Transfer type thermosetting resin sheet, method for coating transfer type thermosetting resin sheet, vehicle, and vehicle member

Abstract

To provide a transfer type thermosetting resin sheet which can cure a coating layer without damaging the coating layer by dust, scratches and the like.SOLUTION: A transfer type thermosetting resin sheet includes a coating layer composed of a thermosetting resin composition, and a transfer layer, wherein the thermosetting resin composition contains block isocyanate, and air permeability of the transfer layer is 5 to 30,000 seconds by a Gurley testing machine method.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a transfer type thermosetting resin sheet, a coating method for a transfer type thermosetting resin sheet, and a vehicle and a vehicle component coated with a transfer type thermosetting resin sheet. [Background technology]

[0002] Furniture, steel plates, vehicle bodies, and the like are painted and decorated from the viewpoint of design and durability. It is known that decoration is performed using a film such as a decorative film. A decorative film is generally provided with a protective layer for protecting a decorative resin layer (paint layer) and a transfer layer that serves as a base material when transferring the resin layer to an object. For example, in Patent Document 1, a decorative thermosetting covering sheet is laminated on a support layer that serves as a transfer layer, and the thermosetting covering sheet is attached to the object while still laminated on the support layer.

[0003] Patent Document 2 discloses a coating film comprising a support sheet and a transfer layer supported by the support sheet and having a plurality of through holes with a diameter of 0.3 mm to 0.7 mm. In Patent Document 1, the transfer layer is transferred to the surface of an object to become a decorative layer. The through holes are used as air bubble vents to guide air bubbles trapped between the surface of the object and the transfer layer to between the transfer layer (decorative layer) and the support sheet. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 2688105 [Patent Document 2] Patent No. 6821695 Summary of the Invention [Problem to be solved by the invention]

[0005] Generally, the paint layer constituting the decorative film is formed from a thermosetting resin composition, and is often heated and cured after being attached to the object as described above. In addition, the paint layer constituting the decorative film may use a curing agent such as blocked isocyanate that generates gas when heated for curing. In that case, it is necessary to peel off the transfer layer before heating in order to remove the generated gas from the paint layer.

[0006] However, if the transfer layer is peeled off before curing, the uncured paint layer is exposed on the back side of the decorative film, which can lead to problems such as dust or other foreign matter adhering to the paint layer during heating or scratches when the paint layer comes into contact with an object, making it prone to poor appearance.

[0007] As a means for dealing with the above problem, it is conceivable to heat and cure the paint layer while the transfer layer is attached to the paint layer. However, when heating is performed while the conventional transfer layer is attached, there is a risk that the paint layer will not be sufficiently cured because the gas generated when the curing agent such as blocked isocyanate in the paint layer reacts will not escape. For example, when the thermosetting sheet disclosed in Patent Document 1 is used, the support layer does not have holes, making it difficult to release the gas during heating, resulting in a problem of insufficient curing.

[0008] On the other hand, the coating film disclosed in Patent Document 2 has holes, but the holes are merely 0.3 mm or larger in size in the decorative layer in order to remove air bubbles between the decorative layer and the adherend.

[0009] Therefore, an object of the present invention is to provide a transfer type thermosetting resin sheet that is capable of curing a paint layer without impairing the appearance of the paint layer due to adhesion of foreign matter such as dust or scratches. [Means for solving the problem]

[0010] As a result of extensive research, the present inventors have found that the above problem can be solved by adjusting the air permeability, as measured by the Gurley tester method, of the transfer layer constituting the transfer-type thermosetting resin sheet to 5 seconds or more and 30,000 seconds or less. That is, the present invention provides the following [1] to

[11] .

[0011] [1] A transfer type thermosetting resin sheet comprising a paint layer made of a thermosetting resin composition and a transfer layer, wherein the thermosetting resin composition contains at least one compound selected from the group consisting of blocked isocyanates and melamine-based compounds, and the air permeability of the transfer layer is 5 seconds or more and 30,000 seconds or less, measured by a Gurley tester. [2] The transfer type thermosetting resin sheet according to [1], wherein the transfer layer has an air permeability of 5 seconds or more and 10,000 seconds or less, measured by a Gurley tester. [3] The transfer type thermosetting resin sheet according to [1] or [2], wherein the transfer layer has an air permeability of 5 seconds or more and 5,000 seconds or less as measured by a Gurley tester. [4] The transfer type thermosetting resin sheet according to any one of [1] to [3], wherein the thermosetting resin composition contains a (meth)acrylic polyol. [5] The transfer type thermosetting resin sheet according to any one of [1] to [4], wherein the transfer layer contains a polypropylene resin or a polyethylene resin. [6] The transfer type thermosetting resin sheet according to any one of [1] to [5], wherein the average pore size of the surface of the transfer layer is 1 μm or less. [7] A coating method for applying a coating to an object to be coated, comprising: a first step of attaching a transfer-type thermosetting resin sheet, which comprises a paint layer made of a thermosetting resin composition containing at least one compound selected from the group consisting of blocked isocyanates and melamine-based compounds, and a transfer layer having an air permeability of 5 to 30,000 seconds as measured by the Gurley tester, to the object to be coated; and a second step of heat-curing the transfer-type thermosetting resin sheet in a state in which the transfer layer is laminated on the paint layer. [8] The coating method described in [7], further comprising a third step of peeling the transfer layer from the paint layer after the second step, and a fourth step of further heating and curing the paint layer after the third step. [9] The coating method according to [8], wherein in the second step, the transfer type thermosetting resin sheet is heated and cured until the paint layer has a pencil hardness of 6B or more.

[10] A vehicle painted with a transfer type thermosetting resin sheet according to any one of [1] to [6].

[11] A vehicle component coated with the transfer type thermosetting resin sheet according to any one of [1] to [6]. Effect of the Invention

[0012] According to the present invention, it is possible to provide a transfer type thermosetting resin sheet that is capable of curing a paint layer without impairing the appearance of the paint layer due to adhesion of foreign matter such as dust or scratches. [Brief description of the drawings]

[0013] [Figure 1] 1 is a schematic cross-sectional view showing an example of a coating method, illustrating first and second steps. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] [Transferable thermosetting resin sheet] The transfer type thermosetting resin sheet of the present invention comprises a paint layer made of a thermosetting resin composition and a transfer layer, and the air permeability of the transfer layer is 5 seconds or more and 30,000 seconds or less, measured by the Gurley tester method. In the present invention, by heating and curing the paint layer with the transfer layer attached to it, it is possible to prevent foreign matter from adhering to the paint layer and to prevent the paint layer from being scratched, thereby maintaining a good appearance of the paint layer, while allowing gas generated during the curing reaction in the paint layer to be released from the paint layer through holes provided in the transfer layer. Each layer will be described in detail below.

[0015] (Transfer layer) The transfer layer is a member that protects the paint layer from damage and adhesion of foreign matter, and also serves as a support when the paint layer is attached to an object to be coated. The transfer layer has an air permeability (hereinafter simply referred to as "air permeability") measured by the Gurley tester method of 5 seconds or more and 30,000 seconds or less. If the air permeability is less than 5 seconds, the transfer layer will have excessive holes or the holes will be excessively large, making it difficult to prevent foreign matter from adhering to the paint layer during heat curing of the paint layer, which may result in poor appearance of the paint layer. If the air permeability exceeds 30,000 seconds, the transfer layer will have insufficient air permeability, making it difficult to remove gas generated from the paint layer when the paint layer is heat cured, and the paint layer may not be sufficiently cured. From the above viewpoints, the air permeability is preferably 5 seconds or more and 10,000 seconds or less, and more preferably 5 seconds or more and 5,000 seconds or less. The air permeability can be adjusted to a desired range by the material of the resin film constituting the transfer layer, the thickness of the transfer layer, the density and diameter of the holes provided in the transfer layer, and the like.

[0016] The transfer layer may be formed from a porous resin film. Examples of resins used in the porous resin film include polyolefin resins such as polyethylene resins and polypropylene resins, and polyimide resins. In addition, materials other than porous resin films may be used as the transfer layer, and breathable cloth or paper may also be used. Among these, it is preferable to include at least one selected from polypropylene resin, polyethylene resin, and polyimide resin. Among these, it is more preferable to include polypropylene resin or polyethylene resin from the viewpoint of production cost and handling, and more preferable to include polypropylene resin or polyimide resin from the viewpoint of heat resistance.

[0017] The polypropylene resin may be homopropylene or a copolymer of propylene such as random polypropylene and a small amount (for example, 10 mass % or less) of other α-olefins. Examples of other α-olefins include linear α-olefins having 1 to 12 carbon atoms, such as ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-nonene, and 1-decene. Polyethylene resins include low-density polyethylene (LDPE, density: 0.930 g / cm 3 less than 0.930g / cm 3 More than 0.942g / cm 3 less than 0.942g / cm 3 or more), and linear low density polyethylene (LLDPE).

[0018] The resin film constituting the transfer layer may be a single layer film consisting of one single layer, or may be a multilayer film consisting of two or more layers. In addition, in the resin film constituting the transfer layer, the resin contained in the resin film may be used alone or in combination of two or more types. When two or more types of resins are used in combination, different types of resins may be used in each layer to form a multilayer film. In addition, a single layer film may be formed by mixing two or more types of resins, or one or more layers in a multilayer film may be formed.

[0019] The average pore size of the transfer layer surface is preferably 50 μm or less, more preferably 10 μm or less, and even more preferably 1 μm or less. In this case, it is preferable that the pore sizes of all pores present on the transfer layer surface are equal to or less than the above upper limit. When the pore size is equal to or less than the above upper limit, adhesion of foreign matter to the paint layer and damage to the paint layer can be easily prevented. On the other hand, the average pore size of the transfer layer surface is not particularly limited, but from the viewpoint of easily adjusting the air permeability of the transfer layer to a predetermined range, the average of the entire transfer layer is preferably 0.05 μm or more, more preferably 0.1 μm or more, and even more preferably 1 μm or more.

[0020] The density of holes in the transfer layer is 10,000 to 50,000,000 holes / cm 2 It is preferable that the number of particles is 100,000 to 50,000,000 particles / cm. 2 More preferably, the number of particles is 1,000,000 to 50,000,000 particles / cm. 2It is more preferable that the density of the holes in the transfer layer is equal to or greater than the lower limit, the air permeability is equal to or less than a certain level, and this makes it easier to remove gas generated from the paint layer and to obtain a sufficiently cured paint layer. On the other hand, when the density of the holes is equal to or less than the upper limit, the air permeability is equal to or more than a certain level, and this makes it easier to prevent foreign matter from adhering to the paint layer.

[0021] The transfer layer may have at least one surface that has been release-treated with a release agent such as a silicone-based release agent or a fluorine-based release agent. When the transfer layer is release-treated, it is preferable that the release-treated surface constitutes the surface on the paint layer side. The transfer layer is easily released from the paint layer by being release-treated. However, the transfer layer does not need to be release-treated as long as it can be released from the paint layer. The thickness of the transfer layer is not particularly limited, but is, for example, 10 μm to 1000 μm, preferably 30 μm to 700 μm, more preferably 50 μm to 500 μm. If the thickness of the transfer layer is below the upper limit, the air permeability value is likely to be below a certain level, making it easier to remove gas generated from the paint layer. If the thickness of the transfer layer is above the lower limit, a certain level of strength can be imparted to the transfer layer.

[0022] (Paint layer) The paint layer in the transfer type thermosetting resin sheet is formed from a thermosetting resin composition as described above. The thermosetting resin composition contains at least one compound selected from blocked isocyanates and melamine-based compounds (hereinafter also referred to as compound (X)). Compound (X) is a curing agent that generates gas during a curing reaction. In the present invention, even if the thermosetting resin composition contains these compounds, the gas generated during the curing reaction can be released from the paint layer through the holes provided in the transfer layer, so that the curing reaction can proceed appropriately.

[0023] Of the above, the compound (X) is preferably a blocked isocyanate. A blocked isocyanate is a compound in which an isocyanate group is blocked with a protecting group. When exposed to high temperatures, the protecting group (blocking agent) is thermally dissociated and removed, and a curing reaction occurs between the resulting isocyanate group and a functional group in the above-mentioned curable resin (typically, a hydroxyl group of a polyol). When a blocked isocyanate is used, as the paint layer is heated and cured, the thermally dissociated blocking agent in the paint layer is gasified, and gas is generated from the paint layer. In the present invention, the gas generated from the paint layer is released through the holes present in the transfer layer, whereby the blocking agent is released from the blocked isocyanate, and the curing reaction between the thermosetting resin and the isocyanate compound can be promoted. A blocked isocyanate can be obtained, for example, by reacting an isocyanate compound having two or more isocyanate groups in one molecule with a blocking agent.

[0024] The isocyanate compound having two or more isocyanate groups in one molecule is not particularly limited, but examples thereof include tolylene diisocyanate, diphenylmethane diisocyanate, hexamethylene diisocyanate, pentamethylene diisocyanate, isophorone diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, and modified products thereof. Examples of blocking agents include pyrazole, phenols, oximes, lactams, malonic acid esters, etc. Among these, pyrazole is preferred. The content of the blocked isocyanate in the thermosetting resin composition is preferably adjusted so that the ratio of the number of functional groups in the curable resin to the number of isocyanate groups in the blocked isocyanate is preferably 0.4 to 1.8, more preferably 0.6 to 1.5.

[0025] The melamine-based compound is a compound having a melamine skeleton in the compound, and any compound capable of generating a dehydration condensation reaction may be used. Examples of the melamine-based compound include alkylolated melamine derivatives such as monomethylolmelamine and hexamethylolmelamine obtained by reacting melamine with formaldehyde under an alkali, compounds partially etherified by reacting an alkylolated melamine derivative with an alcohol, and mixtures thereof. The melamine-based compound may be either a monomer or a dimer or higher polymer, or a mixture thereof may be used.

[0026] The content of the compound (X) in the thermosetting resin composition is preferably 5% by mass or more, more preferably 10% by mass or more, and even more preferably 15% by mass or more, based on the total amount of the thermosetting resin composition. When the content of the compound (X) is equal to or more than the above lower limit, the thermosetting resin composition can be sufficiently cured, and it becomes easier to obtain a coating material having excellent strength. In addition, the content of the compound (X) is preferably 50% by mass or less, more preferably 45% by mass or less, and even more preferably 40% by mass or less, based on the total amount of the thermosetting resin composition, from the viewpoint of being able to contain the thermosetting resin and colorant described later at a certain ratio. In addition, the thermosetting resin composition may be diluted with a volatile component such as a solvent as described later, but in this specification, the content (mass%) of each component in the thermosetting resin composition means a value based on the solid content excluding the volatile components.

[0027] The thermosetting resin composition preferably further contains a thermosetting resin. The thermosetting resin preferably has a functional group, and the functional group is preferably a functional group that reacts with a reactive group (e.g., an isocyanate group) contained in the curing agent. Specific examples of the functional group include a hydroxyl group, a carboxyl group, and an amino group, and among these, a hydroxyl group is preferable. The thermosetting resin may have only one type of functional group, or may have two or more types. In addition, it is preferable that two or more functional groups are contained in one molecule.

[0028] The content of the thermosetting resin in the thermosetting resin composition is not particularly limited, but is preferably 40 mass % or more and 95 mass % or less, more preferably 50 mass % or more and 90 mass % or less, and even more preferably 60 mass % or more and 85 mass % or less, based on the total amount of the thermosetting resin composition.

[0029] Examples of the thermosetting resin include (meth)acrylic resin, polycarbonate resin, polyester resin, and epoxy resin, among which (meth)acrylic resin is preferred. Therefore, the thermosetting resin composition for the paint layer preferably contains (meth)acrylic resin and blocked isocyanate. By containing (meth)acrylic resin and blocked isocyanate, the paint layer is more likely to have the desired flexibility, and the adhesion and adhesive strength to the coated object are more likely to be improved. In addition, after curing by heat curing, it is easier to achieve high hardness, and the scratch resistance of the cured paint is also improved.

[0030] The (meth)acrylic resin used in the thermosetting resin composition may be a (meth)acrylic resin having a plurality of functional groups. The functional group is as described above, and the (meth)acrylic resin preferably has a hydroxyl group. The (meth)acrylic resin may have only one type of functional group, or may have two or more types. Therefore, the (meth)acrylic resin preferably contains a (meth)acrylic polyol having a plurality of hydroxyl groups, and more preferably contains an acrylic polyol.

[0031] The (meth)acrylic resin is an acrylic polymer obtained by polymerizing a monomer mixture containing a (meth)acrylic acid ester monomer and a functional group-containing monomer having the above-mentioned functional group such as a hydroxyl group, an amino group, or a carboxyl group. The monomer mixture may contain monomers other than the (meth)acrylic acid ester monomer and the functional group-containing monomer, such as a styrene derivative monomer. Note that (meth)acrylic means methacryl or acrylic, and the same applies to other similar terms.

[0032] Examples of the (meth)acrylic acid ester monomer include (meth)acrylic acid ester monomers that do not have the above-mentioned functional group, such as alkyl (meth)acrylates having an alkyl group with about 1 to 18 carbon atoms, (meth)acrylates having an aromatic ring such as benzyl (meth)acrylate and phenoxydiethylene glycol (meth)acrylate, and 2-ethoxyethyl (meth)acrylate. Examples of functional group-containing monomers include (meth)acrylic acid ester monomers having a hydroxyl group, such as 2-hydroxyethyl (meth)acrylate, (meth)acrylic acid ester monomers having an amino group, such as 2-aminoethyl (meth)acrylate, and monomers having a carboxyl group, such as (meth)acrylic acid. Furthermore, as the (meth)acrylic resin, a copolymer obtained by block or graft polymerization of the above-mentioned acrylic polymer with another monomer or polymer may be used.

[0033] The content of the (meth)acrylic polyol in the thermosetting resin composition is not particularly limited, but is preferably 40% by mass or more and 90% by mass or less, more preferably 50% by mass or more and 85% by mass or less, and even more preferably 60% by mass or more and 80% by mass or less, based on the total amount of the thermosetting resin composition. By keeping the (meth)acrylic resin within the above range, the coatability and curability of the coating layer can be easily improved.

[0034] The thermosetting resin composition preferably contains, as the (meth)acrylic resin, a (meth)acrylic resin having a weight average molecular weight (Mw) of 50,000 or more and 1,000,000 or less, which is solid and has a plurality of functional groups (hereinafter also referred to as a high molecular weight (meth)acrylic resin). By containing a (meth)acrylic resin having a weight average molecular weight within the above range, it becomes easier to maintain the paint layer in a certain shape even before curing, and it becomes easier to properly form it on a transfer layer or the like. In addition, it becomes easier to impart tackiness and extensibility to the paint layer. By having tackiness and extensibility, the paint layer has good shape followability during vacuum molding, and color unevenness is also less likely to occur. Furthermore, when the weight average molecular weight is within the above range, it becomes easier to increase the hardness of the resin layer after curing. The weight average molecular weight is preferably 100,000 or more and 500,000 or less, more preferably 120,000 or more and 400,000 or less. In this specification, the weight average molecular weight (Mw) is measured by gel permeation chromatography (GPC) and is calculated as a standard polystyrene equivalent value. In addition, being solid means being solid at room temperature (23°C) and normal pressure (1 atm).

[0035] The high molecular weight (meth)acrylic resin is preferably a (meth)acrylic polyol having a plurality of hydroxyl groups. As described above, the (meth)acrylic polyol can be obtained, for example, by polymerizing a monomer mixture containing a (meth)acrylic acid ester monomer and a hydroxyl group-containing monomer. In the thermosetting resin composition, the (meth)acrylic resin may be used alone or in combination of two or more kinds.

[0036] The thermosetting resin composition may contain, as the thermosetting resin, a resin having a weight average molecular weight of less than 50,000 (hereinafter also referred to as a plasticizing resin) in addition to the high molecular weight (meth)acrylic resin described above. The thermosetting resin composition contains a plasticizing resin having a low weight-average molecular weight in addition to a high molecular weight (meth)acrylic resin, which makes it easier to achieve a good balance between coatability, curability, tackiness, extensibility, etc. Also, the wettability to the substrate can be improved, thereby increasing the adhesive strength to the substrate.

[0037] The plasticizing resin is preferably one that is compatible with the high molecular weight (meth)acrylic resin and has a thermosetting functional group. Examples of the resin used for the plasticizing resin include (meth)acrylic resin, polycarbonate resin, polyester resin, and epoxy resin, and among these, (meth)acrylic resin or polycarbonate resin is preferred. The (meth)acrylic resin used as the plasticizing resin may be an oligomer having a functional group such as a hydroxyl group, an amino group, or a carboxyl group. The (meth)acrylic resin used as the plasticizing resin may be, for example, as described above in the (meth)acrylic resin, and preferably, a (meth)acrylic polyol having a plurality of hydroxyl groups is used. Poly(meth)acrylate having a carboxyl group is also preferred. The polycarbonate resin used as the plasticizing resin is preferably a polycarbonate polyol. The weight average molecular weight of the plasticizing resin is preferably 450 or more and 30,000 or less, and more preferably 1000 or more and 20,000 or less. Moreover, it is desirable for the plasticizing resin to be liquid at room temperature and pressure. The plasticizing resin is preferably at least one of a (meth)acrylic polyol having a plurality of hydroxyl groups and a polycarbonate polyol.

[0038] The content of the plasticizing resin in the thermosetting resin composition is, for example, 0 to 0.9, preferably 0.01 to 0.5, and more preferably 0.03 to 0.1, in terms of mass ratio relative to the content of the high molecular weight (meth)acrylic resin.

[0039] In addition to the thermosetting resin and the curing agent, the thermosetting resin composition may appropriately contain components according to the performance required for the coating formed from the paint layer, for example, when the coating formed from the paint layer is to be a colored coating, it is preferable to contain a colorant such as a pigment, dye, or luster material to make the paint layer a colored layer. Also, when the coating formed from the paint layer is to be a heat-shielding coating, it is preferable to contain a heat-shielding material in the thermosetting resin composition to make the paint layer a heat-shielding layer. The paint layer may contain components other than those described above, for example additives other than those described above. Examples of additives include crosslinking agents, dispersants, inorganic fillers other than pigments and luster materials, antiaging agents, antioxidants, and rust inhibitors. Furthermore, the paint layer may be made of a clear layer, which will be described later. Among these, it is preferable that the thermosetting resin composition contains at least a colorant.

[0040] Examples of pigments used in the colorant include, but are not limited to, metal oxide pigments such as titanium oxide and iron oxide; inorganic pigments such as carbon black, clay, kaolin, barium sulfate, barium carbonate, calcium carbonate, talc, silica, and alumina white; and organic pigments such as azo pigments, quinacridone pigments, diketopyrrolopyrrole pigments, perylene pigments, perinone pigments, benzimidazolone pigments, vat pigments, isoindoline pigments, isoindolinone pigments, metal chelate azo pigments, phthalocyanine pigments, indanthrone pigments, dioxane pigments, and indigo pigments. As the dye, known dyes can be used, and examples of the dye include azo dyes, anthraquinone dyes, indigoid dyes, and stilbene dyes. The lustrous material is a compound that can impart lustrous properties to the coating layer and can impart the property of showing gloss when observed from multiple directions. The lustrous material is not particularly limited, but examples thereof include compounds in which a titanium oxide layer is provided on the surface of natural mica, synthetic mica, alumina flakes, glass flakes, etc. The paint layer preferably contains at least one of a pigment or a luster material as a colorant, and more preferably contains a pigment. It is also preferable that the paint layer contains both a pigment and a luster material. The content of the colorant in the thermosetting resin composition is not particularly limited, but is, for example, about 0.1 to 25 mass %, preferably 0.3 to 20 mass %, and more preferably 0.5 to 12 mass %. In addition to the above-mentioned additives such as a colorant and a heat-shielding material, the thermosetting resin composition may appropriately contain additives such as an inorganic filler, a curing catalyst, a curing accelerator, a surface conditioner, a defoamer, a crosslinking agent, a dispersant, an antiaging agent, and an antioxidant.

[0041] The paint layer may be a single layer or may have a multi-layer structure of two or more layers, but a multi-layer structure is preferable. By having a multi-layer structure, various functions can be imparted to the coating formed from the paint layers. In the case where the paint layer has a multi-layer structure, each layer may be made of the above-mentioned thermosetting resin composition. Each layer may contain a colorant as described above to form a colored layer, a heat-shielding material to form a heat-shielding layer, or a clear layer that does not substantially contain a colorant.

[0042] In the case of a multi-layer structure, the paint layer preferably has at least a colored layer and a clear layer. In the case of having a colored layer and a clear layer, the clear layer and the colored layer are preferably arranged in this order from the transfer layer side. With such a layer structure, when the transfer type thermosetting resin sheet is attached to the object to be coated, the colored layer and the clear layer are arranged in this order from the object to be coated. The paint layer has a colored layer, so that the object to be painted can be colored by the paint formed by the paint layer. Furthermore, by providing a clear layer in addition to the colored layer, the colored layer can be protected and glossy. The colored layer preferably contains a pigment as a colorant, and therefore, it is particularly preferable that the paint layer has a clear layer and a pigment layer.

[0043] The colored layer and the clear layer may both be made of the above-mentioned thermosetting resin composition, and the thermosetting resin composition for the colored layer may contain a colorant as described above. When a (meth)acrylic resin is used as the curable resin, the thermosetting resin composition for the colored layer may contain at least a high molecular weight (meth)acrylic resin, but preferably contains both a high molecular weight (meth)acrylic resin and a plasticizing resin. On the other hand, the clear layer is a transparent layer, and it is sufficient that the color of the colored layer can be seen from the outside through the clear layer, and for example, the transmittance of light with a wavelength of 450 nm is 80% or more. The clear layer is preferably a coating film that does not contain a colorant, but may contain a small amount of colorant as long as it does not impair its function. In addition, when a (meth)acrylic resin is used as the curable resin, the thermosetting resin composition for the clear layer may contain at least a high molecular weight (meth)acrylic resin, and in that case, it may or may not contain a plasticizing resin.

[0044] Of course, when the paint layer has a multi-layer structure, it is not limited to a two-layer structure of a clear layer and a colored layer, and various laminated structures are possible, and a structure of three or more layers may be formed by providing two or more colored layers and one or more clear layers, or a structure consisting of two colored layers without the clear layer. Also, two or more clear layers may be provided. Also, a heat-shielding layer or the like may be provided between the clear layer and the colored layer to form a structure of three or more layers.

[0045] The thickness of the paint layer is not particularly limited, but is, for example, from 20 μm to 200 μm, and preferably from 30 μm to 100 μm. In addition, when a colored layer and a clear layer are provided on the paint layer, the thickness of the colored layer is not particularly limited, but is, for example, 10 μm to 100 μm, preferably 15 μm to 50 μm. In addition, the thickness of the clear layer is not particularly limited, but is, for example, 10 μm to 100 μm, preferably 15 μm to 50 μm.

[0046] (protective layer) The transfer type thermosetting resin sheet may have a protective layer. The protective layer is a member that protects the paint layer from scratches and adhesion of foreign matter. The protective layer is preferably formed of a resin film. Examples of resins used in the resin film for the protective layer include thermoplastic resins. In addition, it is preferable to use a resin whose tensile breaking elongation can be adjusted to within the above-mentioned desired range. Specific examples of the resin used in the resin film include polyolefin resins, polyester resins such as polybutylene terephthalate and polyethylene terephthalate, polyamide resins, polycarbonate resins, acrylic resins, fluororesins, soft vinyl chloride resins, polymethylpentene resins, tetrafluoroethylene resins, etc. When using a polyolefin resin, the same resin as that used in the transfer layer can be used. Of the above, polyester resins are preferred.

[0047] The resin film forming the protective layer may be a single layer film consisting of one layer, or may be a multilayer film consisting of two or more layers. In addition, in the resin film constituting the protective layer, the resin contained in the resin film may be used alone or in combination of two or more kinds. The resin film used for the protective layer may be a stretched resin film or a non-stretched resin film, but is preferably a non-stretched resin film. The protective layer may have at least one surface that has been release-treated with a release agent such as a silicone-based release agent or a fluorine-based release agent. When the protective layer is release-treated, it is preferable that the release-treated surface constitutes the surface on the paint layer side. The protective layer is release-treated to facilitate good peelability from the paint layer. However, the protective layer does not need to be release-treated as long as it can be peeled from the paint layer. The thickness of the protective layer is not particularly limited, but is, for example, from 10 μm to 1000 μm, preferably from 30 μm to 700 μm, and more preferably from 50 μm to 500 μm.

[0048] The method for producing the transfer type thermosetting resin sheet is not particularly limited, but it can be produced by a known method. For example, a thermosetting resin composition is prepared, and the prepared thermosetting resin composition is applied onto the transfer layer, and dried as necessary to form a paint layer. In addition, when the transfer type thermosetting resin sheet has a protective layer, the thermosetting resin composition is applied onto the protective layer, and dried as necessary to form a paint layer, and the transfer layer may be further laminated onto the paint layer formed on the obtained protective layer to obtain a transfer type thermosetting resin sheet. In addition, when applying the thermosetting resin composition to the transfer layer or the protective layer, the thermosetting resin composition may be appropriately diluted with a solvent or the like. Examples of the solvent include ethyl acetate, butyl acetate, and toluene. In addition, when the paint layer is multi-layered, each layer may be formed in sequence and laminated. For example, when a clear layer and a colored layer are provided, the clear layer and the colored layer may be laminated in this order on the transfer layer. In addition, when the transfer type thermosetting resin sheet has a protective layer, the colored layer formed on the protective layer and the clear layer formed on the transfer layer may be laminated to obtain the transfer type thermosetting resin sheet.

[0049] [Painting method 1] Hereinafter, a coating method for applying coating to an object to be coated using the transfer type thermosetting resin sheet of the present invention will be provided. The coating method according to one embodiment of the present invention (hereinafter also referred to as "coating method 1") comprises the following first and second steps. First step: The transfer type thermosetting resin sheet is attached to the object to be painted. The second step is to heat and cure the transfer-type thermosetting resin sheet with the transfer layer laminated on the paint layer.

[0050] (1st step) The first step is a step of attaching the transfer type thermosetting resin sheet 10 to the object 20 to be coated as shown in Fig. 1 (B) and (C). The object 20 to which the transfer type thermosetting resin sheet 10 is attached is not particularly limited, but includes vehicle components such as electric appliances, automobiles, and railway vehicle interior materials, vehicle exterior materials such as automobiles and railway vehicle exterior materials, exterior materials for miscellaneous goods, heavy machinery, ships, and aircraft, exterior walls or roof materials for houses and buildings, bridges, steel frames, plants, wind power generation blades, and the like. Among these, vehicle exterior materials such as automobile exterior materials are preferred. Examples of vehicle exterior materials include hoods, roofs, door panels, bumpers, fuel filler panels, trunk lids, and rear gates. When the transfer type thermosetting resin sheet is attached to a vehicle exterior material, it may be attached to the exterior material attached to the vehicle body, or it may be attached to the exterior material before being attached to the vehicle body. The material of the object 20 to be coated is not particularly limited, and may be any of a resin material, an inorganic material such as ceramic, and a metal material such as steel, with metal materials such as steel being preferred among these.

[0051] The transfer type thermosetting resin sheet 10 used in the first step is a sheet for forming a coating on the object 20 to be coated. As shown in Figs. 1(A) and (B), the transfer type thermosetting resin sheet 10 comprises a paint layer 11 and a transfer layer 12 formed on one side of the paint layer 11. The paint layer 11 is made of a thermosetting resin composition and can be cured by heating. The paint layer 11 constitutes part of the coating formed on the object 20 to be coated.

[0052] As shown in FIG. 1(A), the transfer type thermosetting resin sheet 10 may have a protective layer 13 attached to the other surface of the paint layer 11 before being attached to the substrate 20. When the protective layer 13 is attached, the transfer type thermosetting resin sheet 10 may be attached to the substrate 20 by peeling the protective layer 13 from the paint layer 11 to expose the paint layer 11 before being attached to the substrate 20. The method for peeling the protective layer 13 is not particularly limited, and the protective layer 13 may be peeled off by a peeling device or by hand. Of course, the protective layer 13 may be omitted in the transfer type thermosetting resin sheet 10.

[0053] In this step, the transfer type thermosetting resin sheet 10 with the paint layer 11 exposed may be attached to the object 20 so that the paint layer 11 is in contact with the object 20 as shown in FIG. 1(B). In this case, the attachment of the transfer type thermosetting resin sheet 10 to the object 20 is not particularly limited, and may be performed by hand attachment using a squeegee or the like, or may be performed using a laminating device. The paint layer 11 is made of a thermosetting resin composition and is not yet cured when attached, so it is easy to ensure a certain degree of flexibility. Therefore, the paint layer 11 can be appropriately adhered to the object 20 and temporarily fixed to the object 20 with an appropriate adhesive strength.

[0054] The transfer type thermosetting resin sheet 10 may be preformed by vacuum molding, press molding, compressed air molding, etc., and may be shaped to have a shape corresponding to the shape of the object to be coated 20, and the shaped transfer type thermosetting resin sheet 10 may be attached to the object to be coated 20. When the transfer type thermosetting resin sheet 10 has a protective layer 13, the preform may be performed before the protective layer 13 is peeled off from the paint layer 11, or after the protective layer 13 is peeled off from the paint layer 11. By performing the preform, even if the object to be coated 20 has a complex shape, the transfer type thermosetting resin sheet can be easily attached in close contact with the object to be coated. Among the above, the preform is preferably performed by vacuum molding. The preform may be performed by pressing the paint sheet against a jig or a mold by vacuum molding, and stretching the transfer type thermosetting resin sheet by the jig or the mold to form a shape corresponding to the surface shape of the object to be coated. Here, the vacuum molding is preferably TOM molding. TOM stands for "Three dimension Overlay Method," and when TOM molding is applied, it is possible to form a complex shape.

[0055] (2nd process) The second step is a step performed after the first step, and as shown in FIG. 1(D), the paint layer 11 of the transfer type thermosetting resin sheet 10 is heated and cured while the transfer layer 12 is still laminated on the paint layer 11. In this step, it is preferable to cure the paint layer 11 sufficiently to the extent that it can be used as a coating. By the heat curing in this step, the pencil hardness of the paint layer 11 is preferably 2B or more, more preferably B or more, and even more preferably HB or more. By curing the paint layer 11 until the pencil hardness is equal to or greater than the above lower limit, the paint layer can be made hard and the adhesive strength to the coated object can be increased by curing, so that the paint can be used appropriately even when the paint is used for a long period of time in a harsh environment such as a vehicle exterior material. Furthermore, the pencil hardness of the paint layer 11 after the second step is not particularly limited, but in practice it is, for example, 3H or less, and preferably 2H or less.

[0056] In the second step, the transfer-type thermosetting resin sheet 10 may be heated, while attached to the object 20, using a heating device 21 such as an oven or an infrared heater. The heating temperature is preferably 50° C. or higher and 170° C. or lower, more preferably 60° C. or higher and 160° C. or lower. The heating time is, for example, 5 minutes or higher and 120 minutes or lower, and preferably 10 minutes or higher and 90 minutes or lower.

[0057] (3rd step) The coating method of the present invention preferably further comprises the following third step. The third step is to peel off the transfer layer from the paint layer.

[0058] The third step is a step performed after the second step, in which the transfer layer is peeled off from the paint layer. The transfer layer may be peeled off by a peeling device or by hand. In the coating method 1, the third step makes it possible to obtain a decorative object having a coating, which is a cured product of the paint layer, on the substrate.

[0059] [Painting method 2] In the above coating method 1, the paint layer is heat-cured only before the transfer layer is peeled off from the paint layer, but as described below, the paint layer may be heat-cured both before and after the transfer layer is peeled off (hereinafter, also referred to as coating method 2). Coating method 2 will be described in detail below.

[0060] When the coating layer is heat-cured both before and after the transfer layer is peeled off, it is preferable to include the following first to fourth steps in this order. First step: The transfer type thermosetting resin sheet is attached to the object to be painted. The second step is to heat and cure the transfer-type thermosetting resin sheet with the transfer layer laminated on the paint layer. The third step is to peel off the transfer layer from the paint layer. The fourth step: The paint layer is further heated and cured. The specific procedures of the first and third steps are the same as those of the coating method 1, and therefore a detailed description thereof will be omitted.

[0061] (2nd process) The second step in Coating Method 2 is a step carried out after the first step, similar to the second step in Coating Method 1. In the second step in Coating Method 2, it is preferable to partially cure the paint layer rather than completely cure it, in order to further cure the paint layer in the fourth step described below. Therefore, in coating method 2, the pencil hardness of the paint layer 11 after the second step should be lower than the pencil hardness when the paint layer is fully cured, and is preferably B or less, more preferably 2B or less, and even more preferably 3B or less. By setting the pencil hardness of the paint layer 11 to the above upper limit or less and limiting it to partial curing, it is possible to further cure in the fourth step. In addition, in coating method 2, as described below, by curing the paint layer 11 in separate steps, the paint layer 11 is more likely to become glossy, and the appearance of the paint layer can be further improved. Furthermore, in the second step of coating method 2, the paint layer 11 is preferably cured until the pencil hardness is 6B or more, more preferably 5B or more, and even more preferably 4B or more. By curing the paint layer 11 until the pencil hardness is equal to or greater than the above-mentioned lower limit, it becomes easier to prevent foreign matter such as dust from adhering to the paint layer 11 exposed by peeling off the transfer layer 12 in the third step, and to prevent the paint layer 11 from being scratched. The above pencil hardness can be measured by the method described in the Examples.

[0062] In coating method 2 as well, in the second step, the paint layer 11 of the transfer-type thermosetting resin sheet 10 is heated and cured while the transfer layer 12 remains laminated on the paint layer 11. The heating temperature in the second step of coating method 2 is preferably 40°C or higher and 160°C or lower, and more preferably 50°C or higher and 150°C or lower. The heating time is, for example, 1 minute or higher and 120 minutes or lower, and preferably 5 minutes or higher and 60 minutes or lower. The specific method for heating the paint layer 11 is as described in coating method 1.

[0063] (4th step) The fourth step is carried out after the third step, and is a step of further heating and curing the paint layer after the paint layer 11 has been partially cured in the second step and the transfer layer 12 has been peeled off from the paint layer 11. In the coating method 2, by carrying out the above first to fourth steps, a decorative article having a coating, which is a cured product of the paint layer, can be obtained on the substrate. In the fourth step, it is preferable to heat the paint layer 11 using a heating device, as in the second step. In coating method 2, the paint layer 11 is cured in two steps, the second step and the fourth step, which makes the paint layer 11 more glossy. Although the principle behind this is unclear, it is presumed that the paint layer that is not completely cured is softened by heating in the fourth step, and unevenness caused by holes in the transfer layer attached to the paint layer disappears or becomes smaller, thereby smoothing the surface of the paint layer 11. The pencil hardness of the paint layer 11 after the fourth step is similar to the pencil hardness of the paint layer 11 after the second step explained in the coating method 1, so a detailed explanation thereof will be omitted.

[0064] The heating temperature in the fourth step is preferably higher than that in the second step, and specifically, is preferably from 50° C. to 170° C., more preferably from 60° C. to 160° C. The heating time is, for example, from 5 minutes to 120 minutes, and preferably from 10 minutes to 90 minutes.

[0065] The paint layer after the fourth step preferably has a specular gloss at an incidence angle of 60°, as measured according to JIS K 5600-4-7, of at least 50, more preferably at least 70, and even more preferably at least 80. When the gloss is at least the above-mentioned lower limit, unevenness on the paint layer surface caused by holes in the transfer layer becomes less noticeable after the transfer layer is peeled off, and the appearance of the paint layer is good.

[0066] The present invention also provides a coating object coated with the above-described transfer type thermosetting resin sheet. Specific examples of the coating object are as described above, but preferred are vehicle components such as automobiles, railroad cars, and vehicle interior materials and vehicle exterior materials. Also preferred are vehicles equipped with vehicle components coated with the above-described transfer type thermosetting resin sheet. EXAMPLES

[0067] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples in any way.

[0068] The measurement and evaluation methods in the present invention are as follows.

[0069] <Pencil hardness> The pencil hardness of the surface of the sheet A obtained in each of the examples and comparative examples was measured in accordance with JIS K 5600-5-4. In the above measurements, a pencil scratch tester (manufactured by TP Giken Co., Ltd.) was used as the test equipment, and the test equipment was pressed at a speed of 10 mm / s.

[0070] <Curing performance compared to without transfer layer> In addition to Sheet A obtained in each Example and Comparative Example, a transfer-type thermosetting resin sheet obtained in each Example and Comparative Example was further prepared and bonded to a steel plate via a paint layer. Thereafter, the transfer layer was peeled off, and the paint layer was cured under the heat curing conditions shown in Tables 2 to 4 to obtain Sheet B. The pencil hardness of Sheet B was then measured using the same method as above, and the pencil hardness of Sheet A and Sheet B were compared for each heating and curing condition, and the curability of Sheet A was evaluated based on the following evaluation criteria. (Evaluation Criteria) ◯: The pencil hardness of Sheet A was the same as that of Sheet B. ×: The pencil hardness of sheet A was different from that of sheet B.

[0071] The components of the film for transfer layer and the paint layer used in each of the examples and comparative examples are as follows.

[0072] <Appearance of paint layer> The surface of the sheet A obtained in each of the examples and comparative examples was visually observed, and the appearance of the paint layer was evaluated according to the following evaluation criteria. (Evaluation Criteria) Good: No dust or other foreign matter was found, and no scratches were found. ×: Dust or other foreign matter was found attached, or the surface was scratched.

[0073] <Coating film gloss> The specular gloss of the surface of the sheet A obtained in each of the examples and comparative examples was measured using BYK micro-TRI-gloss (manufactured by Tetsutani Co., Ltd.) in accordance with JIS K 5600-4-7, and the gloss of the paint layer was evaluated according to the following evaluation criteria. (Evaluation Criteria) ⊚: The specular gloss at an incident angle of 60° was 80 or more. ◯: The specular gloss at an incident angle of 60° was 70 or more and less than 80. △: The specular gloss at an incident angle of 60° was 50 or more and less than 70. ×: The specular gloss at an incident angle of 60° was less than 50.

[0074] <Air permeability measured by the Gurley tester (Gurley air permeability)> The air permeability of the film for transfer layer used in each example was measured in accordance with JIS P 8117:2009 (Gurley tester method).

[0075] The following materials were used as the components of the transfer layer film and the thermosetting resin composition.

[0076] <Transfer layer film> Non-oriented polypropylene film (Toray Industries, Inc. "Treyfan", thickness 20 μm), air permeability > 1,000,000 seconds Porous polyethylene film 1 (Nitto Denko "Sunmap LC", thickness 100 μm), air permeability 200 seconds Porous polyethylene film 2 (Nittoms "Breathlon BRN-A120E", thickness 250 μm), air permeability 28,000 seconds Porous polyethylene film 3 (Nittoms "Breathlon BRN-1860", thickness 350 μm), air permeability 4500 seconds

[0077] Porous polypropylene film 1 (Asahi Kasei's "Celgard 2500", thickness 25 μm), air permeability 200 seconds Porous polypropylene film 2 (Sekisui Chemical "HP separator", thickness 20 μm), air permeability 50 seconds Porous polypropylene film 3 (Koike Sangyo Co., Ltd. "100P", thickness 100 μm), air permeability 550 seconds

[0078] Porous polyimide film 1 (Tokyo Ohka Kogyo Co., Ltd. "TAPM-7040i1"), air permeability 263 seconds Porous polyimide film 2 (Tokyo Ohka Kogyo Co., Ltd. "TAPM-7040i10"), air permeability 31.2 seconds Porous polyimide film 3 (Tokyo Ohka Kogyo Co., Ltd. "TAPM-7040i25"), air permeability 9.5 seconds *The air permeability of unstretched polypropylene film is a catalog value.

[0079] <(Meth)acrylic resin (A1)> Acrylic polyol (1): weight average molecular weight 250,000, glass transition temperature (Tg) 40°C, solid content (NV) = 23.3% by mass (solvent: ethyl acetate) Acrylic polyol (2): weight average molecular weight 250,000, glass transition temperature (Tg) 40°C, solid content (NV) = 29.6% by mass (solvent: ethyl acetate) <Plasticized resin (A2)> Polycarbonate diol: hydroxyl value 204-244 mg KOH / g, weight average molecular weight 500, "PH-50", manufactured by UBE Corporation

[0080] <Blocked isocyanate (B)> HDI blocked isocyanate, Mitsui Chemicals' "Takenate B-882N", blocking agent type: pyrazole <Urethane catalyst> "XK-639", manufactured by Kusumoto Chemicals Co., Ltd.

[0081] <Pigments> "NSP-UP 841B" manufactured by Nikko Vicks Co., Ltd., effective pigment concentration = 9% by mass, NV = 24% by mass <Shining material> Merck's "Xiramic T60-10 WNT Crystal Silver" Alumina flakes coated with at least one layer of metal oxide, including titanium dioxide

[0082] [Preparation of Thermosetting Resin Compositions A and B] Each component was added in the proportions shown in Table 1, and ethyl acetate was added as a solvent to prepare diluted solutions of thermosetting resin compositions A and B so that the solid content concentration was 40 mass %.

[0083] [Table 1] *Table 1 shows the amount of each component in thermosetting resin compositions A and B based on the solid content, and the solid content of the total thermosetting resin composition is taken as 100 parts by mass. *The amount of active pigment ingredient is the value in Table 1 multiplied by 9 / 24.

[0084] [Example 1] Thermosetting resin composition A was applied onto the surface of the film for the transfer layer shown in Table 2 using an applicator, and then a drying process was carried out under conditions of a drying temperature of 60°C and a drying time of 30 minutes to form a clear layer having a thickness of 30 μm on the transfer layer. Next, the thermosetting resin composition B was applied onto the surface of the film for the protective layer using an applicator, and then a drying process was carried out under conditions of a drying temperature of 60°C and a drying time of 30 minutes to form a colored layer having a thickness of 30 μm on the protective layer. The clear layer on the transfer layer and the colored layer on the protective layer were attached together and laminated at 25°C, and then the protective layer was peeled off from the colored layer to obtain a transfer type thermosetting resin sheet in which the transfer layer, the clear layer, and the colored layer were laminated in this order. The obtained transfer type thermosetting resin sheet was attached to a steel plate via a paint layer. The paint layer (clear layer and colored layer) attached to the steel plate was cured in a state in which the transfer layer was laminated under the heat curing conditions shown in Table 2, and then the transfer layer was peeled off to obtain a sheet A, and the above-mentioned evaluations were performed on Sheet A. The evaluation results are shown in Table 2.

[0085] [Examples 2 to 9, Comparative Examples] The procedure was the same as in Example 1, except that the film used for the transfer layer and the heat curing conditions were changed as shown in Tables 2 to 4.

[0086] [Example 10] The heat curing conditions of the paint layer were changed as shown in Table 4. Specifically, the paint layer was first partially cured in a state in which the transfer layer was laminated, at a heat curing condition of 100°C for 30 minutes, and then the transfer layer was peeled off. After that, the paint layer was further cured at a heat curing condition of 120°C for 60 minutes. Other than the above changes, the procedure was the same as in Example 1.

[0087] [Table 2]

[0088] [Table 3]

[0089] [Table 4] *In Tables 2 to 4, the numbers in parentheses in the column "Whether or not the paint layer is glossy after the transfer layer is peeled off" indicate the measured specular gloss at an incident angle of 60°.

[0090] As is clear from the above examples, the transfer type thermosetting resin sheet satisfying the requirements of the present invention had an air permeability above a certain level, and therefore was able to prevent foreign matter such as dust from adhering to the back surface of the paint layer after the sheet was attached to an object to be coated and the transfer layer was peeled off. Furthermore, because the air permeability was below a certain level, in the process of curing the paint layer before peeling off the transfer layer, gas generated from the paint layer could be sufficiently released through the transfer layer, and the paint layer could be sufficiently cured. In contrast, the transfer-type thermosetting resin sheet produced in the comparative example used a non-porous, unoriented polypropylene film for the transfer layer, and because its air permeability was excessively high, the gas generated from the paint layer could not be sufficiently vented through the transfer layer, and the paint layer could not be sufficiently cured. [Explanation of symbols]

[0091] 10 Transferable thermosetting resin sheet 11 Paint layer 12 Transfer layer 13 Protective layer 20 Object to be painted 21 Heating device

Claims

1. A transfer type thermosetting resin sheet comprising a paint layer made of a thermosetting resin composition and a transfer layer, The thermosetting resin composition includes at least one selected from the group consisting of a blocked isocyanate and a melamine-based compound, The transfer layer has an air permeability of 5 seconds or more and 30,000 seconds or less as measured by a Gurley tester.

2. 2. The transfer type thermosetting resin sheet according to claim 1, wherein the transfer layer has an air permeability of 5 seconds or more and 10,000 seconds or less, measured by a Gurley tester.

3. 3. The transfer type thermosetting resin sheet according to claim 1, wherein the transfer layer has an air permeability of 5 seconds or more and 5,000 seconds or less, measured by a Gurley tester.

4. The transfer type thermosetting resin sheet according to claim 1 or 2, wherein the thermosetting resin composition contains a (meth)acrylic polyol.

5. The transfer type thermosetting resin sheet according to claim 1 or 2, wherein the transfer layer contains a polypropylene resin or a polyethylene resin.

6. The transfer type thermosetting resin sheet according to claim 1 or 2, wherein the average pore size of the surface of the transfer layer is 1 μm or less.

7. A coating method for applying a coating to an object to be coated, comprising the steps of: A first step of attaching a transfer type thermosetting resin sheet, which comprises a paint layer made of a thermosetting resin composition containing at least one selected from the group consisting of blocked isocyanates and melamine-based compounds, and a transfer layer having an air permeability of 5 to 30,000 seconds as measured by a Gurley tester, to an object to be coated; A second step of heat-curing the transfer type thermosetting resin sheet in a state in which the transfer layer is laminated on the paint layer.

8. a third step of peeling the transfer layer from the paint layer after the second step; The coating method according to claim 7, further comprising a fourth step of further heating and curing the paint layer after the third step.

9. 9. The coating method according to claim 8, wherein in the second step, the transfer type thermosetting resin sheet is heated and cured until the paint layer has a pencil hardness of 6B or more.

10. A vehicle painted with the transfer type thermosetting resin sheet according to claim 1 or 2.

11. A vehicle component coated with the transfer type thermosetting resin sheet according to claim 1 or 2.

Images