Decorative laminate, decorative laminate with protection film, transfer sheet, decorative member, and movable body

Abstract

To provide a decorative laminate that has excellent moldability and excellent designability even after molding process.SOLUTION: A decorative laminate 10 includes: a shaping layer 20 including a first surface 20a and a second surface 20b opposed to the first surface 20a; and a brightness control layer 30 that covers the first surface 20a. The first surface 20a in the shaping layer 20 has an uneven structure 25. The shaping layer 20 contains a cured product of a thermoplastic resin and a curable resin.SELECTED DRAWING: Figure 2A

Description

[Technical field]

[0001] The present disclosure relates to a decorative laminate, a decorative laminate with a protective film, a transfer sheet, a decorative member, and a moving body. [Background technology]

[0002] 2. Description of the Related Art Decorative laminates for decorating interior and exterior products of automobiles (eg, instrument panels), home appliances, houses, and the like are known (eg, see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6774387 Summary of the Invention [Problem to be solved by the invention]

[0004] However, such decorative laminates are required to have excellent design, particularly excellent design with a three-dimensional effect. A decorative laminate with a three-dimensional effect allows for rich design expression with a luxurious feel. Therefore, the present inventors have considered applying a concave-convex structure to the decorative laminate.

[0005] However, the present inventors have found that when a concave-convex structure is applied to a decorative laminate, the concave-convex structure may be deformed during molding of the decorative laminate, and the decorative laminate may not be able to exhibit sufficient design properties. The present disclosure aims to provide a decorative laminate that is excellent in moldability and has excellent design properties even after molding. [Means for solving the problem]

[0006] In one embodiment, the decorative laminate of the present disclosure comprises a mold layer including a first surface and a second surface opposite to the first surface, and a brightness adjustment layer covering the first surface, wherein the first surface of the mold layer has an uneven structure, and the mold layer contains a thermoplastic resin and a cured product of a curable resin. Effect of the Invention

[0007] According to the present disclosure, it is possible to provide a decorative laminate that has excellent moldability and also has excellent design even after molding. [Brief description of the drawings]

[0008] [Figure 1A] FIG. 1A is a perspective view showing a moving body including a decorative member according to an embodiment. [Figure 1B] FIG. 1B is a cross-sectional view taken along line II in FIG. 1A, showing the decorative member in FIG. 1A together with a sensor. [Figure 2A] FIG. 2A is a cross-sectional view showing a decorative laminate of one embodiment. [Figure 2B] FIG. 2B is an enlarged view of a portion surrounded by a two-dot chain line in the cross section shown in FIG. 2A. [Diagram 3] FIG. 3 is a partially enlarged plan view showing the decorative laminate of one embodiment. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Diagram 5] FIG. 5 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 6] FIG. 6 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 7] FIG. 7 is an enlarged plan view showing the reflective layer of the decorative laminate shown in FIG. [Figure 8] FIG. 8 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 9] FIG. 9 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 10] FIG. 10 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 11A]FIG. 11A is a cross-sectional view showing a modified example of the decorative laminate. [Figure 11B] FIG. 11B is a cross-sectional view showing a modified example of the decorative laminate. [Figure 12] FIG. 12 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 13] FIG. 13 is a cross-sectional view showing a modified example of the decorative laminate. [Figure 14A] FIG. 14A is a cross-sectional view showing a modified example of the decorative laminate. [Figure 14B] FIG. 14B is a cross-sectional view showing a modified example of the decorative laminate. [Figure 15A] FIG. 15A is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 15B] FIG. 15B is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 15C] FIG. 15C is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 16A] FIG. 16A is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 16B] FIG. 16B is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 17] FIG. 17 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 18] FIG. 18 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 19A] FIG. 19A is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 19B] FIG. 19B is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 19C] FIG. 19C is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 20A] FIG. 20A is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 20B] FIG. 20B is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 21A] FIG. 21A is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 21B] FIG. 21B is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 22] FIG. 22 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 23] FIG. 23 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 24] FIG. 24 is a diagram illustrating an example of a method for producing a decorative laminate. [Diagram 25] FIG. 25 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 26] FIG. 26 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 27] FIG. 27 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 28] FIG. 28 is a diagram illustrating an example of a method for producing a decorative laminate. [Figure 29A] FIG. 29A is a cross-sectional view showing a configuration of a decorative member according to one embodiment. [Figure 29B] FIG. 29B is a diagram showing a modified example of the decoration member. [Figure 29C] FIG. 29C is a diagram showing a modified example of the decoration member. [Figure 29D] FIG. 29D is a diagram showing a modified example of the decoration member. [Figure 29E] FIG. 29E is a diagram showing a modified example of the decoration member. [Figure 29F] FIG. 29F is a diagram showing a modified example of the decoration member. [Figure 29G] FIG. 29G is a diagram showing a modified example of the decoration member. [Fig. 29H] FIG. 29H is a diagram showing a modified example of the decoration member. [Figure 29I] FIG. 29I is a diagram showing a modified example of the decoration member. [Figure 29J] FIG. 29J is a diagram showing a modified example of the decoration member. [Figure 29K] FIG. 29K is a diagram showing a modified example of the decoration member. [Figure 29L]FIG. 29L is a diagram showing a modified example of the decoration member. [Figure 29M] FIG. 29M is a diagram showing a modified example of the decoration member. [Figure 29N] FIG. 29N is a diagram showing a modified example of the decoration member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the drawings attached to this specification, the scale and aspect ratios have been appropriately changed and exaggerated from those of the actual objects for the convenience of illustration and ease of understanding.

[0010] In order to clarify the relationship between directions between the drawings, common directions are indicated in several drawings by arrows with common symbols. The tip of the arrow is one side of each direction. An arrow pointing into the paper in a direction perpendicular to the paper surface of the drawing is indicated by a symbol of a cross in a circle, as shown in FIG. 1B, for example. An arrow pointing toward the viewer in a direction perpendicular to the paper surface of the drawing is indicated by a symbol of a dot in a circle, as shown in FIG. 3, for example.

[0011] Terms used in this specification that specify shapes and geometric conditions and their degrees, such as "parallel," "perpendicular," and "same," as well as values ​​of lengths and angles, are not limited to their strict meanings but are interpreted to include a range within which similar functions can be expected.

[0012] In this specification, terms such as "film," "sheet," and "plate" are not distinguished from one another solely on the basis of differences in name. For example, a "decorative sheet" cannot be distinguished from a member called a decorative film solely on the basis of differences in name.

[0013] Each of the components (for example, resins such as thermoplastic resins and curable resins, diluents, and additives) appearing in the following description may be used alone or in combination of two or more kinds.

[0014] 1 to 29 are diagrams for explaining each embodiment. Fig. 1A and Fig. 1B are diagrams showing an application example of a decorative member 3 including a decorative laminate 10. The decorative laminate is formed in a sheet shape and is also called a decorative sheet. The decorative laminate displays a design and imparts design to an article to which the decorative laminate is applied (the decorative member 3 in the example shown in Fig. 1A and Fig. 1B), etc.

[0015] In the example shown in Fig. 1A and Fig. 1B, the decorative member 3 is applied to a moving body 1. In the illustrated example, the decorative member 3 is installed on a front panel 2 of the moving body 1. The front panel 2 is formed as a front grille in an engine vehicle. In an electric vehicle, a heat exchanger to be air-cooled, such as a radiator, may not be installed. Therefore, the front panel 2 does not have to be formed as a grille with a large number of holes formed therein.

[0016] Hereinafter, each embodiment will be described with reference to specific application examples shown in the drawings. The moving body 1 shown in FIG. 1A is an automobile. However, the moving body to which the decorative member is applied is not limited to an automobile. The decorative member can also be applied to other moving bodies as movable devices. Examples of moving bodies other than automobiles include railroad cars, dollies, ships, airplanes, helicopters, drones, and robots. The decorative member and the decorative laminate may be used, for example, in the interior body of a moving body. The decorative member and the decorative laminate can also be applied, for example, to building materials such as interior materials, exterior materials, ceiling materials, and floor materials, as well as cases for home appliances, communication device housings, and cosmetic containers.

[0017] [Decorative materials] An example of the overall configuration of the decorative member 3 will be described with reference to FIG. 1B. As shown in FIG. 1B, the decorative member 3 has a front side surface 3a and a back side surface 3b facing the front side surface 3a. The front side surface 3a and the back side surface 3b extend along a front side surface 66 and a back side surface 67 of a molded portion 65, which will be described later, respectively. In the illustrated example, the front side surface 3a and the back side surface 3b extend in a planar shape in the X direction Dx and the Y direction Dy perpendicular to the X direction Dx, respectively. The front side surface 3a and the back side surface 3b face each other in the Z direction Dz perpendicular to both the X direction Dx and the Y direction Dy. However, this is not limited to this example, and the front side surface 3a and the back side surface 3b may be curved.

[0018] In the example shown in FIG. 1B, the decorative member 3 includes a decorative laminate 10 and a molded portion 65. The decorative laminate 10 covers at least a part of the molded portion 65. In the example shown in FIG. 1B, the molded portion 65 and the decorative laminate 10 are laminated in this order along the direction from the back side surface 3b to the front side surface 3a of the decorative member 3 (Z direction Dz). In this example, the decorative laminate 10 and the molded portion 65 are directly bonded. However, this is not limited to this example, and a bonding layer may be provided between the decorative laminate 10 and the molded portion 65. In other words, the molded portion 65, the bonding layer, and the decorative laminate 10 may be laminated in this order along the Z direction Dz.

[0019] The decorative laminate 10 has a front side surface 11 and a back side surface 12. In the example shown in FIG. 1B, the front side surface 11 is a surface constituting the front side surface 3a of the decorative member 3, and the back side surface 12 is a surface facing the back side surface 3b side (the molded portion 65 side) of the decorative member 3. The front side surface 11 and the back side surface 12 extend along the front side surface 66 of the molded portion 65 described later. In the illustrated example, the front side surface 11 and the back side surface 12 extend in a planar shape in the X direction Dx and the Y direction Dy, respectively. The front side surface 11 and the back side surface 12 face each other in the Z direction Dz. However, this is not limited to this example, and the front side surface 11 and the back side surface 12 may be curved. The decorative laminate 10 will be described in detail later.

[0020] The molded portion 65 is overlaid on the decorative laminate 10 in the Z direction Dz. The molded portion 65 faces the back side 12 of the decorative laminate 10. The molded portion 65 has a front side 66 and a back side 67. The back side 67 is a surface that constitutes the back side 3b of the decorative member 3, and the front side 66 is a surface that faces the front side 3a side (the decorative laminate 10 side) of the decorative member 3. In the illustrated example, the front side 66 and the back side 67 extend in a planar shape in the X direction Dx and the Y direction Dy, respectively. The front side 66 and the back side 67 face each other in the Z direction Dz. However, this is not limited to this example, and the front side 66 and the back side 67 may be curved.

[0021] The molded portion 65 is made of a resin. Examples of the resin that constitutes the molded portion 65 include (meth)acrylic resins such as polymethyl methacrylate, polyolefins such as polyethylene and polypropylene, polycarbonate, acrylonitrile-butadiene-styrene copolymer resin (ABS resin), acrylonitrile-ethylene-propylene-diene-styrene copolymer resin (AES resin), and acrylonitrile-styrene-acrylate copolymer resin (ASA resin). The molded portion 65 may be transparent or opaque. When the molded portion 65 is opaque, the molded portion 65 can conceal at least a part of the article to which the decorative member 3 is applied. For example, in the example shown in FIG. 1B, the molded portion 65 is opaque, so that the decorative member 3 can conceal the sensor 5. The molded portion 65 may be colored. The molded portion 65 may be molded by, for example, injection molding.

[0022] As used in this specification, "transparent" means that the total light transmittance measured using a haze meter ("HM-150N" manufactured by Murakami Color Research Laboratory, Inc., compliant with JIS K7361:1997) is 50% or more, and preferably 80% or more.

[0023] As shown in FIG. 1B, the decorative member 3 may be disposed facing a sensor 5 that uses electromagnetic waves with a longer wavelength than visible light. In the example shown in FIG. 1B, the molded portion 65 faces the sensor 5, and the decorative laminate 10 faces the observer 6. The sensor 5 may monitor the surroundings of the moving body 1, for example. The detection result of the sensor 5 may be transmitted to a control device 4 of the moving body 1. The control device 4 may issue an alarm or control the movement of the moving body 1 based on the detection result of the sensor 5. For example, the sensor 5 may detect an obstacle or the like in front of the moving body 1. This sensor 5 may be capable of transmitting electromagnetic waves and receiving electromagnetic waves. The sensor 5 can detect the presence or absence of an obstacle and the distance to the obstacle by receiving a reflected wave reflected by an obstacle or the like. The sensor 5 may be a millimeter wave radar device. The millimeter wave radar device may use millimeter waves with a wavelength of 1 mm or more and 10 mm or less as electromagnetic waves. Alternatively, the sensor 5 may be a lidar device. The lidar device may use infrared rays as electromagnetic waves.

[0024] The sensor 5 faces the back side surface 3b of the decorative member 3. The electromagnetic waves used by the sensor 5 pass through the decorative member 3 along the Z direction Dz. The front side surface 3a and the back side surface 3b are the emission surface and the incidence surface of the electromagnetic waves, respectively. The front side surface 3a and the back side surface 3b are preferably smooth surfaces at least in the region facing the sensor 5 in the Z direction Dz. By making the front side surface 3a and the back side surface 3b smooth surfaces, it is possible to suppress a decrease in the sensitivity of the sensor 5 due to diffusion of the electromagnetic waves.

[0025] The shape of the decorative member may be any shape. In other words, the shape of the molded part to which the decorative laminate is applied may be any shape. For example, the decorative member may include a curved surface. More specifically, the molded part may include a curved surface corresponding to the curved surface of the decorative member, and the decorative laminate may cover the curved surface of the molded part. The radius of curvature of the curved surface of the decorative member (hence the curved surface of the molded part) is preferably 250 mm or less, more preferably 100 mm or less.

[0026] In the example shown in FIG. 1B, the decorative laminate 10 and the molded portion 65 are directly bonded. For example, when manufacturing a decorative member by insert molding and in-mold molding, the decorative laminate can be directly bonded to the molten resin introduced into a mold to form the molded portion. Therefore, if the resin is solidified while the decorative laminate is bonded to the molten resin, the decorative laminate and the molded portion can be directly bonded without using a bonding layer. However, this is not limited to this example, and the decorative member may have a bonding layer between the decorative laminate and the molded portion.

[0027] The bonding layer, which is provided as desired, is disposed between the decorative laminate and the molded part, in other words, it is overlapped with the decorative laminate 10 and the molded part 65 in the Z direction Dz. The bonding layer bonds (adheses, sticks or heat seals) the decorative laminate 10 and the molded part 65. Examples of materials that form the bonding layer include thermoplastic resins. Examples of thermoplastic resins include (meth)acrylic resins, styrene resins, polyamides, polyesters, polyurethanes, vinyl chloride resins, vinyl chloride-vinyl acetate copolymer resins, chlorinated polyolefins and chlorinated rubbers. In this specification, the term (meth)acrylic means one or both of "acrylic" and "methacrylic".

[0028] [Decorative laminate] The decorative laminate of the present disclosure will be described in detail below. The decorative laminate of the present disclosure includes a shape-imparting layer including a first surface and a second surface facing the first surface, and a brightness adjustment layer covering the first surface. The first surface is a shape-imparting surface on which a concave-convex structure is formed. The second surface is, for example, a non-shape-imparting surface. The first surface of the shape-imparting layer preferably has a lens structure including concave-convex structures. The shape-imparting layer contains a thermoplastic resin and a cured product of a curable resin.

[0029] As shown in Figures 2A and 2B, the decorative laminate 10 includes a shape-imparting layer 20 and a brightness adjustment layer 30. As shown in Figures 2A and 2B, the shape-imparting layer 20 has a first surface (shape-imparting surface) 20a on which a concave-convex structure 25 is formed, and a second surface (non-shape-imparting surface) 20b opposite to the first surface 20a. The brightness adjustment layer 30 covers the first surface 20a.

[0030] As shown in FIG. 3, the decorative laminate 10 has at least one unit optical element 13. Each unit optical element 13 reflects, refracts, and / or diffracts light incident on the front side surface 3a according to the uneven structure 25 of the first surface 20a. This allows the decorative laminate 10 to express a three-dimensional effect that is greater than the thickness of the decorative laminate 10. As a result, the design of the decorative laminate 10 is improved. In the illustrated example, the decorative laminate 10 has multiple unit optical elements 13. This allows the decorative laminate 10 to be given a complex design by combining multiple unit optical elements 13.

[0031] The thickness of the decorative laminate is preferably 0.005 mm or more, more preferably 0.025 mm or more, even more preferably 0.05 mm or more, even more preferably 0.1 mm or more, and is preferably 2 mm or less, more preferably 1 mm or less, even more preferably 0.75 mm or less, even more preferably 0.5 mm or less, for example, 0.005 mm or more and 2 mm or less. The thickness of the decorative laminate and each layer contained in the decorative laminate is measured by observing an image of the cross section of the decorative laminate using a scanning electron microscope.

[0032] <Shaping layer> The first surface (shaping surface) of the shaping layer has a concave-convex structure, preferably a lens structure including concave-convex. The shaping layer will be described with reference to the drawings. In the example shown in FIG. 3, the shaping layer 20 has at least one unit shaping element 23. In the illustrated example, the shaping layer 20 has a plurality of unit shaping elements 23. One unit shaping element 23 corresponds to one unit optical element 13. On the first surface 20a, each unit shaping element 23 has a concave-convex structure 25 formed thereon. The concave-convex structure 25 can be formed by shaping the shaping layer 20 using a shaping mold 100 described later.

[0033] In the illustrated example, the molding layer 20 is transparent so that the brightness adjusting layer 30 can be seen from the front side surface 11. In the illustrated example, gap regions 24 are formed between adjacent unit molding elements 23. The multiple uneven structures 25 of the multiple unit molding elements 23 included in the molding layer 20 may be integrally molded without seams.

[0034] Since the first surface 20a has the uneven structure 25, the light incident on the unit optical element 13 is subjected to an optical action (reflection, refraction, and / or diffraction) according to the uneven structure 25. In the illustrated example, the uneven structure 25 is determined so as to converge and / or diverge the parallel light incident on the front side surface 11 of the decorative laminate 10. Since the shaping layer 20 includes the unit shaping element 23 having the uneven structure 25, the decorative laminate 10 can express a rich three-dimensional effect that is greater than its thickness. Furthermore, since the shaping layer 20 includes a plurality of unit shaping elements 23, a plurality of unit optical elements 13 can be formed in the decorative laminate 10. In the illustrated example, each uneven structure 25 is configured so that each unit optical element 13 provides the same optical action as a convex lens or an optical action corresponding to the optical action to the light incident on the unit optical element 13. The optical action corresponding to the same optical action as a convex lens means, for example, an optical action similar to a convex mirror. As a result, the unit optical element 13 exerts an optical function similar to that of a convex lens or an optical function corresponding to that optical function. As a result, the decorative laminate 10 can express a design with a sense of depth greater than the actual thickness of the decorative laminate 10, and can express a three-dimensional effect. And, a rich design expression with a sense of luxury is possible. Of course, each uneven structure 25 may be configured so that each unit optical element 13 exerts an optical action similar to that of a concave lens or an optical action corresponding to that optical action on the light incident on the front side surface 11 of the decorative laminate 10. In this case, too, the decorative laminate 10 can express a design with a sense of depth greater than the actual thickness of the decorative laminate 10, and can express a three-dimensional effect. As a result, a rich design expression with a sense of luxury is possible.

[0035] The shape-imparting layer contains a thermoplastic resin and a cured product of a curable resin. The shape-imparting layer containing the cured product of the curable resin can suppress the deformation of the uneven structure due to heat during molding of the decorative laminate, and tends to maintain the three-dimensional effect (e.g., a sense of depth) of the uneven structure even after molding. The shape-imparting layer containing a thermoplastic resin has excellent moldability and can contribute to improving the extensibility of the decorative laminate, such as deep drawing moldability. Therefore, such a shape-imparting layer can suppress the deformation of the uneven structure due to heat during molding such as insert molding, and has good extensibility of the decorative laminate, and tends to be able to perform molding of the decorative laminate well. In the case of a shape-imparting layer made only of a thermoplastic resin, the uneven structure is deformed due to heat during molding such as insert molding, and there is a tendency that sufficient three-dimensional effect (e.g., a sense of depth) due to the uneven structure cannot be maintained. In the case of a shape-imparting layer made only of a cured product of a curable resin, there is a tendency that the extensibility of the decorative laminate is insufficient, and molding such as deep drawing cannot be performed well.

[0036] Examples of thermoplastic resins include (meth)acrylic resins such as polymethyl methacrylate, polyolefins such as polyethylene and polypropylene, acrylonitrile-butadiene-styrene copolymer resins, styrene resins, polyamides, polyesters, polyurethanes, vinyl chloride resins, vinyl chloride-vinyl acetate copolymer resins, chlorinated polyolefins, and chlorinated rubbers.

[0037] Examples of the curable resin include ionizing radiation curable resin and thermosetting resin. The shape-imparting layer may contain two or more types of cured products. The shape-imparting layer may contain a cured product of an ionizing radiation curable resin and a cured product of a thermosetting resin.

[0038] The ionizing radiation curable resin means a resin that crosslinks and hardens by irradiation with ionizing radiation, and has an ionizing radiation curable functional group. The ionizing radiation curable functional group is a group that crosslinks by irradiation with ionizing radiation, and examples thereof include functional groups (ethylenically unsaturated groups) having an ethylenic double bond, such as (meth)acryloyl groups, vinyl groups, and allyl groups. The ionizing radiation means electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Examples of the ionizing radiation include electron beams (EB) and ultraviolet rays (UV), and also include electromagnetic waves such as X-rays and gamma rays; and charged particle beams such as alpha rays and ion beams. The ionizing radiation is preferably an electron beam and ultraviolet rays. That is, the ionizing radiation curable resin is preferably an ultraviolet ray curable resin or an electron beam curable resin.

[0039] Examples of the ionizing radiation curable resin include conventionally used polymerizable oligomers and polymerizable polymers. As the polymerizable oligomers and polymerizable polymers, (meth)acrylates are preferred, and examples thereof include polyfunctional (meth)acrylates having two or more (meth)acryloyl groups in the molecule, such as polyfunctional (meth)acrylate oligomers and polyfunctional (meth)acrylate polymers. The (meth)acrylic equivalent of the polyfunctional (meth)acrylate is preferably 100 g / eq or more and 1,500 g / eq or less, more preferably 400 g / eq or more and 1,000 g / eq or less, and even more preferably 400 g / eq or more and 800 g / eq or less, from the viewpoint of improving heat resistance and being less likely to cause curing shrinkage. The (meth)acrylic equivalent is a value obtained by dividing the weight average molecular weight of the polyfunctional (meth)acrylate by the number of (meth)acryloyl groups. The weight average molecular weight is measured by gel permeation chromatography using polystyrene as a standard substance according to a method in accordance with JIS K7252-3:2016.

[0040] Examples of ionizing radiation curable resins include urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, (meth)acrylic (meth)acrylate, polybutadiene (meth)acrylate, polycarbonate (meth)acrylate, polycaprolactone urethane (meth)acrylate, and polycaprolactone diol urethane (meth)acrylate. In this specification, the term (meth)acrylate means either or both of "acrylate" and "methacrylate", and the term (meth)acryloyl group means either or both of "acryloyl group" and "methacryloyl group".

[0041] When the ionizing radiation curable resin is an ultraviolet curable resin, the precursor layer of the shape-imparting layer described later preferably further contains a photopolymerization initiator together with the ultraviolet curable resin. The content of the photopolymerization initiator in the precursor layer is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, and is preferably 10 parts by mass or less, more preferably 5 parts by mass or less, for example, 0.1 parts by mass or more and 10 parts by mass or less, relative to 100 parts by mass of the ultraviolet curable resin.

[0042] Examples of the thermosetting resin include unsaturated group-containing (meth)acrylic resins, (meth)acrylic polyol resins, unsaturated polyesters, urethane resins, epoxy resins, phenolic resins, aminoalkyd resins, urea resins, melamine resins, melamine-urea co-condensation resins, guanamine resins, diallyl phthalate resins, and silicone resins.

[0043] A curing agent is used together with the thermosetting resin as necessary. In the case of unsaturated group-containing (meth)acrylic resin and unsaturated polyester, for example, a peroxide such as methyl ethyl ketone peroxide or a radical initiator such as azoisobutylnitrile is used. In the case of urethane resin, for example, an isocyanate-based curing agent is used. In the case of epoxy resin, for example, an organic amine-based curing agent is used.

[0044] Specific examples of thermosetting resins include two-liquid curing urethane resins that use a polyol compound as a base and a polyisocyanate compound as a curing agent. Examples of polyols include (meth)acrylic polyols, polyether polyols, polyester polyols, polyethylene glycols, and polypropylene glycols. The isocyanate compounds are polyvalent isocyanates having two or more isocyanate groups, and examples of the isocyanate compounds include aromatic isocyanates such as xylylene diisocyanate, tolylene diisocyanate, and 4,4-diphenylmethane diisocyanate; and aliphatic (or alicyclic) isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, and hydrogenated diphenylmethane diisocyanate. Specific examples of the cured products of thermosetting resins include crosslinked cured products of (meth)acrylic polyols with polyisocyanate compounds.

[0045] The weight average molecular weight (Mw) of the thermoplastic resin, the ionizing radiation curable resin and the thermosetting resin is preferably 5,000 or more, more preferably 6,000 or more, and even more preferably 7,000 or more, and is preferably 100,000 or less, more preferably 80,000 or less, and even more preferably 60,000 or less, for example, 5,000 or more and 100,000 or less. When Mw is the lower limit or more, for example, during the shaping treatment of the precursor layer of the shaping layer (for example, during embossing), the shaping mold tends to be peeled off well from the layer. When Mw is the upper limit or less, for example, the viscosity of the resin forming the shaping layer tends to be in a range that is excellent in coatability. In this specification, the weight average molecular weight (Mw) is measured by gel permeation chromatography using polystyrene as a standard substance according to a method conforming to JIS K7252-3:2016.

[0046] The glass transition temperature (Tg) of the thermoplastic resin, the ionizing radiation curable resin and the thermosetting resin is preferably 20°C or higher, more preferably 40°C or higher, and preferably 100°C or lower, more preferably 80°C or lower, for example, 20°C or higher and 100°C or lower. When Tg is at least the lower limit, for example, during the shaping treatment (e.g., embossing) of the precursor layer of the shape-imparting layer, the shaping mold tends to be peeled off well from the layer. When Tg is at most the upper limit, for example, the resin can be sufficiently softened by the heat during the shaping treatment (e.g., embossing) of the precursor layer of the shape-imparting layer, and the precursor layer tends to be well shaped. In this specification, Tg is the midpoint glass transition temperature obtained by differential scanning calorimetry (DSC) in accordance with JIS K7121:2012.

[0047] The refractive index of the thermoplastic resin, the ionizing radiation curable resin, and the thermosetting resin is preferably 1.55 or less, and preferably 1.40 or more, each independently. If the refractive index is equal to or greater than the lower limit, for example, the difference in refractive index between the mold-imparting layer and the reflective layer is sufficient, and high designability tends to be obtained. In this specification, the refractive index is measured using an Abbe refractometer ("Multi-wavelength Abbe refractometer DR-M2" manufactured by Atago Co., Ltd.) under the conditions of a measurement wavelength of 589 nm and a measurement temperature of 25°C.

[0048] The mold layer is formed, for example, as follows. A resin composition containing a thermoplastic resin and a curable resin is applied, for example, to the surface of a film, and dried as necessary to form a precursor layer of the mold layer. In this specification, the layer of the resin composition before the molding process is also referred to as a "precursor layer". Next, a molding die (for example, a roll-shaped molding plate) heated to, for example, 130°C to 170°C is pressed against the precursor layer to mold (for example, emboss) the precursor layer. The molding die has an uneven structure corresponding to a lens structure such as a Fresnel lens structure. Next, after peeling the molding die from the precursor layer, the precursor layer is subjected to a curing process to harden the precursor layer. The curing process is selected according to the type of curable resin contained in the precursor layer, and examples of the curing process include ionizing radiation irradiation such as ultraviolet irradiation process and electron beam irradiation process, and heat treatment. When the curable resin contains an electron beam curable resin, the curable resin is irradiated with an electron beam, when the curable resin contains an ultraviolet curable resin, the curable resin is irradiated with ultraviolet light, when the curable resin contains a thermosetting resin, the curable resin is cured by a heat treatment. In this way, a shape-imparting layer having a concave-convex structure is formed on the first surface. In addition, the precursor layer may be cured while the shape-imparting mold is pressed against the precursor layer, and the precursor layer may be cured to form a shape-imparting layer, and then the shape-imparting mold may be peeled off from the shape-imparting layer.

[0049] The wavelength of the ultraviolet light is, for example, 190 nm or more and 380 nm or less. Examples of the light source include a xenon lamp, a low pressure mercury lamp, a high pressure mercury lamp, an extra high pressure mercury lamp, a metal halide lamp, a carbon arc lamp, and a tungsten lamp. The irradiation dose of the ultraviolet light is preferably 5 mJ / cm. 2 More preferably, 50 mJ / cm 2 or more, preferably 5,000 mJ / cm 2 Less than or equal to 1,000 mJ / cm 2 For example, 5 mJ / cm 2 More than 5,000mJ / cm 2 The following is the result.

[0050] The dose of the electron beam is preferably 0.5 Mrad or more, more preferably 1 Mrad or more, and preferably 30 Mrad or less, more preferably 20 Mrad or less, for example, 0.5 Mrad or more and 30 Mrad or less. The acceleration voltage of the electron beam is preferably 30 kV or more and 300 kV or less. There is no particular limitation on the electron beam source, and various electron beam accelerators such as Cockroft-Walton type, Van de Graff type, resonant transformer type, insulating core transformer type, linear type, dynamitron type, and high frequency type can be used.

[0051] The heating temperature in the heat treatment is preferably 30°C or higher and 120°C or lower. The heating time in the heat treatment is preferably from 0.1 hours to 120 hours.

[0052] The resin composition may contain a diluent for the purpose of adjusting the viscosity of the resin composition. As the diluent, a monofunctional (meth)acrylate monomer such as methyl (meth)acrylate, or a normal solvent may be used. Examples of the solvent include hydrocarbon solvents such as toluene, xylene, hexane, and octane; alcohol solvents such as ethanol, propanol, butanol, pentanol, hexanol, octanol, and decanol; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, diisobutyl ketone, and cyclohexanone; ester solvents such as ethyl acetate, butyl acetate, amyl acetate, ethyl butyrate, butyl butyrate, butyl stearate, methyl benzoate, methyl lactate, ethyl lactate, and butyl lactate; and water.

[0053] The content ratio of the thermoplastic resin relative to the total content of the thermoplastic resin and the cured product of the curable resin in the mold-imparting layer is preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, even more preferably 50% by mass or more, particularly preferably 60% by mass or more, particularly preferably 70% by mass or more or 75% by mass or more, and preferably 95% by mass or less, more preferably 90% by mass or less, even more preferably 85% by mass or less, for example 20% by mass or more and 95% by mass or less. A decorative laminate having a mold-imparting layer in which the content ratio of the thermoplastic resin is equal to or more than the lower limit has good elongation and excellent moldability. A mold-imparting layer in which the content ratio of the thermoplastic resin is equal to or less than the upper limit can suppress deformation of the uneven structure due to heat during molding, such as insert molding.

[0054] The content ratio of thermoplastic resin to the total content of thermoplastic resin and curable resin in the precursor layer of the mold-imparting layer is preferably 20 mass% or more, more preferably 30 mass% or more, even more preferably 40 mass% or more, still more preferably 50 mass% or more, particularly preferably 60 mass% or more, particularly preferably 70 mass% or more or 75 mass% or more, and is preferably 95 mass% or less, more preferably 90 mass% or less, even more preferably 85 mass% or less, for example, 20 mass% or more and 95 mass% or less.

[0055] In one embodiment, the shape-imparting layer may contain a cured product of an ionizing radiation curable resin and a cured product of a thermosetting resin. The content ratio of the cured product of the ionizing radiation curable resin to the total content of the cured product of the ionizing radiation curable resin and the cured product of the thermosetting resin in the shape-imparting layer in this embodiment is preferably 20% by mass or more, more preferably 30% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, for example 20% by mass or more and 80% by mass or less.

[0056] In one embodiment, the precursor layer of the shape-imparting layer may contain an ionizing radiation curable resin and a thermosetting resin. The content ratio of the ionizing radiation curable resin to the total content of the ionizing radiation curable resin and the thermosetting resin in the precursor layer of this embodiment is preferably 20% by mass or more, more preferably 30% by mass or more, and preferably 80% by mass or less, more preferably 70% by mass or less, for example, 20% by mass or more and 80% by mass or less.

[0057] The mold-imparting layer and its precursor layer may contain additives, such as ultraviolet absorbers, light stabilizers, antioxidants, abrasion resistance improvers, infrared absorbers, antistatic agents, hydrolysis inhibitors, leveling agents, thixotropic agents, coupling agents, defoamers, flame retardants, plasticizers, pigments, dyes, light-diffusing particles, and antiblocking agents.

[0058] The first surface (shaping surface) of the mold layer preferably has a lens structure including concaves and convexes. An example of the lens structure is a Fresnel lens structure. The Fresnel lens structure has a Fresnel lens surface. The Fresnel lens surface includes, for example, a plurality of lens surfaces obtained by dividing a continuous convex lens surface along a surface perpendicular to the thickness direction, and a plurality of rise surfaces connecting adjacent lens surfaces. In one embodiment, the mold layer functions as a lens such as a Fresnel lens, thereby fulfilling the role of expressing a rich three-dimensional effect that is greater than the thickness of the mold layer.

[0059] In one embodiment, the shape-imparting layer is a layer having a Fresnel lens structure on the first surface (hereinafter also referred to as "Fresnel lens layer"). The Fresnel lens layer plays a role in improving the design by expressing a three-dimensional effect equal to or greater than the thickness of the decorative laminate. In the example shown in FIG. 4, the decorative laminate 10 includes a Fresnel lens layer 20f as the shape-imparting layer 20. The Fresnel lens layer 20f has a first surface 20a and a second surface 20b facing the first surface 20a. A plurality of Fresnel lens structures 25f are formed on the first surface 20a as the uneven structure 25. In the illustrated example, the decorative laminate 10 further includes a brightness adjustment layer 30 covering the first surface 20a of the Fresnel lens layer 20f, and the brightness adjustment layer 30 is a colored layer 30a. In this example, the second surface 20b of the Fresnel lens layer 20f constitutes the front side surface 11 of the decorative laminate 10, and the brightness adjustment layer 30 constitutes the back side surface 12 of the decorative laminate 10. The Fresnel lens structure 25f functions as a Fresnel lens.

[0060] In the illustrated example, the Fresnel lens layer 20f is transparent so that the brightness adjustment layer 30 can be viewed from the front side surface 11. In the illustrated example, gap regions 24 are formed between adjacent unit lens elements 23a. The multiple Fresnel lens structures 25f of the multiple unit lens elements 23a included in the Fresnel lens layer 20f may be molded integrally without any seams.

[0061] 4, the Fresnel lens layer 20f has a plurality of unit lens elements 23a each functioning as a Fresnel lens. On the first surface 20a of the Fresnel lens layer 20f, a Fresnel lens structure 25f is formed in each unit lens element 23a. The Fresnel lens structure 25f can be formed by shaping a precursor layer of the Fresnel lens layer 20f using a shaping mold.

[0062] The Fresnel lens layer includes unit lens elements that function as Fresnel lenses, thereby enabling the Fresnel lens layer to express a richer three-dimensional effect than the thickness of the Fresnel lens layer. The Fresnel lens layer includes a plurality of unit lens elements, enabling the decorative laminate to be given a complex design by combining a plurality of unit lens elements. In the example shown in FIG. 4, the Fresnel lens structure 25f is configured to function as a convex lens. That is, the central portion of the Fresnel lens structure 25f forms a curved surface that protrudes from the back surface 12 toward the front surface 11 in the Z direction Dz. Therefore, when the decorative laminate 10 is observed from the front surface 11 side, the unit lens element 23a functions as a convex lens.

[0063] The dimensions of each unit shaping element in a planar view of the decorative laminate (and therefore the dimensions of each unit optical element) are not particularly limited and can be appropriately set according to the design expressed by the decorative laminate. However, from the viewpoint of making the visual effect of the unit optical elements effective, it is preferable that each unit shaping element has a size that can be distinguished by the naked eye. Specifically, the shortest length of the unit shaping element is preferably 1 mm or more, more preferably 10 mm or more, and even more preferably 20 mm or more. The longest length of the unit shaping element is preferably 200 mm or less, more preferably 100 mm or less. The dimensions of each unit shaping element in a planar view of the decorative laminate are, for example, 1 mm or more and 200 mm or less. In one embodiment, the unit shaping element is a unit lens element.

[0064] In the example shown in FIG. 3, the multiple unit shaping elements 23 (multiple unit optical elements 13) have the same shape in plan view. The multiple unit shaping elements 23 are quadrangular in plan view. The multiple unit shaping elements 23 are regularly arranged. The multiple unit shaping elements 23 are arranged in a square. However, this is not limited to this example. The multiple unit shaping elements may have different shapes from each other. Each unit shaping element may have a polygonal shape other than a quadrangular shape. For example, each unit shaping element may be triangular, pentagonal, hexagonal, or octagonal. The multiple unit shaping elements may have a shape other than a polygonal shape. That is, the unit shaping element may include a curved portion or a portion extending in an arc shape. The unit shaping element may have any shape, such as a circle, a semicircle, an ellipse, a sector, a crescent, a heart, or a letter shape. The multiple unit shaping elements may be arranged in an irregular array. Although not shown in the figure, each unit shaping element may be arranged so as to overlap each other. In the illustrated example, a gap region 24 is formed between adjacent unit shaping elements 23. However, this is not limited, and the gap region 24 may not be formed.

[0065] As shown in FIG. 2A and FIG. 2B, each unit optical element 13 has a region 131. In the illustrated example, the first surface 20a includes, in the region 131, a plurality of inclined surfaces 26A inclined with respect to the normal direction Dn of the decorative laminate 10, and a plurality of connecting surfaces 26B connecting adjacent inclined surfaces 26A. The region 131 includes, for example, at least 10 inclined surfaces 26A. The number of inclined surfaces 26A included in the region 131 may be 10 or more, 50 or more, 100 or more, or 200 or more. In the example shown in FIG. 2A and FIG. 2B, the plurality of inclined surfaces 26A are aligned in a direction toward the reference line L1 (optical axis) of the concave-convex structure 25 extending along the normal direction Dn of the decorative laminate 10.

[0066] In the example shown in FIG. 2A and FIG. 2B, the inclined surfaces 26A correspond to a plurality of lens surfaces obtained by dividing a continuous convex lens surface along a surface perpendicular to the thickness direction. The connecting surface 26B corresponds to a rise surface connecting adjacent lens surfaces. According to such a concave-convex structure 25, it is possible to effectively suppress an increase in the thickness of the decorative laminate 10 caused by making the unit optical elements 13 function as convex lenses. For example, as in the illustrated example, when the decorative member 3 is used for the front grille of a vehicle, the decorative member 3 may be required to be thin in order to reduce weight. In addition, when the decorative member 3 is disposed facing the sensor 5, the decorative laminate 10 is required to transmit the electromagnetic waves emitted from the sensor 5 through the decorative member 3 with high transmittance. In this case, it is preferable to reduce the thickness of the decorative laminate 10.

[0067] In one embodiment, the inclined surface 26A may extend along the contour of the unit shaping element 23 (unit optical element 13). This allows the contour of each unit optical element 13 to be effectively accentuated. In one embodiment, a gap region 24 may be formed between adjacent unit shaping elements 23. This also allows the contour of each unit optical element 13 to be effectively accentuated.

[0068] In this specification, the angle of the inclined surface 26A with respect to the normal direction Dn of the decorative laminate 10 (hereinafter also referred to as the "inclined surface angle") θA is measured as the angle of the straight line LA connecting the top and bottom of each inclined surface 26A with respect to the normal direction Dn in the cross section of the molding layer 20 along the direction in which the multiple inclined surfaces 26A are arranged, as shown in FIG. 2B. Similarly, in this specification, the angle of the connecting surface 26B with respect to the normal direction Dn of the decorative laminate 10 (hereinafter also referred to as the "connecting surface angle") θB is measured as the angle of the straight line LB connecting the top and bottom of each connecting surface 26B with respect to the normal direction Dn in the cross section of the molding layer 20 along the direction in which the multiple connecting surfaces 26B are arranged, as shown in FIG. 2B. The inclined surface angle θA of each inclined surface 26A is greater than the connecting surface angle θB of the connecting surface 26B connected to the inclined surface 26A.

[0069] The connection surface angle θB (the rise angle of the rise surface in one embodiment) can be set appropriately. The connection surface angle θB may be, for example, approximately 0°. That is, the connection surface 26B may extend in the Z direction Dz. In the illustrated example, in consideration of the formability of the concave-convex structure 25 and the adhesion between the first surface 20a and the brightness adjustment layer 30, the connection surface angle θB may be 5° or more, 10° or more, or 15° or more. From the viewpoint of ensuring a sufficient area of ​​the inclined surface 26A, the connection surface angle θB is preferably 55° or less, more preferably 45° or less. The connection surface angle θB is, for example, 0° or more and 55° or less.

[0070] When the thickness of the decorative laminate is reduced while expressing a three-dimensional effect equal to or greater than the thickness of the decorative laminate, the height H25 of the uneven structure such as a Fresnel lens structure is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 3 μm or more, and is preferably 10 μm or less, more preferably 9 μm or less, and even more preferably 8 μm or less, for example, 1 μm or more and 10 μm or less. When the height H25 of the uneven structure is 1 μm or more, the visibility of the design displayed by optical action can be improved. When the height of the uneven structure is 10 μm or less, it is possible to suppress the occurrence of rainbow light on the front side surface of the decorative laminate by the mold-imparting layer. In this specification, the "height of the uneven structure" (H25) means the maximum value of the height (dimension in the Z direction Dz) H26 of the inclined surface 26A or the connecting surface 26B forming the uneven structure, as shown in FIG. 2B. In the illustrated example, the height H26 of the multiple inclined surfaces 26A or multiple connecting surfaces 26B of the uneven structure 25 is uniform, and the height H25 is equal to the height H26.

[0071] In order to suppress the occurrence of rainbow light on the front side of the decorative laminate, the pitch WA of the inclined surfaces 26A is preferably 10 μm or more, more preferably 12 μm or more, and even more preferably 15 μm or more. In order to realize a small size of the unit optical element, the pitch WA of the inclined surfaces 26A is preferably 100 μm or less, more preferably 50 μm or less, and even more preferably 20 μm or less. The pitch WA of the inclined surfaces 26A is, for example, 10 μm or more and 100 μm or less.

[0072] When it is desired to generate rainbow light on the front side of the decorative laminate, the height H25 of the uneven structure such as a Fresnel lens structure is preferably 0.1 μm or more, more preferably 0.5 μm or more. In this case, the height H25 of the uneven structure is preferably 1 μm or less. Therefore, the height H25 of the uneven structure is, for example, 0.1 μm or more and 1 μm or less.

[0073] When it is desired to generate rainbow light on the front side surface of the decorative laminate, the pitch WA of the inclined surfaces 26A is preferably less than 10 μm, more preferably 5 μm or less, and even more preferably 2 μm or less.

[0074] From the viewpoint of improving the formability of the concave-convex structure, the height H25 of the concave-convex structure is preferably 0.2 μm or more, more preferably 0.5 μm or more, and even more preferably 1.5 μm or more. From the same viewpoint, the pitch WA of the inclined surface 26A is preferably 2 μm or more, more preferably 4 μm or more, and even more preferably 8 μm or more.

[0075] 4, the pitch WA of the inclined surface 26A may vary depending on the distance from the reference line L1 (optical axis) of the concave-convex structure 25. Specifically, the pitch WA may become smaller as it moves away from the reference line L1 (optical axis).

[0076] As shown in FIG. 2B, the ratio (T20 / H25) of the thickness T20 of the mold layer 20 to the height H25 of the uneven structure 25 may be 1.5 or more, 1.8 or more, 2.5 or more, 8.0 or less, 6.0 or less, or 4.0 or less, for example, 1.5 or more and 8.0 or less. In this specification, the "thickness of the mold layer" (T20) means the maximum value of the distance (dimension in the Z direction Dz) T26 between the second surface 20b and the top of the inclined surface 26A or the connecting surface 26B, as shown in FIG. 2B. In the illustrated example, the distance T26 between the second surface 20b and the top of the multiple inclined surfaces 26A or the multiple connecting surfaces 26B is uniform, and the thickness T20 is equal to the distance T26. The thickness T20 of the mold layer 20 is, for example, 3 μm or more and 20 μm or less.

[0077] The inclined surface angle θA, the connecting surface angle θB, the height H25 and the pitch WA of the uneven structure 25 are measured by observing an image of a cross section of the decorative laminate 10 using a scanning electron microscope.

[0078] 4, the Fresnel lens structure 25f has a Fresnel lens surface. The Fresnel lens surface includes, for example, a plurality of lens surfaces 26A obtained by dividing a continuous convex lens surface along a surface perpendicular to the thickness direction of the lens surface, and a plurality of rise surfaces 26B connecting adjacent lens surfaces 26A. According to the Fresnel lens structure 25f, it is possible to effectively suppress an increase in the thickness of the Fresnel lens layer 20f caused by making the Fresnel lens layer 20f function as a convex lens.

[0079] In the example shown in FIG. 3, the concave-convex structure 25 of each unit shaping element 23 is a circular Fresnel lens. In the example shown by the solid line in FIG. 3, the multiple inclined surfaces (lens surfaces) 26A are arranged in a concentric circle shape, but this is not limited thereto. For example, as shown by the dashed line in FIG. 3, the contour of the multiple inclined surfaces (lens surfaces) 26A may be elliptical. The direction in which the major axis of the ellipse extends (hereinafter simply referred to as the major axis direction) may be different between the multiple unit shaping elements 23. For example, the major axis direction of one unit shaping element 23 may be non-parallel to or perpendicular to the major axis direction of another unit shaping element 23.

[0080] In the above example, the concave-convex structure 25 is a circular Fresnel lens, but is not limited thereto. As shown by the two-dot chain line in FIG. 3, the concave-convex structure 25 may be a linear Fresnel lens. In this case, the arrangement direction of the inclined surface (lens surface) 26A and the connecting surface (rise surface) 26B of the linear Fresnel lens forming the concave-convex structure 25 may be different between the multiple unit shaping elements 23. For example, the arrangement direction of the inclined surface (lens surface) 26A and the connecting surface (rise surface) 26B of one linear Fresnel lens may be non-parallel or perpendicular to the arrangement direction of the inclined surface (lens surface) 26A and the connecting surface (rise surface) 26B of another linear Fresnel lens.

[0081] When the Fresnel lens structure is configured to function as a convex lens, the focal length of the Fresnel lens structure (i.e., the focal length of the Fresnel lens) is preferably 0.5 mm or more, more preferably 2 mm or more, even more preferably 5 mm or more, and preferably 350 mm or less, more preferably 250 mm or less, even more preferably 150 mm or less. By having the focal length of the Fresnel lens structure be 0.5 mm or more and 350 mm or less, a three-dimensional effect that is greater than or equal to the thickness of the Fresnel lens layer can be effectively expressed. This allows for a rich design expression with a sense of luxury, and further improves the design.

[0082] The focal length of the Fresnel lens structure in at least some of the unit lens elements may be different from the focal length of the Fresnel lens structure in the other unit lens elements, so that the observer perceives the positions of the unit lens elements in the Z direction Dz differently from each other, thereby effectively improving the design by providing a three-dimensional effect.

[0083] The function of the Fresnel lens layer will be described. The decorative laminate displays a design and imparts design to an article to which the decorative laminate is applied. If the decorative laminate can express a three-dimensional effect, a rich design expression with a sense of luxury is possible. The three-dimensional effect of the decorative laminate can be expressed by forming a physical uneven structure. On the other hand, depending on the application of the decorative laminate, the thickness of the decorative laminate may not be sufficiently thick. Due to such restrictions, the design may not be sufficiently improved. For example, many decorative members, such as decorative members used in the front grille of a vehicle, are required to be thin from the viewpoint of weight reduction. In addition, the thickness of the decorative member that is expected to transmit electromagnetic waves such as millimeter waves is set according to the wavelength of the millimeter waves and is subject to restrictions. In addition, it is preferable to reduce the thickness of the decorative laminate from the viewpoint of improving the transmittance of electromagnetic waves.

[0084] As shown in FIG. 4, when the decorative laminate 10 includes a Fresnel lens layer 20f having a Fresnel lens structure 25f, the reflection interface formed on the Fresnel lens surface of the Fresnel lens layer 20f functions as a convex mirror. As a result, an observer who observes the reflection on the reflection interface feels as if the Fresnel lens layer 20f functioning as a convex mirror is located deeper than the actual position of the Fresnel lens layer 20f. That is, the Fresnel lens layer 20f can display a design with a sense of depth that is deeper than the actual thickness of the Fresnel lens layer 20f. In this way, the Fresnel lens layer 20f can display a design with a sense of depth that is greater than its thickness. Therefore, while reducing the thickness of the Fresnel lens layer 20f, a three-dimensional effect that is greater than the thickness of the Fresnel lens layer 20f can be expressed. This allows for a rich design expression with a sense of luxury to be realized, improving the design.

[0085] In the above example, the Fresnel lens structure 25f is configured to function as a convex lens, but the present invention is not limited to this example. For example, as shown in FIG. 5, the Fresnel lens structure 25f may be configured to function as a concave lens. That is, the center of the Fresnel lens structure 25f may form a curved surface recessed from the front side surface 11 toward the back side surface 12 in the Z direction Dz. Therefore, when the decorative laminate 10 is observed from the front side surface 11 side, the reflection interface formed on the Fresnel lens surface functions as a concave mirror. In this case, the lens surface 26A of the Fresnel lens surface may be configured to be formed by dividing a continuous concave lens surface along a surface perpendicular to the thickness direction.

[0086] When the Fresnel lens structure is configured to function as a concave lens, the focal length of the Fresnel lens structure (i.e., the focal length of the Fresnel lens) is preferably -350 mm or more, more preferably -250 mm or more, even more preferably -150 mm or more, and preferably -0.5 mm or less, more preferably -2 mm or less, and even more preferably -5 mm or less. By having the focal length of the Fresnel lens structure be -350 mm or more and -0.5 mm or less, a three-dimensional effect that is greater than or equal to the thickness of the Fresnel lens layer can be effectively expressed. This allows for a rich design expression with a sense of luxury to be realized, and the design can be further improved.

[0087] 5, an observer who observes the reflection in the unit lens element 23a feels as if the unit lens element 23a functioning as a concave mirror is located closer to the viewer than the actual position of the Fresnel lens layer 20f. Therefore, even in this case, a design that gives a sense of depth greater than the actual thickness of the Fresnel lens layer 20f can be displayed.

[0088] <Brightness adjustment layer> The brightness adjustment layer is a layer that adjusts the brightness of light reflected by the decorative laminate. The brightness adjustment layer covers the first surface of the shape-imparting layer. By adjusting the brightness of the light reflected by the decorative laminate, a rich design with a luxurious feel can be effectively imparted to the decorative laminate. Examples of the brightness adjustment layer include a reflective layer, a refractive index modulation layer, and a colored layer, and any combination of these may be used.

[0089] In the example shown in FIG. 2A, the brightness adjustment layer 30 is provided to adjust the reflectance of visible light measured on the front side 11 side of the decorative laminate 10. The brightness adjustment layer 30 covers the first surface 20a of the molding layer 20. This adjusts the reflectance of visible light at the reflection interface between the first surface 20a and the brightness adjustment layer 30, and adjusts the reflectance of visible light measured on the front side 11 side of the decorative laminate 10. The surface of the brightness adjustment layer 30 facing the molding layer 20 has unevenness corresponding to the first surface 20a. In other words, the brightness adjustment layer 30 has an uneven structure corresponding to the uneven structure 25 of the molding layer 20. In this example and the examples shown in FIG. 4 and FIG. 5, the brightness adjustment layer 30 is a colored layer 30a, and also functions as a planarizing layer that fills in the unevenness of the first surface 20a.

[0090] In the examples shown in FIG. 4 and FIG. 5, the brightness adjustment layer 30 is a colored layer 30a, but is not limited thereto. As shown in FIG. 6, the brightness adjustment layer 30 may be a reflective layer 30b or a refractive index modulation layer 30c. The decorative laminate 10 may further include a filling layer 40 that fills the unevenness of the brightness adjustment layer 30. In the example shown in FIG. 6, the filling layer 40, the reflective layer 30b or the refractive index modulation layer 30c, and the shape-imparting layer 20 are laminated in this order along the Z direction Dz. The decorative laminate 10 may further include a bonding layer that fills the unevenness of the brightness adjustment layer 30 instead of the filling layer 40. However, the reflective layer 30b or the refractive index modulation layer 30c may be formed so as to fill the unevenness of the first surface 20a of the shape-imparting layer 20.

[0091] (reflective layer) The reflective layer covers the first surface (shaping surface) of the shaping layer to form a reflective interface between the first surface and the reflective layer. The reflective layer improves the reflectance of visible light at the reflective interface between the first surface and the brightness adjustment layer, thereby adjusting the brightness of the light reflected by the decorative laminate. In one embodiment, the reflective layer is formed on the Fresnel lens surface of the Fresnel lens structure.

[0092] The reflective layer can be formed by, for example, a film-forming method such as sputtering and vacuum deposition using a metal material or an inorganic material, or a coating method using a coating liquid containing a metal material or an inorganic material. The reflective layer may be a transparent deposition layer. The reflective layer is a thin film-like layer. The thickness of the reflective layer may be thinner than the height H26 of the connection surface 26B. The thickness of the reflective layer may be half or less of the height H26 of the connection surface 26B, 25% or less of the height H26 of the connection surface 26B, or 10% or less of the height H26 of the connection surface 26B. A reflective layer of such a thickness does not fill the unevenness of the shaping surface, but has unevenness corresponding to the unevenness of the shaping surface on the side opposite to the side facing the shaping surface. Although not shown, the reflective layer may fill the unevenness of the shaping surface. In this case, the decorative laminate does not need to have a filling layer.

[0093] Examples of the material constituting the reflective layer include metal materials and inorganic materials. Examples of the metal materials include aluminum, indium, and tin. Examples of the inorganic materials include metal oxides, metal sulfides, and metal nitrides, specifically, aluminum oxide, barium titanate, and zinc sulfide. As the material constituting the reflective layer, it is preferable to use a material that improves the reflectance of the reflection interface formed by the reflective layer, and it is more preferable to use a material that has radio wave transparency.

[0094] In one embodiment, the electromagnetic waves used in the sensor are transmitted through the decorative laminate. When the reflective layer is formed as a layer that continuously spreads over the entire surface of the shaping surface, the electromagnetic waves are blocked or attenuated. Therefore, as shown in FIG. 7, the reflective layer 30b may include a plurality of metal grain portions 31. The metal grain portions 31 have a metallic luster and are capable of reflecting visible light. The reflective layer 30b forms islands in a so-called sea-island structure. The island-like metal grain portions 31 are spaced apart from each other. Between the plurality of metal grain portions 31, gaps that form the sea of ​​the sea-island structure are provided. The electromagnetic waves used in the sensor, for example, millimeter waves, are transmitted through the reflective layer 30b by passing through the gaps. Such a metal layer can be formed by a film formation method such as sputtering and vacuum deposition using a metal material such as indium. The electromagnetic wave transmittance of the reflective layer may be improved by using a metal oxide, metal sulfide, or metal nitride as a material constituting the reflective layer. The reflective layer may be formed integrally without seams across a plurality of unit shaping elements.

[0095] The reflective layer may be formed by coating a coating liquid containing metal particles having an average particle size of 100 nm or less on the first surface of the mold-imparting layer. In this case, the metal particles may be composed of at least one selected from aluminum and barium titanate. For example, an aluminum particle dispersion liquid can be used as the coating liquid containing such metal particles. The coating liquid may or may not contain a binder resin. For example, a thermoplastic resin can be used as the binder resin, and the details of these are as described above.

[0096] The thickness of the reflective layer is preferably a thickness capable of improving the reflectance of the reflective interface formed by the reflective layer, and is preferably 30 nm or more, more preferably 50 nm or more, even more preferably 70 nm or more, and is preferably 20 μm or less, more preferably 10 μm or less, even more preferably 1 μm or less, for example, 30 nm or more and 20 μm or less.

[0097] (Refractive index modulation layer) The refractive index modulation layer is a layer whose refractive index is different from that of the mold layer. When the concave-convex structure of the mold layer is covered with the refractive index modulation layer, a reflective interface is formed between the mold layer and the refractive index modulation layer, and the reflectance of light on the mold surface can be improved. This allows the brightness of the light reflected by the decorative laminate to be adjusted.

[0098] The refractive index modulation layer can be formed by deposition or coating of a high refractive index material (e.g., metal oxide, metal sulfide, or metal nitride). The refractive index modulation layer may be a transparent deposition layer. As the high refractive index material, any one of titanium oxide, zirconium oxide, aluminum oxide, zinc oxide, zinc sulfide, and barium titanate, or a combination of these, can be used. By forming the refractive index modulation layer from such a material, the electromagnetic wave transmittance of the refractive index modulation layer can be improved.

[0099] When the refractive index modulation layer is formed by coating a high refractive index material, the refractive index modulation layer can be formed, for example, by the following method. An ink containing high refractive index particles having an average particle diameter of 100 nm or less formed from a high refractive index material is prepared, and the ink is coated on the shaping surface. This allows the refractive index modulation layer to be formed. For example, a zirconium oxide dispersion can be used as the ink containing high refractive index particles. The ink may or may not contain a binder resin. As the binder resin, an ultraviolet curable resin, an electron beam curable resin, or the like can be used. A refractive index modulation layer containing an ultraviolet curable resin or an electron beam curable resin as a binder resin is flexible and has extensibility. Therefore, when the decorative laminate is curved or stretched along the surface of the molded part, the refractive index modulation layer can be curved or stretched as desired. In other words, there is little risk that the refractive index modulation layer will hinder the curving or stretching of the decorative laminate.

[0100] The refractive index modulation layer may be a thin film-like layer, similar to the reflective layer. In this case, the thickness of the refractive index modulation layer may be thinner than the height H26 of the connecting surface 26B. The thickness of the refractive index modulation layer may be half or less of the height H26 of the connecting surface 26B, 25% or less of the height H26 of the connecting surface 26B, or 10% or less of the height H26 of the connecting surface 26B. A refractive index modulation layer of such a thickness does not fill the unevenness of the shaping surface, but has unevenness corresponding to the unevenness of the shaping surface on the side opposite to the side facing the shaping surface. The refractive index modulation layer may fill the unevenness of the shaping surface. In this case, the decorative laminate does not need to have a filling layer.

[0101] The thickness of the refractive index modulation layer is preferably a thickness capable of improving the reflectance of the reflection interface formed by the refractive index modulation layer, and is preferably 0.005 μm or more and preferably 20 μm or less.

[0102] (colored layer) The color layer absorbs a portion of the light incident on the decorative laminate, thereby adjusting the reflectance of visible light at the reflection interface between the shape-imparting layer and the brightness adjustment layer. The color layer can impart a desired color to the decorative laminate. The color layer contains, for example, a resin and a colorant. The color layer may contain the above-mentioned additives.

[0103] The resin may be a thermoplastic resin or a cured product of a curable resin. Specific examples of these are as described above, and will not be described in this section. Specifically, the resin may be a (meth)acrylic resin such as polymethyl methacrylate. Specifically, the resin may be a crosslinked cured product of a (meth)acrylic polyol with a polyisocyanate compound.

[0104] Colorants include, for example, pigments and dyes. Examples of pigments include color pigments such as black pigments, blue pigments, red pigments, yellow pigments, green pigments, magenta pigments, and purple pigments. Examples of black pigments include carbon black, titanium black, composite metal oxides, and perylene black. Examples of blue pigments include copper phthalocyanine pigments, anthraquinone pigments, cobalt blue, and composite metal oxides. Examples of red pigments include diketopyrrolopyrrole pigments, anthraquinone pigments, quinacridone pigments, perylene pigments, composite metal oxides, and iron oxides. Examples of yellow pigments include isoindoline pigments, isoindolinone pigments, anthraquinone pigments, condensed azo pigments, composite metal oxides, and iron oxides. Examples of green pigments include phthalocyanine pigments and isoindoline pigments. Examples of magenta pigments include quinacridone pigments. Examples of purple pigments include quinacridone pigments and dioxazine pigments.

[0105] Examples of the dyes include color dyes such as black dyes, blue dyes, red dyes, green dyes, magenta dyes, yellow dyes, and purple dyes. Examples of the black dyes include azo-based black dyes and nigrosine black dyes. Examples of the blue dyes include methine-based dyes, anthraquinone-based dyes, azo-based dyes, triarylmethane-based dyes, and phthalocyanine-based dyes. Examples of the red dyes include azo-based dyes, anthraquinone-based dyes, and perinone-based dyes. Examples of the green dyes include triphenylmethane-based basic dyes and phthalocyanine-based dyes. Examples of the magenta dyes include vermilion and anthraquinone-based dyes. Examples of the yellow dyes include azo-based dyes, anthraquinone-based dyes, methine-based dyes, quinophthalone-based dyes, and pyrazolone-based dyes. Examples of the purple dyes include azo-based dyes, anthraquinone-based dyes, azine-based dyes, and quinoline-based dyes.

[0106] The colored layer may be, for example, a black layer containing a black pigment and / or a black dye.

[0107] The content of the colorant in the colored layer is preferably 10% by mass or more, more preferably 20% by mass or more, and preferably 60% by mass or less, more preferably 50% by mass or less, for example, 10% by mass or more and 60% by mass or less. The content of the resin in the colored layer is preferably 40% by mass or more, more preferably 50% by mass or more, and preferably 90% by mass or less, more preferably 80% by mass or less, for example, 40% by mass or more and 90% by mass or less.

[0108] The colored layer can be formed, for example, by applying a liquid precursor material to the first surface of the mold layer and curing it as necessary. The precursor material of the colored layer contains a resin (thermoplastic resin and / or curable resin) and a colorant.

[0109] The decorative laminate may include a reflective layer and a colored layer in this order as a brightness adjustment layer on the first surface of the mold layer. That is, the colored layer, the reflective layer, and the mold layer may be laminated in this order along the Z direction Dz. This allows the decorative laminate to be colored in a desired color. In addition to the reflective layer, the colored layer can also adjust the brightness of the reflected light in the decorative laminate. In the example shown in FIG. 8, the colored layer 30a, the reflective layer 30b, and the mold layer 20 are laminated in this order along the Z direction Dz. In this case, the colored layer 30a is observed through the mold layer 20 and the reflective layer 30b. Therefore, the mold layer 20 and the reflective layer 30b are transparent. In this case, the colored layer 30a may function as a flattening layer that fills the unevenness of the reflective layer 30b. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0110] The colored layer may be a colored adhesive layer that bonds the shape-imparting layer to a backer layer, which will be described later. In one embodiment, the colored adhesive layer is an adhesive layer made of a colored adhesive. The colored adhesive may be any of a one-component curing adhesive, a two-component curing adhesive, and a non-curing adhesive. The colored adhesive may be a solventless adhesive or a solvent-based adhesive. Examples of the adhesive include a rubber-based adhesive, a vinyl-based adhesive, an olefin-based adhesive, a polyether-based adhesive, a polyester-based adhesive, a silicone-based adhesive, an epoxy-based adhesive, a phenol-based adhesive, a (meth)acrylic-based adhesive, and a urethane-based adhesive. The colored adhesive contains the above-mentioned colorant.

[0111] In this embodiment, for example, a colored adhesive is applied to the first surface of the mold layer, dried as necessary, a backer film corresponding to the backer layer is laminated, and the colored adhesive is cured as necessary to obtain a decorative laminate having a mold layer, a colored adhesive layer, and a backer layer. The method of laminating the backer film using the colored adhesive may be, for example, a dry lamination method or a non-solvent lamination method.

[0112] The thickness of the colored layer is preferably a thickness capable of improving the reflectance of the reflection interface formed by the reflective layer, and is preferably 0.5 μm or more, more preferably 1 μm or more, and preferably 10 μm or less, more preferably 7 μm or less, for example, 0.5 μm or more and 10 μm or less.

[0113] <Filled layer> When the brightness adjustment layer does not fill the unevenness of the shaping surface of the shaping layer, the brightness adjustment layer also has unevenness. In this case, the decorative laminate may further include a filling layer on the brightness adjustment layer that fills the unevenness of the brightness adjustment layer. The filling layer functions as a flattening layer that fills the unevenness of the brightness adjustment layer. In the example shown in FIG. 6, the surface of the reflective layer 30b or the refractive index modulation layer 30c facing the filling layer 40 has unevenness corresponding to the unevenness of the first surface 20a. In the illustrated example, the filling layer 40 constitutes the back side surface 12 of the decorative laminate 10.

[0114] The filling layer is a transparent or opaque resin layer. The filling layer may be formed of the material forming the bonding layer described above. In this case, the filling layer can also serve as the bonding layer. When the filling layer is opaque, it can conceal at least a part of the article to which the decorative member is applied. That is, the filling layer may also serve as a concealing layer described later. For example, in the example shown in FIG. 1B, the filling layer 40 is opaque, so that the decorative member 3 can conceal the sensor 5. The filling layer may be composed of a cured product of an ionizing radiation curable resin. Alternatively, the decorative laminate may not have a filling layer. In this case, the unevenness of the brightness adjustment layer in the decorative member may be filled with the bonding layer.

[0115] The thickness of the filling layer is, for example, not less than 0.01 mm and not more than 1 mm.

[0116] <Protective layer> The decorative laminate may further include a protective layer on the second surface of the mold-imparting layer. The protective layer is, for example, a layer that improves the heat resistance, scratch resistance, or weather resistance of the decorative laminate. The protective layer may be a support layer or a base layer for supporting the mold-imparting layer and increasing the strength of the entire decorative laminate. The protective layer may have other functions, such as a peeling function, an anti-reflection function, an anti-glare function, an antistatic function, and an anti-fouling function. In the example shown in FIG. 9, the decorative laminate 10 includes a protective layer 50 as a layer constituting its front side surface 11. In the illustrated example, the brightness adjustment layer 30, the mold-imparting layer 20, and the protective layer 50 are laminated in this order along the Z direction Dz. In this case, the brightness adjustment layer 30 is observed through the protective layer 50 and the mold-imparting layer 20. Therefore, the protective layer 50 is transparent.

[0117] The protective layer is formed, for example, from a thermoplastic resin and / or a curable resin. Specific examples of the thermoplastic resin and the curable resin are as described above, and will not be described in this section. The protective layer may contain the above-mentioned additives. From the viewpoint of the weather resistance of the decorative laminate, it is preferable that the protective layer contains a weather resistance improver such as an ultraviolet absorber, a light stabilizer, and an antioxidant.

[0118] Specific examples of the resin constituting the protective layer include (meth)acrylic resins such as polymethyl methacrylate, polyesters such as polyethylene terephthalate, polyolefins such as polyethylene and polypropylene, acrylonitrile-butadiene-styrene copolymer resins (ABS resins), styrene resins, vinyl chloride resins, chlorinated polyolefins, and polycarbonates. Among these, (meth)acrylic resins are preferred from the viewpoints of weather resistance and moldability. The resin constituting the protective layer may be a thermoplastic resin. By using a thermoplastic resin as the resin constituting the protective layer, molding and pressure molding onto a three-dimensional curved surface can be performed more smoothly.

[0119] In one embodiment, the weight average molecular weight (Mw) of the thermoplastic resin is preferably 5,000 or more, more preferably 10,000 or more, even more preferably 20,000 or more, and preferably 400,000 or less, more preferably 300,000 or less, even more preferably 200,000 or less, for example, 5,000 or more and 400,000 or less. In one embodiment, the glass transition temperature (Tg) of the thermoplastic resin is preferably 20°C or more, more preferably 50°C or more, and preferably 140°C or less, more preferably 120°C or less, for example, 20°C or more and 140°C or less.

[0120] The thickness of the protective layer is preferably 1 μm or more, more preferably 5 μm or more, even more preferably 10 μm or more, and is preferably 500 μm or less, more preferably 300 μm or less, even more preferably 150 μm or less, for example, 1 μm or more and 500 μm or less.

[0121] The protective layer may be, for example, a resin film such as a (meth)acrylic resin film, or a coating film such as a (meth)acrylic resin coating film. Among these, from the viewpoint of weather resistance and scratch resistance of the decorative laminate, a resin film is preferred. The thickness of the resin film is preferably 10 μm or more, more preferably 30 μm or more, and even more preferably 50 μm or more. The thickness of the coating film is preferably less than 10 μm.

[0122] <Backer layer> The decorative laminate may further include a backer layer that reinforces the decorative laminate. The decorative laminate includes a backer layer, which improves the strength of the decorative laminate. As a result, the decorative laminate can be preformed before being bonded to the molded portion, as described below. In one embodiment, the backer layer may form the front side or the back side of the decorative laminate.

[0123] In the example shown in FIG. 10, the decorative laminate 10 includes a backer layer 55. In the illustrated example, the backer layer 55, the brightness adjustment layer 30, and the shape-imparting layer 20 are laminated in this order along the Z direction Dz. A bonding layer may be provided between the brightness adjustment layer 30 and the backer layer 55. The bonding layer bonds the brightness adjustment layer 30 and the backer layer 55. In the illustrated example, the backer layer 55 constitutes the back side surface 12 of the decorative laminate 10.

[0124] Examples of the resin constituting the backer layer include acrylonitrile-butadiene-styrene copolymer resin (ABS resin), styrene resin, polyolefins such as polyethylene and polypropylene, (meth)acrylic resins such as polymethyl methacrylate, vinyl chloride resin, chlorinated polyolefin, and polycarbonate. The resin constituting the backer layer is preferably ABS resin, polypropylene, and polycarbonate. When the material constituting the molded part is ABS resin, the resin constituting the backer layer is preferably ABS resin. When the material constituting the molded part is polypropylene, the resin constituting the backer layer is preferably polypropylene. When the material constituting the molded part is polycarbonate, the resin constituting the backer layer is preferably polycarbonate.

[0125] The backer layer may be transparent or opaque. When the backer layer is opaque, it can conceal at least a part of the article to which the decorative member is applied. That is, the backer layer may also serve as a concealing layer, which will be described later. For example, in the example shown in FIG. 29B, which will be described later, the backer layer 55 is opaque, so that the decorative member 3 can conceal the sensor 5.

[0126] The thickness of the backer layer is preferably 50 μm or more, more preferably 100 μm or more, even more preferably 150 μm or more, and is preferably 1,000 μm or less, more preferably 600 μm or less, even more preferably 400 μm or less, for example, 50 μm or more and 1,000 μm or less.

[0127] The backer layer may be a backer film made of the above resin. For example, a backer film as a backer layer may be adhered to the brightness adjustment layer. The backer layer may be directly adhered to the brightness adjustment layer, or may be adhered to the brightness adjustment layer via an adhesive layer.

[0128] In one embodiment, the adhesive layer between the brightness adjustment layer and the backer layer is an adhesive layer made of an adhesive. The adhesive may be any of a one-component curing adhesive, a two-component curing adhesive, and a non-curing adhesive. The adhesive may be a solvent-free adhesive or a solvent-based adhesive. Examples of the adhesive include rubber-based adhesives, vinyl-based adhesives, olefin-based adhesives, polyether-based adhesives, polyester-based adhesives, silicone-based adhesives, epoxy-based adhesives, phenol-based adhesives, (meth)acrylic adhesives, and urethane-based adhesives. In one embodiment, the adhesive layer between the brightness adjustment layer and the backer layer is a resin layer made of a thermoplastic resin. Examples of the thermoplastic resin include (meth)acrylic resins, styrene resins, polyamides, polyesters, polyurethanes, vinyl chloride resins, vinyl chloride-vinyl acetate copolymer resins, chlorinated polyolefins, and chlorinated rubbers. The thickness of the bonding layer between the brightness adjusting layer and the backer layer is preferably 0.1 μm or more, more preferably 0.2 μm or more, even more preferably 0.5 μm or more, and is preferably 10 μm or less, more preferably 8 μm or less, even more preferably 6 μm or less, for example, 0.1 μm or more and 10 μm or less.

[0129] In this embodiment, for example, an adhesive or a thermoplastic resin is applied to the surface of the brightness adjustment layer, dried as necessary, a backer film corresponding to the backer layer is laminated, and the adhesive is cured as necessary, thereby obtaining a decorative laminate having a shape-imparting layer, a brightness adjustment layer, a bonding layer, and a backer layer. The method of laminating the backer film using an adhesive may be, for example, a dry lamination method or a non-solvent lamination method. The method of laminating the backer film using a thermoplastic resin may be, for example, an extrusion lamination method.

[0130] <Joining layer> The decorative laminate may further include a bonding layer as a layer constituting the back side or the front side. The bonding layer bonds (adheses, sticks or heat-seals) other layers of the decorative laminate to the molded portion. Examples of the bonding layer include an adhesive layer, a pressure-sensitive adhesive layer and a heat-sealable resin layer. The adhesive layer, the pressure-sensitive adhesive layer and the heat-sealable resin layer can be any layer known in the art. The adhesive constituting the adhesive layer is as described above, and the description will be omitted in this section. Examples of the adhesive constituting the pressure-sensitive adhesive layer include (meth)acrylic adhesives, urethane adhesives, silicone adhesives and rubber adhesives. Examples of the resin constituting the heat-sealable resin layer include thermoplastic resins such as (meth)acrylic resins, styrene resins, polyamides, polyesters, polyurethanes, vinyl chloride resins, vinyl chloride-vinyl acetate copolymer resins, chlorinated polyolefins and chlorinated rubbers. The thickness of the bonding layer is preferably 1 μm or more, more preferably 5 μm or more, and is preferably 100 μm or less, more preferably 50 μm or less.

[0131] <Other layers> The decorative laminate may include layers other than the layers described above.

[0132] The decorative laminate may further include a release layer. In one embodiment, the release layer constitutes the front side of the decorative laminate. The release layer has a release property that facilitates the release of the decorative laminate from a release substrate in a decorative laminate (transfer sheet) with a release substrate described later. As a material for forming the release layer, for example, thermoplastic resins such as (meth)acrylic resins, vinyl chloride-vinyl acetate copolymers, polyurethanes, polyolefins, polyesters, epoxy resins, and silicone resins, thermosetting resins in which these thermoplastic resins are combined with a curing agent, ultraviolet curing resins, and electron beam curing resins can be adopted. Other layers of the decorative laminate can be observed through the release layer. Therefore, in one embodiment, the release layer is transparent. The above-mentioned protective layer may also serve as the release layer.

[0133] The decorative laminate may include a pattern layer on which a pattern such as a figure, design, picture, photograph, character, mark, pictogram, letter, or number is formed. The pattern layer may also perform a design expression to display a background on the decorative laminate. The pattern layer may be provided with, for example, a wood grain or marble pattern, a metallic texture, or a geometric pattern. The pattern layer may be a print layer formed by printing, or a transfer layer formed by transfer.

[0134] The decorative laminate may include an opaque concealing layer. The concealing layer conceals at least a part of the article or molded part to which the decorative member is applied. The concealing layer may be composed of, for example, a pigment and / or a dye and a binder resin. The concealing layer may be formed of the same material as the colored layer. Examples of the pigment contained in the concealing layer include black pigments such as carbon black, white pigments such as titanium oxide, and aluminum-based pigments. The concealing layer has improved concealing properties due to the inclusion of such pigments in the concealing layer. The concealing layer may be formed by vapor deposition of metals such as aluminum, indium, and tin on other layers constituting the decorative laminate.

[0135] When the brightness adjustment layer is a colored layer, the decorative laminate may further include a concealing layer. The concealing layer, for example, constitutes the back surface of the decorative laminate, or is disposed between the shape-imparting layer and the brightness adjustment layer and the back surface. In this case, a color that is a combination of the color of the brightness adjustment layer and the color of the concealing layer can be imparted to the decorative laminate.

[0136] <Examples of decorative laminates> Specific examples of the decorative laminate are given below. Laminate having a brightness adjusting layer and a shape-imparting layer in this order A laminate having a brightness adjusting layer, a shape-imparting layer, and a protective layer in this order. A laminate having a coloring layer, a reflective layer, and a shape-imparting layer in this order. A laminate having a coloring layer, a reflective layer, a shape-imparting layer, and a protective layer in this order. A laminate having a filling layer, a reflective layer, and a shape-imparting layer in this order. A laminate having a filling layer, a reflective layer, a shape-imparting layer, and a protective layer in this order. A laminate having a backer layer, a brightness adjusting layer, and a shape-imparting layer in this order. A laminate including a backer layer, a brightness adjusting layer, a shape-imparting layer, and a protective layer in this order. A laminate including a backer layer, a bonding layer, a brightness adjusting layer, and a shape-imparting layer in this order. A laminate including a backer layer, a bonding layer, a brightness adjusting layer, a shape-imparting layer, and a protective layer in this order. The decorative laminate exemplified above may further include a bonding layer constituting the back side of the decorative laminate. The decorative laminate exemplified above may further include a refractive index modulation layer instead of the reflective layer. The decorative laminate exemplified above may further include a peeling layer instead of the protective layer. The decorative laminate exemplified above may further include a peeling layer constituting the front side of the decorative laminate on the protective layer. Further, the following decorative laminates are also included. A laminate having a concealing layer, a brightness adjusting layer, a shape-imparting layer, and a bonding layer in this order. A laminate having a concealing layer, a brightness adjusting layer, a shape-imparting layer, a protective layer, and a bonding layer in this order.

[0137] Several specific examples of the decorative laminate will be described below with reference to the drawings. The decorative laminate 10 shown in Fig. 11A includes a bonding layer 35, a coloring layer 30a, a shaping layer 20, and a protective layer 50, in this order, from the back surface 12 toward the front surface 11 of the decorative laminate 10. In this example, the protective layer 50 constitutes the front surface 11 of the decorative laminate 10, and the bonding layer 35 constitutes the back surface 12 of the decorative laminate 10. In the example shown in Fig. 11A, the coloring layer 30a is observed through the protective layer 50 and the shaping layer 20. Therefore, the protective layer 50 and the shaping layer 20 are transparent.

[0138] 11B includes a bonding layer 35, a reflective layer 30b, a mold layer 20, and a protective layer 50, in this order, in a direction from the back surface 12 toward the front surface 11 of the decorative laminate 10. In this example, the protective layer 50 constitutes the front surface 11 of the decorative laminate 10, and the bonding layer 35 constitutes the back surface 12 of the decorative laminate 10. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0139] The decorative laminate 10 shown in FIG. 12 includes a bonding layer 35, a colored layer 30a, a reflective layer 30b, a shape-imparting layer 20, and a protective layer 50, in this order, from the back surface 12 toward the front surface 11 of the decorative laminate 10. The colored layer 30a covers the reflective layer 30b. In the example shown in FIG. 12, the colored layer 30a is observed through the protective layer 50, the shape-imparting layer 20, and the reflective layer 30b. Therefore, the protective layer 50, the shape-imparting layer 20, and the reflective layer 30b are transparent. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0140] 13 includes a bonding layer 35, a filling layer 40, a reflective layer 30b, a shape-imparting layer 20, and a protective layer 50, in this order, in a direction from the back surface 12 toward the front surface 11 of the decorative laminate 10. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0141] The decorative laminate 10 shown in Fig. 14A includes a backer layer 55, a bonding layer 56, a coloring layer 30a, a molding layer 20, and a protective layer 50, in this order, from the back side surface 12 toward the front side surface 11 of the decorative laminate 10. In the example shown in Fig. 14A, the coloring layer 30a is observed through the protective layer 50 and the molding layer 20. Therefore, the protective layer 50 and the molding layer 20 are transparent.

[0142] 14B includes a backer layer 55, a bonding layer 56, a reflective layer 30b, a shape-imparting layer 20, and a protective layer 50, in this order, in a direction from the back surface 12 to the front surface 11 of the decorative laminate 10. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0143] [Decorative laminate with protective film and method for producing same] The decorative laminate with a protective film according to the present disclosure comprises: A protective film; The decorative laminate of the present disclosure described above, Equipped with.

[0144] In one embodiment, the decorative laminate with protective film includes a protective film on the second surface of the mold layer in the decorative laminate, or on the surface of the protective layer opposite to the surface facing the mold layer. That is, the decorative laminate with protective film may include a brightness adjustment layer, a mold layer, and a protective film in this order, or may include a brightness adjustment layer, a mold layer, a protective layer, and a protective film in this order. The protective film protects a layer covered by the protective film, such as a protective layer. By providing a protective film, the heat resistance of the decorative laminate can be improved, and the occurrence of wrinkles in the decorative laminate during a mold treatment such as embossing tends to be suppressed. The protective film may be peeled off from the decorative laminate. For example, when the decorative laminate is a film for insert molding, the protective film is peeled off at a stage before preforming. When the decorative laminate is a film for insert molding, the protective film may be peeled off at a stage after preforming.

[0145] The thickness of the protective film is preferably 10 μm or more, more preferably 15 μm or more, even more preferably 20 μm or more, and preferably 1,000 μm or less, more preferably 500 μm or less, even more preferably 300 μm or less, particularly preferably 100 μm or less, for example, 10 μm or more and 1,000 μm or less.

[0146] Examples of the protective film include polyester films such as polyethylene terephthalate films, polyolefin films such as polyethylene films and polypropylene films, (meth)acrylic resin films such as polymethyl methacrylate films, and resin films such as polycarbonate films. Among these, polyethylene terephthalate films and polypropylene films are preferred from the viewpoints of excellent heat resistance and suppression of the occurrence of wrinkles.

[0147] An example of a method for producing a decorative laminate with a protective film will be described below. Fig. 15A to Fig. 18 are cross-sectional views showing a method for producing a decorative laminate with a protective film 74 including a protective film 73 and a decorative laminate 10 provided on the protective film 73.

[0148] As shown in FIG. 15A, a laminate is prepared by laminating a film corresponding to protective layer 50 onto flat protective film 73.

[0149] Next, as shown in FIG. 15B, a precursor layer 29 of the mold layer 20 is formed on the protective layer. Next, as shown in FIG. 15C, a mold 100 is pressed against the precursor layer 29 to mold the precursor layer 29. The mold 100 has unevenness corresponding to the uneven structure 25. Next, the mold 100 is removed from the precursor layer 29, and then a hardening process is performed on the precursor layer 29. As a result, a mold layer 20 having the uneven structure 25 formed on the first surface (molding surface) 20a is formed. Alternatively, the precursor layer 29 may be hardened while the mold 100 is pressed against the precursor layer 29, and after the mold layer 20 is formed, the mold 100 may be removed from the mold layer 20. In this way, a mold layer 20 having the uneven structure 25 is formed on the protective layer.

[0150] Next, as shown in Fig. 16A, a colored layer 30a serving as the luminance adjustment layer 30 is formed on the first surface (shape-imparting surface) 20a of the shape-imparting layer 20. Next, as shown in Fig. 16B, a bonding layer 35 is formed on the colored layer 30a. This produces a decorative laminate 74 with a protective film, which includes the bonding layer 35, the colored layer 30a serving as the luminance adjustment layer 30, the shape-imparting layer 20, and the protective film 73 in this order.

[0151] Alternatively, as shown in FIG. 17, a reflective layer 30b as the brightness adjustment layer 30 is formed on the first surface (shape-imparting surface) 20a of the shape-imparting layer 20 by a film-forming technique such as sputtering and vacuum deposition. Next, as shown in FIG. 18, a bonding layer 35 is formed on the reflective layer 30b. The surface of the reflective layer 30b that contacts the bonding layer 35 has unevenness according to the uneven structure 25 of the shape-imparting layer 20. In this manner, a decorative laminate 74 with a protective film is produced, which includes the bonding layer 35, the reflective layer 30b as the brightness adjustment layer 30, the shape-imparting layer 20, the peeling layer 37, and the protective film 73 in this order. A refractive index modulation layer 30c may be provided instead of the reflective layer 30b.

[0152] [Transfer sheet and its manufacturing method] The transfer sheet of the present disclosure is A release substrate; The decorative laminate of the present disclosure described above, Equipped with.

[0153] In one embodiment, the transfer sheet includes a release substrate on the second surface of the shape-imparting layer in the decorative laminate, or on the surface of the protective layer opposite to the surface facing the shape-imparting layer. That is, the transfer sheet may include a brightness adjustment layer, a shape-imparting layer, and a release substrate in this order, or may include a brightness adjustment layer, a shape-imparting layer, a protective layer, and a release substrate in this order. The release substrate protects the layer covered by the release substrate, such as a protective layer. By providing a release substrate, the heat resistance of the decorative laminate can be improved, and the occurrence of wrinkles in the decorative laminate during a shape-imparting process such as embossing tends to be suppressed. The release substrate may be peeled off from the decorative laminate. For example, when the decorative laminate is a film for insert molding, the release substrate is peeled off at a stage before preforming.

[0154] The explanation of the thickness and material of the release substrate of the transfer sheet can be applied to the explanation of the protective film of the decorative laminate with a protective film.

[0155] The release substrate may have a release layer on the surface of the resin film facing the shape-imparting layer or protective layer. That is, the release substrate may have the resin film and a release layer. The release layer has a release property that facilitates the release of the release substrate from the decorative laminate. Examples of materials for forming the release layer include thermoplastic resins such as (meth)acrylic resins, vinyl chloride-vinyl acetate copolymers, polyurethanes, polyolefins, polyesters, epoxy resins, and silicone resins, as well as thermosetting resins, ultraviolet curing resins, and electron beam curing resins that combine these thermoplastic resins with a curing agent. Instead of forming a release layer on the resin film, a known release treatment may be applied to the surface of the resin film. In this case, the release substrate can also be easily peeled off from the decorative laminate.

[0156] The decorative laminate included in the transfer sheet may further include a release layer that constitutes a surface that contacts the release substrate. In one embodiment, the release layer constitutes the front side surface of the decorative laminate. Details of the release layer are as described above, and will not be described in this section. The release layer may also serve as the protective layer described above.

[0157] An example of a method for producing a transfer sheet will be described below. Figures 19A to 21B are cross-sectional views showing a method for producing a transfer sheet 70 including a release substrate 72 and a decorative laminate 10 provided on the release substrate 72.

[0158] As shown in FIG. 19A, a flat release substrate 72 is prepared. The release substrate 72 may include a release layer. Next, a release layer 37 is formed on the release substrate 72. When the release substrate 72 includes a release layer, the release layer 37 is formed on the release layer. Instead of the release layer 37, the above-mentioned protective layer may be provided, or the above-mentioned protective layer may be further provided on the release layer 37. Alternatively, the release layer 37 may also serve as the above-mentioned protective layer.

[0159] Next, as shown in FIG. 19B, a precursor layer 29 of the mold layer 20 is formed on the peeling layer 37 (or protective layer). Next, as shown in FIG. 19C, a mold 100 is pressed against the precursor layer 29 to mold the precursor layer 29. The mold 100 has unevenness corresponding to the uneven structure 25. Next, the mold 100 is removed from the precursor layer 29, and then a hardening process is performed on the precursor layer 29. As a result, a mold layer 20 having the uneven structure 25 formed on the first surface (molding surface) 20a is formed. Alternatively, the mold 100 may be pressed against the precursor layer 29 and then a hardening process is performed on the precursor layer 29 to form the mold layer 20, after which the mold 100 may be removed from the mold layer 20. In this way, a mold layer 20 having the uneven structure 25 is formed on the peeling layer 37 (or protective layer).

[0160] Next, as shown in Fig. 20A, a colored layer 30a serving as the brightness adjustment layer 30 is formed on the first surface (shape-imparting surface) 20a of the shape-imparting layer 20. Next, as shown in Fig. 20B, an adhesive layer 35 is formed on the colored layer 30a. This produces a transfer sheet 70 including, in this order, the adhesive layer 35, the colored layer 30a serving as the brightness adjustment layer 30, the shape-imparting layer 20, the release layer 37, and the release substrate 72.

[0161] Alternatively, as shown in FIG. 21A, a reflective layer 30b as the brightness adjustment layer 30 is formed on the first surface (shape-imparting surface) 20a of the shape-imparting layer 20 by a film-forming technique such as sputtering and vacuum deposition. Next, as shown in FIG. 21B, a bonding layer 35 is formed on the reflective layer 30b. The surface of the reflective layer 30b that contacts the bonding layer 35 has unevenness according to the uneven structure 25 of the shape-imparting layer 20. In this manner, a transfer sheet 70 is produced that includes the bonding layer 35, the reflective layer 30b as the brightness adjustment layer 30, the shape-imparting layer 20, the peeling layer 37, and the peeling substrate 72 in this order. Instead of the reflective layer 30b, a refractive index modulation layer 30c may be provided.

[0162] [Method of manufacturing decorative laminate and method of manufacturing decorative member] The decorative laminate can be manufactured, for example, as follows. A laminate of a protective film and a film corresponding to the protective layer is prepared. A shape-imparting layer is formed on the film corresponding to the protective layer. Instead of preparing a laminate of a protective film and a film corresponding to the protective layer, the above-mentioned release substrate may be prepared and a coating film as a protective layer may be formed on the release substrate. In this case, the shape-imparting layer is formed on the coating film. The method of forming the shape-imparting layer is as described above. Next, a brightness adjustment layer is formed on the first surface of the shape-imparting layer. The method of forming the brightness adjustment layer varies depending on the type of the layer, and the method of forming each layer is as described above. In addition, each of the above-mentioned layers may be provided as necessary. In this way, a decorative laminate formed on a protective film or a release substrate is obtained. When a protective film is used in the manufacture of the decorative laminate, the protective film may be removed. When a release substrate is used in the manufacture of the decorative laminate, the release substrate may be removed.

[0163] In one embodiment, the decorative member of the present disclosure can be manufactured by a method in which the decorative laminate and the molded portion are joined simultaneously with molding of the molded portion. In one embodiment, the decorative member of the present disclosure can be manufactured by joining the decorative laminate to the molded portion after molding of the molded portion.

[0164] <Decorative laminate and decorative member shown in FIG. 29A> The decorative laminate 10 and the decorative member 3 shown in FIG. 29A will be described below. A decorative laminate 74 with a protective film as shown in FIG. 16B or FIG. 18 is prepared. Next, in the decorative laminate 74 with a protective film, the protective film 73 is peeled off from the decorative laminate 10. Then, the decorative laminate 10 from which the protective film 73 has been peeled off is used as a film for insert molding. That is, first, the decorative laminate 10 from which the protective film 73 has been peeled off is preformed by vacuum forming or the like using a preform corresponding to the shape of the front side surface 3a of the decorative member 3. Then, the preformed decorative laminate 10 is placed in a mold for forming the molded portion 65. Next, a molten resin is introduced between the back side surface 12 (i.e., the bonding layer 35) of the decorative laminate 10 and the inner surface of the mold, and the resin is solidified in the mold. As a result, the molded portion 65 bonded to the decorative laminate 10 is molded in the mold, and the decorative member 3 shown in FIG. 29A is completed. Such a molding method for the decorative member 3 is known as insert molding.

[0165] <Decorative laminate and decorative member shown in Figs. 29B and 29C> When the brightness adjustment layer 30 is the reflective layer 30b or the refractive index modulation layer 30c, the decorative laminate 10 may further have a colored layer 45 as shown in FIG. 29B. This allows the decorative laminate 10 to be colored to a desired color. In addition, the brightness of the reflected light in the decorative laminate 10 can be adjusted not only by the brightness adjustment layer 30 but also by the colored layer 45. In the example shown in FIG. 29B, the colored layer 45 is disposed closer to the back surface 12 of the decorative laminate 10 than the shape-imparting layer 20 and the brightness adjustment layer 30. More specifically, the bonding layer 35, the colored layer 45, the brightness adjustment layer 30, the shape-imparting layer 20, and the peeling layer 37 are laminated in this order in the direction from the back surface 12 to the front surface 11 of the decorative laminate 10. The colored layer 45 covers the brightness adjustment layer 30. In this case, the colored layer 45 may be observed through the peeling layer 37, the shape-imparting layer 20, and the brightness adjustment layer 30. In this case, the peeling layer 37, the shape-imparting layer 20, and the brightness adjustment layer 30 are transparent. As shown in Fig. 29C, the colored layer 45 may be disposed closer to the front side surface 11 of the decorative laminate 10 than the shape-imparting layer 20 and the brightness adjustment layer 30. In this case, the shape-imparting layer 20 and / or the brightness adjustment layer 30 are observed through the colored layer 45. Therefore, the colored layer 45 is transparent.

[0166] The color layer 45 includes a pigment or a dye. The color layer 45 may be formed of the same material and by the same method as the color layer 30a described above. In this case, the color layer 45 may function as a planarizing layer that fills in the unevenness of the luminance adjustment layer 30.

[0167] <Decorative laminate and decorative member shown in FIG. 29D> The decorative laminate 10 and the decorative member 3 shown in FIG. 29D will be described below. In the same manner as in the procedure shown in FIG. 19A to FIG. 20A, the peeling layer 37, the shape-imparting layer 20, and the colored layer 30a are formed on the peeling substrate 72. Instead of the peeling layer 37, the above-mentioned protective layer may be provided, or the above-mentioned protective layer may be further provided between the peeling layer 37 and the shape-imparting layer 20. Alternatively, the peeling layer 37 may also serve as the above-mentioned protective layer. Next, as shown in FIG. 22, the bonding layer 56 is formed on the colored layer 30a. Next, as shown in FIG. 23, the backer layer 55 is bonded to the bonding layer 56. Finally, the peeling substrate 72 is peeled off from the decorative laminate 10. In this manner, the decorative laminate 10 is produced, which includes the backer layer 55, the bonding layer 56, the colored layer 30a as the luminance adjusting layer 30, the shape-imparting layer 20, and the peeling layer 37 in this order.

[0168] Alternatively, the peeling layer 37, the shape-imparting layer 20, and the reflective layer 30b are formed on the peeling substrate 72 in the same manner as in the procedure shown in Figs. 19A to 19C and 21A. Instead of the peeling layer 37, the above-mentioned protective layer may be provided, and the above-mentioned protective layer may be further provided between the peeling layer 37 and the shape-imparting layer 20. Alternatively, the peeling layer 37 may also serve as the above-mentioned protective layer. Next, as shown in Fig. 24, the bonding layer 56 is formed on the reflective layer 30b. Note that the surface of the reflective layer 30b that contacts the bonding layer 56 has unevenness corresponding to the uneven structure 25 of the shape-imparting layer 20. Next, although not shown, the backer layer 55 is bonded to the bonding layer 56, and finally, the peeling substrate 72 is peeled off from the decorative laminate 10. In this manner, the decorative laminate 10 having the backer layer 55, the bonding layer 56, the reflective layer 30b as the brightness adjustment layer 30, the shape-imparting layer 20, and the peeling layer 37 in this order is produced. A refractive index modulation layer 30c may be provided in place of the reflective layer 30b.

[0169] Next, the decorative laminate 10 is preformed by vacuum forming or the like using a preform mold corresponding to the shape of the front side surface 3a of the decorative member 3. After that, the preformed decorative laminate 10 is placed in a mold for forming the molded part 65. Next, molten resin is introduced between the back side surface 12 (i.e., the backer layer 55) of the decorative laminate 10 and the inner surface of the mold, and the resin is solidified in the mold. As a result, the molded part 65 joined to the decorative laminate 10 is molded in the mold, and the decorative member 3 shown in FIG. 29D is completed. Such a molding method of the decorative member 3 can also be called insert molding. Since the decorative laminate is heated and greatly stretched (for example, about 50% or 100%) during preformation such as vacuum forming, the uneven structure in the mold-imparting layer is easily deformed. In the decorative laminate of the present disclosure, since the molding layer contains a thermoplastic resin and a cured product of a curable resin, such a molding layer can suppress deformation of the uneven structure due to heat during preforming, and can perform preforming of the decorative laminate smoothly.

[0170] <Decorative laminate and decorative member shown in FIG. 29E> The decorative laminate 10 and the decorative member 3 shown in FIG. 29E will be described below. A film is prepared as the protective layer 50 as a support layer or a base layer. Next, as shown in FIG. 25, a shape-imparting layer 20 is formed on the film (protective layer 50). The shape-imparting layer 20 is formed by the same method as that shown in FIG. 15B and FIG. 15C. Next, as shown in FIG. 26, a colored layer 30a as the brightness adjustment layer 30 is formed on the first surface 20a of the shape-imparting layer 20. Next, as shown in FIG. 27, a bonding layer 56 is formed on the colored layer 30a. Next, as shown in FIG. 28, a backer layer 55 is bonded to the bonding layer 56. In this way, a decorative laminate 10 is produced that includes the backer layer 55, the bonding layer 56, the colored layer 30a as the brightness adjustment layer 30, the shape-imparting layer 20, and the protective layer 50 in this order. Instead of the colored layer 30a, a reflective layer 30b or a refractive index modulation layer 30c may be provided.

[0171] Next, the decorative laminate 10 is preformed by vacuum forming or the like using a preform mold corresponding to the shape of the front side surface 3a of the decorative member 3. The preformed decorative laminate 10 is then placed in a mold for forming the molded portion 65. Next, molten resin is introduced between the back side surface 12 of the decorative laminate 10 (i.e., the backer layer 55) and the inner surface of the mold, and the resin is solidified in the mold. As a result, the molded portion 65 joined to the decorative laminate 10 is molded in the mold, and the decorative member 3 shown in FIG. 29E is completed.

[0172] <Decorative laminate and decorative member shown in FIG. 29F> The decorative laminate 10 and the decorative member 3 shown in FIG. 29F will be described below. When the decorative laminate 10 includes the protective layer 50 as a support layer or a base layer, the decorative laminate 10 does not need to include the bonding layer 56 and the backer layer 55. In the example shown in Fig. 29F, the brightness adjustment layer 30, the shape-imparting layer 20, and the protective layer 50 are laminated in this order in a direction from the back side surface 12 toward the front side surface 11 of the decorative laminate 10. The protective layer 50 constitutes the front side surface 11 of the decorative laminate 10, and the brightness adjustment layer 30 constitutes the back side surface 12 of the decorative laminate 10.

[0173] Next, the decorative laminate 10 is preformed by vacuum forming or the like using a preform mold corresponding to the shape of the front side surface 3a of the decorative member 3. The preformed decorative laminate 10 is then placed in a mold for forming the molded portion 65. Next, molten resin is introduced between the back side surface 12 of the decorative laminate 10 (i.e., the brightness adjustment layer 30) and the inner surface of the mold, and the resin is solidified in the mold. As a result, the molded portion 65 bonded to the decorative laminate 10 is molded in the mold, and the decorative member 3 shown in FIG. 29F is completed.

[0174] In the example shown in Fig. 29A to Fig. 29F, the decorative laminate 10 constitutes the front side surface 3a of the decorative member 3, but is not limited thereto. As shown in Fig. 29G to Fig. 29N, the decorative laminate 10 may constitute the back side surface 3b of the decorative member 3. In the example shown in Fig. 29A to Fig. 29F, the shape-imparting layer 20 and the brightness adjustment layer 30 are laminated in this order in the direction from the front side surface 3a to the back side surface 3b of the decorative member 3, but is not limited thereto. As shown in Fig. 29G to Fig. 29I, the shape-imparting layer 20 and the brightness adjustment layer 30 may be laminated in this order in the direction from the back side surface 3b to the front side surface 3a of the decorative member 3.

[0175] <Decorative laminate and decorative member shown in FIG. 29G> In the example shown in FIG. 29G, the decorative laminate 10 includes a peeling layer 37, a shaping layer 20, a brightness adjustment layer 30, and a bonding layer 35 in this order. The peeling layer 37, the shaping layer 20, the brightness adjustment layer 30, and the bonding layer 35 are laminated in this order in a direction from the back surface 3b to the front surface 3a of the decorative member 3. The bonding layer 35 constitutes the front surface 11 of the decorative laminate 10, and the peeling layer 37 constitutes the back surface 12 of the decorative laminate 10. The bonding layer 35 bonds the back surface 67 of the molding portion 65 to other layers of the decorative laminate 10. The decorative laminate 10 may include the above-mentioned protective layer instead of the peeling layer 37, or may further include the above-mentioned protective layer between the peeling layer 37 and the shaping layer 20. Alternatively, the peeling layer 37 may also serve as the above-mentioned protective layer.

[0176] The decorative member 3 shown in Fig. 29G can be produced by the same method as the decorative member 3 shown in Fig. 29A. In the example shown in Fig. 29G, the brightness adjustment layer 30 and / or the shaping layer 20 are observed through the molding portion 65 and the bonding layer 35. Therefore, the molding portion 65 and the bonding layer 35 are transparent. The brightness adjustment layer 30 may also be transparent.

[0177] <Decorative laminate and decorative member shown in FIG. 29H> In the example shown in FIG. 29H, the decorative laminate 10 includes a peeling layer 37, a shaping layer 20, a brightness adjustment layer 30, a bonding layer 56, and a backer layer 55 in this order. The peeling layer 37, the shaping layer 20, the brightness adjustment layer 30, the bonding layer 56, and the backer layer 55 are laminated in this order in a direction from the back side 3b to the front side 3a of the decorative member 3. The backer layer 55 constitutes the front side 11 of the decorative laminate 10, and the peeling layer 37 constitutes the back side 12 of the decorative laminate 10. The backer layer 55 is bonded to the back side 67 of the molding portion 65. The decorative laminate 10 may include the above-mentioned protective layer instead of the peeling layer 37, or may further include the above-mentioned protective layer between the peeling layer 37 and the shaping layer 20. Alternatively, the peeling layer 37 may also serve as the above-mentioned protective layer.

[0178] The decorative member 3 shown in Fig. 29H can be produced by the same method as the decorative member 3 shown in Fig. 29D. In the example shown in Fig. 29H, the brightness adjustment layer 30 and / or the shaping layer 20 are observed through the molding portion 65, the backing layer 55, and the bonding layer 56. Therefore, the molding portion 65, the backing layer 55, and the bonding layer 56 are transparent. The brightness adjustment layer 30 may also be transparent.

[0179] <Decorative laminate and decorative member shown in FIG. 29I> In the example shown in FIG. 29I, the decorative laminate 10 includes a protective layer 50, a molding layer 20, a brightness adjustment layer 30, a bonding layer 56, and a backer layer 55 in this order. The protective layer 50, the molding layer 20, the brightness adjustment layer 30, the bonding layer 56, and the backer layer 55 are laminated in this order in a direction from the back side surface 3b toward the front side surface 3a of the decorative member 3. The backer layer 55 constitutes the front side surface 11 of the decorative laminate 10, and the protective layer 50 constitutes the back side surface 12 of the decorative laminate 10. The backer layer 55 is bonded to the back side surface 67 of the molding portion 65.

[0180] The decorative member 3 shown in Fig. 29I can be produced by the same method as the decorative member 3 shown in Fig. 29E. In the example shown in Fig. 29I, the brightness adjustment layer 30 and / or the shaping layer 20 are observed through the molding portion 65, the backing layer 55, and the bonding layer 56. Therefore, the molding portion 65, the backing layer 55, and the bonding layer 56 are transparent. The brightness adjustment layer 30 may also be transparent.

[0181] <Decorative laminate and decorative member shown in FIG. 29J> In the example shown in Fig. 29J, the decorative laminate 10 includes a concealing layer 60, a brightness adjustment layer 30, a molding layer 20, a protective layer 50, and a bonding layer 35. The concealing layer 60, the brightness adjustment layer 30, the molding layer 20, the protective layer 50, and the bonding layer 35 are laminated in this order in a direction from the back surface 3b toward the front surface 3a of the decorative member 3. The bonding layer 35 constitutes the front surface 11 of the decorative laminate 10, and the concealing layer 60 constitutes the back surface 12 of the decorative laminate 10. The bonding layer 35 bonds the back surface 67 of the molding portion 65 to other layers of the decorative laminate 10.

[0182] The decorative member 3 shown in Fig. 29J can be produced as follows. First, the shape-imparting layer 20 and the brightness adjustment layer 30 are laminated on one surface of the protective layer 50 as a support layer or base layer. Next, the concealing layer 60 is formed on the brightness adjustment layer 30. Next, the bonding layer 35 is formed on the other surface of the protective layer 50. Next, the bonding layer 35 is bonded to the back side surface 67 of the molding portion 65. In this way, the decorative member 3 shown in Fig. 29J is produced.

[0183] In the example shown in Figure 29J, the brightness adjustment layer 30 and / or the shaping layer 20 are observed through the molding portion 65, the bonding layer 35, and the protective layer 50. Therefore, the molding portion 65, the bonding layer 35, and the protective layer 50 are transparent. The brightness adjustment layer 30 may also be transparent.

[0184] As shown in Figures 29G to 29J, when the decorative laminate 10 forms the front side surface 3a of the decorative member 3, and when the decorative laminate 10 is disposed between the rear side surface 3b of the decorative member 3 and the molded portion 65 (in other words, when the molded portion 65 is disposed between the front side surface 3a of the decorative member 3 and the decorative laminate 10), the molded portion 65 may be transparent and colored. In this case, too, the decorative laminate 10 may include a colored layer 45, as shown in Figures 29K and 29L. In the example shown in Figure 29L, the shape-imparting layer 20 and / or the brightness adjustment layer 30 are observed through the colored layer 45. For this reason, the colored layer 45 is transparent.

[0185] Alternatively, as shown in FIG. 29M and FIG. 29N, the decorative laminate 10 may include a colored layer 68. In the example shown in FIG. 29M, the colored layer 68 forms the front side surface 3a of the decorative laminate 10. In particular, in the example shown in FIG. 29M, the colored layer 68 covers the front side surface 66 of the molded portion 65. In the example shown in FIG. 29M, the molded portion 65 and the decorative laminate 10 are observed through the colored layer 68. Therefore, the colored layer 68 is transparent. In the example shown in FIG. 29N, the colored layer 68 covers the back side surface 67 of the molded portion 65. In the example shown in FIG. 29N, the decorative laminate 10 is observed through the colored layer 68. Therefore, the colored layer 68 is transparent. The colored layer 68 shown in FIG. 29M and FIG. 29N can be formed by applying a material similar to the colored layer 30a described above to the front side surface 66 or the back side surface 67 of the molded portion 65.

[0186] Although one embodiment and its modified examples have been described with reference to specific examples, the above specific examples are not intended to limit the one embodiment and the modified examples. The one embodiment and the modified examples described above can be implemented in various other specific examples, and various omissions, substitutions, changes, additions, etc. can be made within the scope of the gist of the embodiment.

[0187] [Embodiment] The present disclosure relates to, for example, the following [1] to

[15] .

[0188] [1] A shape-imparting layer including a first surface and a second surface opposite to the first surface; A brightness adjusting layer covering the first surface; A decorative laminate comprising: The first surface of the shape-imparting layer has an uneven structure, The shape-imparting layer contains a thermoplastic resin and a cured product of a curable resin. Decorative laminate.

[0189] [2] The decorative laminate according to [1], wherein the curable resin is at least one selected from a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin.

[0190] [3] The decorative laminate according to [1] or [2], wherein in the mold layer, the content ratio of the thermoplastic resin relative to the total content of the thermoplastic resin and the cured product of the curable resin is 20% by mass or more and 95% by mass or less.

[0191] [4] The decorative laminate described in any one of [1] to [3], further comprising a protective layer on the second surface of the mold-imparting layer, and the mold-imparting layer is disposed between the protective layer and the brightness adjustment layer.

[0192] [5] The decorative laminate according to any one of [1] to [4], wherein the luminance adjusting layer comprises at least one layer selected from a colored layer, a reflective layer, and a refractive index modulation layer.

[0193] [6] The decorative laminate according to any one of [1] to [5], further comprising a backer layer on a surface of the luminance adjusting layer opposite to a surface facing the shape-imparting layer.

[0194] [7] The decorative laminate according to any one of [1] to [6], wherein the concave-convex structure is a lens structure including concaves and convexes.

[0195] [8] The decorative laminate according to [7], wherein the lens structure is a Fresnel lens structure.

[0196] [9] The decorative laminate according to [8], wherein the height of the Fresnel lens structure is 1 μm or more and 10 μm or less.

[0197]

[10] The decorative laminate according to any one of [1] to [9], which is a decorative sheet for insert molding.

[0198]

[11] A protective film; [1] to

[10] , and A decorative laminate with a protective film.

[0199]

[12] A release substrate; [1] to

[10] , and A transfer sheet comprising:

[0200]

[13] A molding portion; A decorative laminate according to any one of [1] to

[10] , which covers at least a part of the molded portion; A decorative member comprising:

[0201]

[14] The molded portion has a curved surface, The decorative member according to

[13] , wherein the decorative laminate covers the curved surface.

[0202]

[15] A moving object comprising the decorative laminate according to any one of [1] to

[10] . EXAMPLES

[0203] The films and resins used in the following examples and comparative examples are described below. [Protective film] Polypropylene (PP) film Thickness: 30 μm, Sanei Kaken Co., Ltd., KD24P ·Polyethylene (PE) film Thickness: 30 μm, Sanei Kaken Co., Ltd., KD26F ·Polyethylene terephthalate (PET) film Thickness: 25μm, Sanei Kaken Co., Ltd., NSA22T [Protective layer: resin film or coating film] Polymethyl methacrylate (PMMA) film Thickness 75μm, Kuraray, Parapure LH09V1 Polymethyl methacrylate (PMMA) Weight average molecular weight: 100,000, Tg: 100℃ [Backer film] ABS resin film Thickness: 250μm [resin] Thermoplastic resin A Polymethyl methacrylate resin, weight average molecular weight: 50,000, Tg: 80℃ ·Ultraviolet (UV) curable resin B Acrylic acrylate polymer, acrylic equivalent: 500g / eq ·Electron beam (EB) curable resin C Multifunctional urethane acrylate oligomer, acrylic equivalent: 200g / eq ·Thermosetting resin D Acrylic polyol resin, Tg: 60℃, hydroxyl value: 80mgKOH / g [glue] Polyester adhesive A mixture of polyester polyol resin and polyisocyanate Acrylic heat sealant Acrylic resin, weight average molecular weight: 100,000, Tg: 105℃

[0204] [Example 1] A PP film as a protective film was attached to a PMMA film as a protective layer to obtain a laminated film. Thermoplastic resin A and UV-curable resin B were mixed in a mass ratio of A / B=70 / 30, and a photopolymerization initiator was added in an amount of 3 parts by mass per 100 parts by mass of thermoplastic resin A to obtain a resin material for a mold-imparting layer. The resin material for a mold-imparting layer was applied to the surface of the PMMA film in the laminated film at a rate of 8 g / m2. 2 The coating was then dried to form a precursor layer having a thickness of 6 μm.

[0205] A resin plate having a structure corresponding to a Fresnel lens structure on its surface was prepared. The resin plate was pressed against the precursor layer and embossed to form a Fresnel lens structure on the surface of the precursor layer. The resin plate was then peeled off from the precursor layer. The precursor layer was then exposed to 250 mJ / cm 2 in the air. 2 The UV-curable resin B was cured by irradiating it with ultraviolet light to form a shape-imparting layer (Fresnel lens layer). A titanium oxide dispersion liquid was applied to the formed shape-imparting layer and dried to form a reflective layer with a thickness of 100 nm.

[0206] A polyester adhesive of 6 g / m is applied to the surface of the reflective layer. 2 The adhesive was applied to a thickness of 100 mm and dried, and an ABS resin film was laminated to the reflective layer via the adhesive at a roll temperature of 70° C. The resulting film was stored in an oven at 40° C. for 72 hours to harden the adhesive, yielding a decorative laminate with a protective film. The decorative laminate with a protective film comprises a PP film (protective film), a PMMA film (protective layer), a shape-imparting layer, a reflective layer (brightness adjustment layer), a polyester adhesive layer (bonding layer), and an ABS resin film (backer layer) in this order.

[0207] The PP film was peeled off from the PMMA film to obtain a film for insert molding (decorative laminate), which was heated to 120°C and vacuum molded (premolded) to obtain a premolded product with the desired shape. Unnecessary parts of the premolded product were trimmed and placed in the mold of an injection molding machine, and polycarbonate was injected to form a molded part, obtaining a decorative member.

[0208] [Examples 2 to 12 and Comparative Examples 1 to 2] A decorative laminate with a protective film, a film for insert molding, and a decorative member were obtained in the same manner as in Example 1, except that the composition of the resin material for the mold layer (type of resin and mass ratio), the conditions of the curing process, and the protective film were changed as shown in Table 1, and the following points were noted below. In Examples 7 to 9, when obtaining the resin material for the mold layer, the resins in Table 1 were mixed, and then polyisocyanate was further mixed as a curing agent. The polyisocyanate was added so that the ratio of the content of isocyanate groups represented by NCO to the hydroxyl value contained in the resin material for the mold layer was 1.2. In Comparative Example 1, ultraviolet irradiation was not performed. In the curing process in Table 1, the ultraviolet irradiation (UV irradiation) conditions were 250 mJ / cm 2 The conditions for electron beam (EB) irradiation were 70 kV and 5 Mrad, and the conditions for heat treatment were storage in an oven at 40° C. for 72 hours.

[0209] [Example 13] PMMA was applied at 3g / m2 onto the surface of the PET film used as the release substrate. 2 The resin material for the shape-imparting layer was obtained by mixing the thermoplastic resin A and the UV-curable resin B in a mass ratio of A / B=70 / 30. The resin material for the shape-imparting layer was applied to the surface of the PMMA coating film of the laminated film at 8 g / m. 2 The subsequent embossing, UV irradiation, and formation of the reflective layer were carried out in the same manner as in Example 1.

[0210] Apply acrylic adhesive at 6g / m to the surface of the reflective layer. 2The adhesive was applied to a thickness of 100 mm and dried, and an ABS resin film was laminated to the reflective layer via the adhesive at a roll temperature of 180°C. The PET film was then peeled off from the PMMA coating film to obtain a film for insert molding (decorative laminate). The film was heated to 120°C and vacuum molded (premolded) to obtain a premolded product having a desired shape. The premolded product was trimmed of unnecessary parts and placed in the mold of an injection molding machine, and polycarbonate was injected to form a molded part, thereby obtaining a decorative member.

[0211] <Moldability> When the insert molding film was stretched by vacuum molding at 120° C., the appearance change regarding the presence or absence of cracks in the mold-imparting layer was evaluated based on the following criteria. The elongation of the film is expressed by the following formula. (L2 / L1) x 100% L1: The length of the original film L2: Length of the film when stretched A: No cracks occurred in the molding layer even when the film was stretched by more than 200%. B: No cracks occurred in the molding layer when the film was stretched by 150% or more but less than 200%, but cracks occurred in the molding layer when the film was stretched by 200% or more. C: No cracks occurred in the molding layer when the film was stretched by 100% or more but less than 150%, but cracks occurred in the molding layer when the film was stretched by 150% or more. D: No cracks occurred in the molding layer when the film was stretched by 50% or more but less than 100%, but cracks occurred in the molding layer when the film was stretched by 100% or more. E: Cracks occurred in the molding layer when the film was stretched by 50%.

[0212] <Emboss fastness> After vacuum molding at 120°C, the design based on the Fresnel lens structure was visually confirmed. In addition, images of the cross section of the insert molding film after vacuum molding were taken using a scanning electron microscope (TM3000, Hitachi High-Tech Corporation). Evaluation was based on the following criteria. A: After vacuum forming at 120°C, the design based on the Fresnel lens structure is equivalent to that before the vacuum forming, or the Fresnel lens structure has a rise surface in a cross-sectional image after vacuum forming. B: After vacuum molding at 120°C, the design based on the Fresnel lens structure is reduced compared to before the vacuum molding, or in a cross-sectional image after vacuum molding, the rise surface of the Fresnel lens structure has changed slightly compared to before molding. C: After vacuum molding at 120°C, the design based on the Fresnel lens structure has disappeared, or in the cross-sectional image after vacuum molding, the rise surface of the Fresnel lens structure has changed significantly compared to before molding. Unable to mold: Cracks occur in the molding layer, making vacuum molding impossible.

[0213] <Appearance after embossing> The appearance of the film after embossing was observed. A: No abnormalities in appearance such as heat wrinkles. B: Slight heat wrinkles etc. are observed. C: Large heat wrinkles, etc. are observed.

[0214] <Sense of depth> The prepared decorative member was observed from multiple angles under fluorescent lighting. A: Decorative materials create a sense of depth through the movement of light. B: The decorative material does not show a sense of depth due to the movement of light.

[0215] <Weather resistance> In accordance with JIS K7350-2:2008, an illuminance of 150W / m was measured using a XeWOM (SX-75 manufactured by Suga Test Instruments Co., Ltd.). 2 The decorative material was exposed to a black panel temperature of 63°C, with an integrated illuminance of 300MJ / m 2 After that, the decorative member was rated as A when there was no change in appearance, and as B when there was a change in appearance.

[0216] [Table 1] [Explanation of symbols]

[0217] 1: moving body, 3: decorative member, 5: sensor, 6: observer, 10: decorative laminate, 13: unit optical element, 131: area, 20: shaping layer, 20f: Fresnel lens layer, 20a: first surface (shaping surface), 20b: second surface, 23: unit shaping element, 23a: unit lens element, 24: gap area, 25: uneven structure, 25f: Fresnel lens structure, 26A: inclined surface (lens surface), 26B: contact connected surface (rise surface), 29: precursor layer of shaping layer, 30: brightness adjusting layer, 30a: colored layer, 30b: reflective layer, 30c: refractive index modulation layer, 35: bonding layer, 37: peeling layer, 40: filling layer, 50: protective layer, 55: backer layer, 56: bonding layer, 60: concealing layer, 65: molding portion, 70: transfer sheet, 72: peeling substrate, 73: protective film, 74: decorative laminate with protective film, 100: shaping mold

Claims

1. A shape-imparting layer including a first surface and a second surface opposite to the first surface; a brightness adjusting layer covering the first surface; A decorative laminate comprising: The first surface of the shape-imparting layer has an uneven structure, The shape-imparting layer contains a thermoplastic resin and a cured product of a curable resin. Decorative laminate.

2. The decorative laminate according to claim 1 , wherein the curable resin is at least one selected from the group consisting of a thermosetting resin, an ultraviolet curable resin, and an electron beam curable resin.

3. The decorative laminate according to claim 1 , wherein in the shape-imparting layer, the content ratio of the thermoplastic resin to the total content of the thermoplastic resin and the cured product of the curable resin is 20% by mass or more and 95% by mass or less.

4. The decorative laminate according to claim 1 , further comprising a protective layer on the second surface of the molding layer, the molding layer being disposed between the protective layer and the brightness adjusting layer.

5. The decorative laminate according to claim 1 , wherein the brightness adjusting layer comprises at least one layer selected from a colored layer, a reflective layer, and a refractive index modulation layer.

6. The decorative laminate according to claim 1 , further comprising a backer layer on a surface of the brightness adjusting layer opposite to a surface facing the shape-imparting layer.

7. The decorative laminate according to claim 1 , wherein the uneven structure is a lens structure including unevenness.

8. The decorative laminate according to claim 7 , wherein the lens structure is a Fresnel lens structure.

9. The decorative laminate according to claim 8 , wherein the height of the Fresnel lens structure is 1 μm or more and 10 μm or less.

10. The decorative laminate according to claim 1 , which is a decorative sheet for insert molding.

11. A protective film; The decorative laminate according to any one of claims 1 to 10, A decorative laminate with a protective film.

12. A release substrate; The decorative laminate according to any one of claims 1 to 10, A transfer sheet comprising:

13. A molding portion; The decorative laminate according to any one of claims 1 to 10, which covers at least a part of the molded portion; A decorative member comprising:

14. The molded portion has a curved surface, The decorative member according to claim 13 , wherein the decorative laminate covers the curved surface.

15. A moving body comprising the decorative laminate according to any one of claims 1 to 10.

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