (Comparative Example 1)

[0246] As the coating liquid for the concavo-convex layer of Comparative Example 1, a coating liquid containing a thermosetting resin having the following formulation was prepared.

[0247] On one side of the substrate (biaxially stretched polyethylene terephthalate film with a thickness of 75 μm), the coating liquid for the concave-convex layer of Comparative Example 1 was applied and dried. As in Example 1, the concave-convex layer was formed on a portion of the substrate. Then, it was cured by aging at 40°C for 96 hours to form a concave-convex layer with a thickness of 2.5 μm and a release layer with a thickness of 3 μm. The other layers were formed in the same manner as in Example 1 to obtain a transfer sheet of Comparative Example 1.

[0248] <Concavoconvex layer coating solution of Comparative Example 1>

[0249] Acrylic polyol (hydroxyl value: 80 mgKOH / g, Tg: 65°C, solid content: 50%, solvent: toluene / ethyl acetate mixed solvent) 40 parts by mass

[0250] Isocyanate (main component: XDI, solid content 75%, solvent: ethyl acetate) 14 parts by mass

[0251] Roughening agent (amorphous silica, average particle size 5.0 μm) 4 parts by mass

[0252] Solvent (ethyl acetate) 40 parts by mass (Comparative Example 2)

[0253] A transfer sheet of Comparative Example 2 was obtained by the same steps as in Example 1 except that the concavo-convex layer was not provided.

[0254] 4. Production of decorative moldings

[0255] The transfer sheets of Examples 1 to 11 and Comparative Examples 1 to 2 were placed on one side of the upper and lower in-mold molds, respectively. At this time, the transfer sheets were placed so that the bonding layer faced the inner side of the mold (the side in contact with the injected resin).

[0256] Next, the mold was closed and injection resin (PC / ABS resin) was injected into the mold to obtain a laminate (10 cm×16 cm×2 mm thick plate-shaped body) in which the transfer sheet and the injection resin layer containing the injection resin were integrated.

[0257] Next, after the mold was opened, the release sheet (substrate to release layer) of the transfer sheet was peeled off from the laminate, thereby obtaining the decorated molded articles of Examples 1 to 11 and Comparative Examples 1 and 2.

[0258] 4. Results

[0259] Table 1 shows the evaluation results of the transfer sheets and decorative molded articles of Examples and Comparative Examples.

[0260] [Table 1]

[0261] Table 1

[0262]

[0263] The transfer sheets of Examples 1 to 11 using thermoplastic resin for the concavoconvex layer all had good releasability. In particular, the decorative molded articles of Examples 1 to 5 had a significant gloss difference within the surface and good design. The decorative molded articles of Examples 6 to 11 were inferior to those of Examples 1 to 5, but had design properties that did not cause any problems in use.

[0264] On the other hand, the transfer sheet of Comparative Example 1 using a thermosetting resin for the concavo-convex layer had poor releasability. In addition, the concavo-convex layer part was observed to have disturbed the pattern shape due to curing shrinkage, and thus the evaluation result showed that the designability was poor.

Claims

1. A transfer sheet having a transfer layer on a release sheet, wherein: The release sheet comprises: Base material; a concavoconvex layer provided on a portion of one surface of the substrate, containing a binder resin and a roughening agent, the binder resin containing a thermoplastic resin; and a release layer, which is provided on the concavo-convex layer and on the substrate where the concavo-convex layer is not formed, The ratio of the thermoplastic resin in the binder resin is 95% by mass or more, The concavoconvex layer contains 50 parts by mass or more and 180 parts by mass or less of the roughening agent based on 100 parts by mass of the binder resin.

2. The transfer sheet according to claim 1, wherein: The release layer is in contact with the transfer layer.

3. The transfer sheet according to claim 1, wherein: The roughening agent included in the concavo-convex layer has an average particle size of 0.5 μm or more and 20 μm or less.

4. The transfer sheet according to claim 1, wherein: The thickness of the release layer is 0.5 μm or more and 50 μm or less.

5. The transfer sheet according to claim 1, wherein: The release layer includes at least one of a cured product of a thermosetting resin composition and a cured product of an ionizing radiation-curable resin composition.

6. The transfer sheet according to claim 1, wherein: The release layer contains 0.1 parts by mass to 10 parts by mass of a roughening agent having an average particle diameter of 0.5 μm to 60 μm, based on 100 parts by mass of the resin component of the release layer.

7. The transfer sheet according to claim 6, wherein: The roughening agent contained in the release layer has an average particle size of 0.5 μm or more and 25 μm or less.

8. The transfer sheet according to claim 1, wherein: The thermoplastic resin is an acrylic resin or a cellulose resin.

9. The transfer sheet according to claim 1, wherein: The weight average molecular weight of the thermoplastic resin is 30,000 to 150,000.

10. A method for manufacturing a decorative molded product, characterized in that: include: A step of bonding the transfer layer of the transfer sheet according to any one of claims 1 to 9 to an adherend, and laminating the transfer sheet on the adherend; and A step of peeling off the release sheet of the transfer sheet to transfer the transfer layer to the adherend.

Images