Transfer sheet, method for producing molded article, and molded article

Abstract

To provide a transfer sheet for producing a molded article by transferring a transfer layer onto a base material, where the transfer sheet allows uneven texture on the surface to be easily perceived by touch and enables the production of a molded article exhibiting good adhesion between the base material and the transfer layer.SOLUTION: A transfer sheet 10 comprises a release film 1, and a transfer layer 2 that is disposed on one surface of the release film and has a plurality of layers. The transfer layer includes a raised layer 3 containing raised portions in a patterned shape, the raised layer being located inside the transfer layer or on the surface on the release film side.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a transfer sheet, a method for manufacturing a molded article, and a molded article. [Background technology]

[0002] The transfer method is known as a method for decorating the surfaces of products used in household electrical appliances, automobile interior parts, miscellaneous goods, residential interior materials, residential exterior materials, etc. The transfer method uses a transfer sheet having a transfer layer on a release film, adheres the transfer sheet to a substrate (the object to be decorated), and then peels off the release film to transfer the transfer layer to the substrate.

[0003] In recent years, there has been a demand for designs that are more realistic and closer to the real thing, and transfer sheets that impart a textured feel to the surface of a molded product have been proposed. For example, Patent Document 1 discloses a transfer sheet having a transfer layer on a substrate, the transfer layer having a surface protection layer and a raised layer in this order from the substrate side, and the transfer layer having a raised portion based on the raised layer in a part of the surface opposite the substrate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2023-19025 Summary of the Invention [Problem to be solved by the invention]

[0005] Molded articles manufactured using the transfer sheet described in Patent Document 1 tend to have rounded corners on the convex portions formed on the surface. As a result, the texture of the surface irregularities may be insufficient. Also, the adhesion between the substrate and the transfer layer may be poor.

[0006] The present disclosure has been made in consideration of the above-mentioned situation, and its main object is to provide a transfer sheet for producing a molded product by transferring a transfer layer to a substrate, which can produce a molded product in which the texture of the surface irregularities is easy to understand and which has good adhesion between the substrate and the transfer layer. [Means for solving the problem]

[0007] The present disclosure provides a transfer sheet having a release film and a transfer layer having a plurality of layers disposed on one side of the release film, the transfer layer having a raised layer including a patterned raised portion inside or on the surface facing the release film.

[0008] The present disclosure provides a method for manufacturing a molded product, the method comprising: a preparation step of preparing the above-mentioned transfer sheet; a lamination step of laminating the transfer sheet onto the substrate so that the surface of the transfer sheet facing the transfer layer faces the substrate to obtain a laminate; and a pressing step of pressing the transfer layer from the substrate side to form a convex portion based on the raised portion on the surface of the transfer layer opposite the substrate.

[0009] The present disclosure provides a molded article having a substrate and a transfer layer having a plurality of layers, wherein the transfer layer has a raised layer including a patterned raised portion inside or on a surface opposite to the substrate, and wherein convex portions based on the raised portion are formed on the surface of the transfer layer. [Effects of the Invention]

[0010] By using the transfer sheet of the present disclosure, it is possible to suppress the rounding of the corners of the convex portions formed on the surface of a molded product, thereby achieving the effect of producing a molded product in which the texture of the surface irregularities is easy to perceive and which has good adhesion between the substrate and the transfer layer. [Brief explanation of the drawings]

[0011] [Figure 1]1 is a schematic cross-sectional view illustrating a transfer sheet according to the present disclosure. [Figure 2] 1 is a schematic cross-sectional view illustrating a method for producing a molded article according to the present disclosure. [Figure 3] 1 is a schematic cross-sectional view illustrating a method for manufacturing a molded product using a conventional transfer sheet. [Figure 4] 1 is a schematic cross-sectional view illustrating a transfer sheet according to the present disclosure. [Figure 5] 1 is a schematic cross-sectional view illustrating a transfer sheet according to the present disclosure. [Figure 6] 1 is a schematic cross-sectional view illustrating a molded article according to the present disclosure. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Below, embodiments will be described with reference to the drawings etc. However, the present disclosure can be implemented in many different forms and should not be limited to the description of the embodiments exemplified below. Furthermore, to make the explanation clearer, the drawings may show the width, thickness, and shape of each part schematically compared to the actual form, but this is merely an example and should not be interpreted as limiting.

[0013] In this specification, when describing a mode in which another component is disposed on a certain component, the term "above" or "below" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified. Also, in this specification, when describing a mode in which another component is disposed on the surface of a certain component, the term "on the surface" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified.

[0014] The transfer sheet, the method for producing a molded article, and the molded article according to the present disclosure will be described in detail below.

[0015] A. Transfer sheet 1(a) and 1(b) are schematic cross-sectional views illustrating an example of a transfer sheet according to the present disclosure. The transfer sheet 10 shown in Fig. 1(a) and 1(b) has a release film 1 and a transfer layer 2 disposed on one side of the release film 1, and the release film 1 and the transfer layer 2 are peelable from each other. The transfer layer 2 has multiple layers.

[0016] In FIG. 1(a), the transfer layer 2 is T 1(a) , the transfer layer 2 has a raised layer 3 including a patterned raised portion 3p disposed inside the transfer layer 2. In this specification, "inside the transfer layer" means not the outermost surface of the transfer layer. In the case of FIG. 1(a), the transfer layer preferably has a high-coverage layer with a coverage of 90% or more on the surface opposite the release film. The high-coverage layer is not particularly limited, but examples include a solid layer or adhesive layer constituting a design layer. In the case of FIG. 1(a), the transfer layer preferably does not have a design layer constituting a design layer on the surface opposite the release film. In addition, in FIG. 1(b), the transfer layer 2 has a raised layer 3 including a patterned raised portion 3p disposed on the surface facing the release film 1. In both FIGS. 1(a) and 1(b), a first convex portion R21 is formed on the surface S1 of the transfer layer 2 opposite the release film 1.

[0017] FIG. 2 is a schematic cross-sectional view illustrating a method for manufacturing a molded product using the transfer sheet 10 shown in FIG. 1(a). First, as shown in FIG. 2(a), the above-described transfer sheet 10 is prepared (preparation step). In FIG. 2(a), first convex portions R21 are formed on the surface S1 of the transfer layer 2 opposite the release film 1. On the other hand, the surface S1 of the transfer layer 2 opposite the release film 1 may not have the first convex portions R21 and may be flat. Next, as shown in FIG. 2(b), the transfer sheet 10 is laminated on the substrate 20 so that the surface of the transfer sheet 10 facing the transfer layer 2 faces the substrate 20, thereby obtaining a laminate 30 (lamination step). In FIG. 2(b), an adhesive layer 15 is interposed between the substrate 20 and the transfer sheet 10. Next, the transfer layer 2 is pressed from the substrate 20 side to form second convex portions R22 based on the raised portions 3p on the surface S2 of the transfer layer 2 opposite the substrate 20 (pressing step). Next, the release film 1 is peeled off from the laminate 30 (peeling step). As a result, the transfer layer 2 of the transfer sheet 10 is transferred to the substrate 20 side, and the transfer layer 2 having the second convex portions R22 on the surface S2, the adhesive layer 15, and the substrate 20 are separated in the thickness direction D T A molded article 100 having the above-mentioned steps in this order is obtained.

[0018] FIG. 3 is a schematic cross-sectional view illustrating a method for manufacturing a molded product using a conventional transfer sheet 50. The conventional transfer sheet 50 shown in FIG. 3(a) has a raised layer 53 having a patterned raised portion 53p disposed on the layer (outermost layer) of the transfer layer 52 located farthest from the release film 51. As shown in FIG. 3(b), when the lamination step and pressing step are performed in the same manner as described above, the corners of the second convex portions R22 formed on the surface S2 of the molded product 200 are rounded due to the influence of the layer interposed between the raised layer 53 including the patterned raised portion 53p and the release film 51 (FIG. 3(c)). Furthermore, air bubbles are likely to form between the raised layer 53 and the substrate 20, which can reduce adhesion.

[0019] In contrast, according to the present disclosure, by arranging the raised layer having a patterned raised portion closer to the release film than the layer (the outermost layer located farthest from the release film) located on the surface opposite the release film among the multiple layers constituting the transfer layer, it is possible to form second convex portions with reduced rounding of corners on the surface of the molded article, and to impart a textured appearance that is easy to recognize. Furthermore, when the transfer sheet is bonded to the substrate, air bubbles are less likely to form at the interface between the transfer layer and the substrate, and a molded article with good adhesion between the substrate and the transfer layer can be obtained.

[0020] 1. Transfer layer The transfer layer in the present disclosure has multiple layers, and has a raised layer containing a patterned raised portion (i) inside or (ii) on the surface facing the release film. Specific layer configurations of the transfer sheet when the transfer layer (i) has a raised layer inside are shown in Figures 4(a) to 4(c). Also, specific layer configurations of the transfer sheet when the transfer layer (ii) has a raised layer on the surface facing the release film are shown in Figure 5.

[0021] In the transfer sheet 10 shown in FIGS. 4(a) to 4(c) and 5, the transfer layer 2 is formed by adhering the surface protection layer 4, the primer layer 5, and the design layer 6 from the release film 1 side in the thickness direction D T The design layer 6 has a pattern layer 61 and a solid layer 62 in this order from the release film 1 side in the thickness direction D. T In this order:

[0022] In the transfer layer 2 in Figure 4(a), a raised layer 3 is disposed between the surface protective layer 4 and the primer layer 5. In the transfer layer 2 in Figure 4(b), a raised layer 3 is disposed between the primer layer 5 and the design layer 6. In the transfer layer 2 in Figure 4(c), a raised layer 3 is disposed between the design layer 61 and the solid layer 62. In Figures 4(a) to 4(c), the transfer layer 2 has the solid layer 62, which constitutes the design layer 6, as a high-coverage layer on the surface S1 opposite the release film 1.

[0023] In the transfer layer 2 in FIG. 5, a raised layer 3 is disposed between a release film 1 and a surface protective layer 4.

[0024] From the viewpoint of improving the surface properties of the molded article (e.g., scratch resistance, weather resistance, and contamination resistance), it is preferable that the transfer layer 2 has a surface protection layer 4 as the layer closest to the release film 1, as shown in Figures 4(a) to 4(c). Furthermore, from the viewpoint of imparting a noticeable uneven texture to the molded article and from the viewpoint of improving adhesion to the substrate, it is preferable that the raised layer in the transfer layer is positioned closer to the release film side. That is, among Figures 4(a) to 4(c), Figures 4(a) and 4(b) are more preferable, and Figure 4(a) is even more preferable.

[0025] (1) Raised layer (a) Shape The raised layer has a patterned raised portion. The raised layer is formed from a plurality of raised portions, thereby improving the design. The pattern is not particularly limited, and examples include wood grain, stone grain, cloth grain, sand grain, circles, squares, polygons, geometric patterns, and letters, and combinations of these are also acceptable. By having the raised portion in the patterned raised layer, it is possible to form regions with convex portions and regions without convex portions within the surface of the molded article, thereby imparting a textured feel to the surface of the molded article.

[0026] The cross-sectional shape of the raised portion is not particularly limited, and may be, for example, rectangular, trapezoidal, triangular, semicircular, or the like.

[0027] The thickness t1 of the raised layer is preferably 5.0 μm or more, more preferably 8.0 μm or more, and even more preferably 12.0 μm or more, to facilitate the formation of convex portions on the surface of the molded article and to obtain a good tactile feel. If the thickness t1 of the raised layer is too thick, the height h1 of the first convex portions formed on the surface of the transfer layer opposite the release film becomes large, making it more likely that air bubbles will be trapped between the transfer sheet and the substrate during transfer. For this reason, the thickness t1 of the raised layer is preferably 70.0 μm or less, more preferably 50.0 μm or less, and even more preferably 40.0 μm or less.

[0028] In this specification, the thickness t1 of the raised layer can be calculated as follows (1) and (2). (1) The maximum thickness of each raised portion is calculated from an image of the cross section of the transfer sheet taken using a scanning electron microscope (SEM). (2) The average of the maximum thicknesses of the 20 raised portions shall be the thickness of the raised layer.

[0029] In the transfer layer of the present disclosure, the total thickness t3 of the layers of the raised layer located on the opposite side from the release film is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 4 μm or more. By having the total thickness t3 within the above range, second convex portions R22 with further reduced rounding of the corners can be formed on the surface of the molded article, imparting a more distinctive tactile feel. Furthermore, a molded article with even better adhesion between the substrate and the transfer layer can be produced. Meanwhile, the total thickness t3 may be, for example, 50 μm or less, 30 μm or less, or 11 μm or less.

[0030] The total thickness t3 of the layer located on the opposite side of the release film of the raised layer is the thickness in the thickness direction D from the surface a of the raised portion 3p on the opposite side of the release film 1 to the surface b of the transfer layer 2 on the opposite side of the release film 1, as shown in FIG. T In this specification, the total thickness t3 of the layers of the protruding layer located on the opposite side of the release film is a value calculated according to the following (1) and (2). (1) From the image of the cross section of the transfer sheet taken using a scanning electron microscope (SEM), the thickness direction D T The maximum thickness at (2) The average of the maximum thicknesses of the 20 raised portions is defined as the total thickness t3.

[0031] 1, the transfer sheet of the present disclosure may or may not have first convex portions R21 based on raised portions 3p formed on a portion of the surface S1 of the transfer layer 2 opposite the release film 1. In the present disclosure, due to the influence of the layer located on the opposite side of the raised layer 3 from the release film 1, the height h1 of the first convex portions R21 is likely to be smaller than the thickness t1 of the raised layer.

[0032] If the height h1 of the first convex portions R21 is too thick, air bubbles are likely to be trapped between the transfer sheet and the substrate during transfer. Therefore, the height h1 of the first convex portions R21 is preferably 30.0 μm or less, more preferably 20.0 μm or less, and even more preferably 15.0 μm or less. On the other hand, the height h1 of the first convex portions R21 may be 1.0 μm or more, 3.0 μm or more, or 5.0 μm or more.

[0033] The ratio (h1 / t1) of the height h1 of the first convex portion R21 to the thickness t1 of the raised layer is preferably 1.0 or less, more preferably 0.8 or less, and even more preferably 0.6 or less. On the other hand, the ratio (h1 / t1) is, for example, 0 or more, or may be 0.1 or more, or may be 0.3 or more.

[0034] In this specification, the height h1 of the first convex portion R21 can be calculated as follows (1) and (2). (1) The maximum thickness of each primary convex portion is calculated from an image of the cross section of the transfer sheet taken using a scanning electron microscope (SEM). (2) The average value of the maximum thicknesses of the 20 primary convex portions is defined as the thickness of the raised layer.

[0035] The width W1 of the raised portion is preferably 0.05 mm or more, more preferably 0.15 mm or more, and even more preferably 0.30 mm or more. This makes the second convex portion formed after transfer easier to see and tends to have a good tactile feel. On the other hand, if the width W1 of the raised portion is too wide, the tactile feel tends to be poor. For this reason, the width W1 of the raised portion is preferably 50 mm or less, more preferably 30 mm or less, even more preferably 10 mm or less, and particularly preferably 5 mm or less.

[0036] The "width W1 of the raised portion" refers to the average value of the measured values ​​at 20 points calculated as in (1) to (2) below. (1) When the raised portion has a pattern extending in a predetermined direction, the length of the raised layer in a plan view in a direction perpendicular to the extending direction is defined as the width of the raised layer. (2) In the case where the raised portions are patterned so as not to extend in a predetermined direction, the maximum diameter of each raised portion when viewed in plan is taken as the width of each raised layer.

[0037] In the present disclosure, the thickness direction D T From this perspective, the area ratio of the raised layer 3 to the total area of ​​the transfer layer 2 is preferably 10% or more, more preferably 25% or more, and even more preferably 40% or more. When the area ratio is within the above range, it is possible to easily improve the texture of the molded article and also improve the tactile feel of the molded article. On the other hand, the area ratio is preferably 90% or less, more preferably 75% or less, and even more preferably 60% or less. When the area ratio is within the above range, it is possible to easily improve the texture of the molded article and also improve the tactile feel of the molded article.

[0038] (b) Physical properties The raised layer has a Martens hardness of 30N / mm 2It is preferable that the resistance is 40N / mm or more. 2 More preferably, it is 50N / mm 2 It is more preferable that the Martens hardness of the raised layer is 30 N / mm 2 By setting the Martens hardness to 400 N / mm or more, it becomes easier to form convex portions on the surface of the molded product. If the Martens hardness of the raised layer is too high, cracks may occur in the raised layer during transfer. For this reason, the Martens hardness of the raised layer should be set to 400 N / mm or less. 2 Preferably, it is less than 300N / mm 2 More preferably, it is 200 N / mm 2 It is even more preferable that:

[0039] The Martens hardness of the raised layer can be adjusted, for example, by adjusting the type and amount of resin material constituting the raised layer, and the type and amount of filler.

[0040] The Martens hardness of the raised layer can be measured using an ultra-microhardness tester. More specifically, a pyramidal diamond indenter is pressed into the surface of the raised layer of the transfer sheet while continuously increasing the load. Then, the surface area A (mm 2 The Martens hardness is calculated by dividing the test load F (N) by the surface area A when the indentation depth reaches 0.5 μm. An example of an ultra-microhardness tester is the microhardness tester "Picodentor HM-500" (manufactured by Fisher Instruments).

[0041] (c) Material The protruding layer preferably contains a resin component, and the proportion of the resin in the protruding layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0042] Examples of resin components of the raised layer include cured products of curable resin compositions and thermoplastic resins. Among these, cured products of curable resin compositions are preferred because they facilitate the formation of convex portions on the molded product. The proportion of the cured product of the curable resin composition relative to the total resin components constituting the raised layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0043] The cured product of the curable resin composition may be a cured product of a heat-curable resin composition or a cured product of an ionizing radiation-curable resin composition. The heat-curable resin composition and ionizing radiation-curable resin composition of the raised layer may be the same as those exemplified as the heat-curable resin composition and ionizing radiation-curable resin composition of the surface protective layer described later.

[0044] Examples of thermoplastic resins include acrylic resins, cellulose resins, urethane resins, vinyl chloride resins, polyester resins, polyolefin resins, polycarbonate, nylon, polystyrene, and ABS resins.

[0045] The raised layer may contain a filler to adjust the Martens hardness and thickness. That is, the raised portion may contain a filler. Examples of fillers include organic particles and inorganic particles. Examples of organic particles include beads made of resins such as acrylic resin, urethane resin, silicone resin, and polyamide resin such as nylon. Examples of inorganic particles include beads made of inorganic materials such as silica, alumina, zirconia, titania (titanium dioxide), kaolinite, calcium carbonate, and barium sulfate. The particles may be used alone or in combination of two or more of the above types.

[0046] The content of the filler in the raised portion may be 10 parts by mass or more, 20 parts by mass or more, or 30 parts by mass or more relative to 100 parts by mass of the resin component of the raised layer, while the content of the filler in the raised layer may be, for example, 50 parts by mass or less, 45 parts by mass or less, or 40 parts by mass or less.

[0047] The raised layer may contain additives such as pigments, colorants, ultraviolet absorbers, light stabilizers, and antioxidants.

[0048] Examples of the method for forming the raised layer include a method of applying an ink for forming the raised layer and drying it. Examples of the coating method include gravure printing (gravure coating), inkjet printing, offset printing, screen printing, flexographic printing, and electrostatic printing.

[0049] (2) Other layer configurations The transfer layer has a plurality of layers, and the layer structure is not particularly limited as long as it has the above-mentioned protruding layer at a predetermined position in the thickness direction. The transfer layer preferably has a surface protective layer. When the transfer layer has a protruding layer inside in the thickness direction, it is preferable to have a surface protective layer 4 between the protruding layer 3 and the release film 1, as shown in Figures 4(a) to (c).

[0050] Furthermore, the transfer layer 2 preferably has a primer layer 5 on the side of the surface protective layer 4 opposite the release film 1. Also, it preferably has a design layer 6 on the side of the surface protective layer 4 opposite the release film 1. In particular, when the transfer layer 2 includes a primer layer 5, it is preferable to have the design layer 6 on the side of the primer layer 5 opposite the release film 1. Furthermore, it is preferable that the design layer 6 has a design layer 61 and a solid layer 62 in this order from the release film 1 side. The raised layer 3 may be disposed between the surface protective layer 4 and the primer layer 5 (FIG. 4(a)), between the primer layer 5 and the design layer 6 (FIG. 4(b)), or between the design layer 61 and the solid layer 62.

[0051] On the other hand, when the transfer layer has a raised layer 3 on the surface facing the release film, it is preferable to have a surface protective layer 4 on the side of the raised layer 3 opposite the release film 1, as shown in Figure 5. Furthermore, it is preferable that the transfer layer 2 has a primer layer 5 on the side of the surface protective layer 4 opposite the release film 1. It is also preferable to have a design layer 6 on the side of the surface protective layer 4 opposite the release film 1. In particular, when the transfer layer 2 includes a primer layer 5, it is preferable to have a design layer 6 on the side of the primer layer 5 opposite the release film 1. Furthermore, it is preferable that the design layer 6 has a pattern layer 61 and a solid layer 62 in this order from the release film 1 side.

[0052] Examples of the layer configuration of the transfer layer in the present disclosure include the layer configurations shown below, from the release film side: The following (i-1) to (i-18) are layer configurations in which the transfer layer has a raised layer inside, and the following (ii-1) to (ii-12) are layer configurations in which the transfer layer has a raised layer on the surface facing the release film. (i-1) Surface protection layer / primer layer / pattern layer / raised layer / solid layer (i-2) Surface protection layer / primer layer / raising layer / pattern layer / solid layer (i-3) Surface protection layer / raising layer / primer layer / pattern layer / solid layer (i-4) Surface protection layer / pattern layer / raised layer / solid layer (i-5) Surface protection layer / raised layer / pattern layer / solid layer (i-6) Surface protection layer / primer layer / raising layer / solid layer (i-7) Surface protection layer / raising layer / primer layer / solid layer (i-8) Surface protection layer / raising layer / primer layer / pattern layer (i-9) Surface protection layer / raising layer / solid layer (i-10) Surface protection layer / primer layer / pattern layer / raised layer / solid layer / adhesive layer (i-11) Surface protection layer / primer layer / raising layer / pattern layer / solid layer / adhesive layer (i-12) Surface protection layer / raising layer / primer layer / pattern layer / solid layer / adhesive layer (i-13) Surface protection layer / pattern layer / raised layer / solid layer / adhesive layer (i-14) Surface protection layer / raised layer / pattern layer / solid layer / adhesive layer (i-15) Surface protection layer / primer layer / raising layer / solid layer / adhesive layer (i-16) Surface protection layer / raising layer / primer layer / solid layer / adhesive layer (i-17) Surface protection layer / raising layer / primer layer / pattern layer / adhesive layer (i-18) Surface protection layer / raising layer / solid layer / adhesive layer (ii-1) Raised layer / surface protection layer / primer layer / pattern layer / solid layer (ii-2) Raised layer / surface protection layer / pattern layer / solid layer (ii-3) Raising layer / surface protection layer / primer layer / solid layer (ii-4) Raising layer / surface protection layer / primer layer / pattern layer (ii-5) Raised layer / surface protection layer / solid layer (ii-6) Raised layer / surface protection layer / pattern layer (ii-7) Raising layer / surface protection layer / primer layer / pattern layer / solid layer / adhesive layer (ii-8) Raising layer / Surface protection layer / Pattern layer / Solid layer / Adhesive layer (ii-9) Raising layer / surface protection layer / primer layer / solid layer / adhesive layer (ii-10) Raising layer / surface protection layer / primer layer / pattern layer / adhesive layer (ii-11) Raising layer / surface protection layer / solid layer / adhesive layer (ii-12) Raising layer / surface protection layer / pattern layer / adhesive layer

[0053] The " / " indicates the relative positional relationship of each layer, and for example, "A / B / C" means that A, B, and C are arranged in this order along the thickness direction from the release film side. Furthermore, for example, when written as "A / B," A and B may be arranged so as to be in direct contact with each other, or may be arranged via another layer.

[0054] (a) Surface protective layer The transfer layer in the present disclosure may have a surface protective layer. The surface protective layer contributes to improving the surface properties (e.g., scratch resistance, weather resistance, and contamination resistance) of the molded article. The surface protective layer and the release film may be arranged so as to be in direct contact with each other, or may be arranged via another layer. As shown in FIG. 5, the transfer layer 2 may have a raised layer 3 between the surface protective layer 4 and the release film 1.

[0055] The surface protective layer preferably contains a resin. The proportion of the resin relative to the total solid content of the surface protective layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more. The surface protective layer preferably contains, as the resin, a cured product (crosslinked structure) of a curable resin composition. The proportion of the cured product of the curable resin composition relative to the total resin components constituting the surface protective layer is, for example, 70% by mass or more, or may be 90% by mass or more, or may be 95% by mass or more, or may be 100% by mass.

[0056] Examples of the cured product of the curable resin composition include a cured product of an ionizing radiation curable resin composition and a cured product of a thermosetting resin composition. Among these, a cured product of an ionizing radiation curable resin composition is preferred in order to improve scratch resistance. Examples of the ionizing radiation curable resin composition include an electron beam curable resin composition and an ultraviolet light curable resin composition. Among these, an electron beam curable resin composition is preferred because it does not require a polymerization initiator, has little odor, and is less likely to cause coloration.

[0057] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). The ionizing radiation-curable functional group is a group that crosslinks and cures upon irradiation with ionizing radiation, and examples thereof include functional groups having an ethylenic double bond, such as a (meth)acryloyl group, a vinyl group, or an allyl group. In this disclosure, the term "(meth)acryloyl group" refers to an acryloyl group or a methcroyl group. In addition, in this disclosure, the term "(meth)acrylate" refers to an acrylate or a methacrylate.

[0058] Ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Examples of ionizing radiation include electron beams (EB) and ultraviolet rays (UV). Other examples of ionizing radiation include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

[0059] The ionizing radiation curable compound can be appropriately selected from, for example, polymerizable monomers and polymerizable oligomers that are commonly used as ionizing radiation curable resins.

[0060] As the polymerizable monomer, a (meth)acrylate-based monomer having a radically polymerizable unsaturated group in the molecule is preferred, and among these, a polyfunctional (meth)acrylate monomer is preferred. Examples of the polyfunctional (meth)acrylate monomer include a (meth)acrylate monomer having two or more ionizing radiation-curable functional groups in the molecule, and the functional groups include at least a (meth)acryloyl group. To achieve a good balance between processing properties and scratch resistance, the number of functional groups in the polyfunctional (meth)acrylate monomer is preferably 2 to 8, more preferably 2 to 6, even more preferably 2 to 4, and particularly preferably 2 to 3. These polyfunctional (meth)acrylates may be used alone or in combination.

[0061] Examples of the polymerizable oligomer include (meth)acrylate oligomers having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the ionizing radiation-curable functional group. Examples of such polymerizable oligomers include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers.

[0062] Further examples of polymerizable oligomers include highly hydrophobic polybutadiene (meth)acrylate oligomers having (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers having polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers obtained by modifying aminoplast resins having many reactive groups in a small molecule, and oligomers having cationically polymerizable functional groups in the molecule, such as novolac epoxy resins, bisphenol epoxy resins, aliphatic vinyl ethers, and aromatic vinyl ethers.

[0063] Among the above, in order to obtain a good balance between processing characteristics and abrasion resistance, urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers are preferred, with urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers being more preferred, and urethane (meth)acrylate oligomers being even more preferred. The polymerizable oligomers may be used alone or in combination of two or more types.

[0064] The number of functional groups of the polymerizable oligomer is preferably 2 to 8, more preferably 2 to 6, even more preferably 2 to 4, and particularly preferably 2 to 3, in order to achieve a good balance between processing characteristics and abrasion resistance. Furthermore, the weight-average molecular weight of these polymerizable oligomers is preferably 2,000 to 7,500, more preferably 2,200 to 6,000, and even more preferably 2,300 to 5,000, in order to achieve a good balance between processing characteristics and abrasion resistance. Here, the weight-average molecular weight is the average molecular weight measured by GPC analysis and converted into standard polystyrene. Two or more types of polymerizable oligomers differing in either the number of functional groups or the weight-average molecular weight may be used.

[0065] The proportion of the polymerizable oligomer relative to the total amount of the ionizing radiation-curable compound is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and most preferably 100% by mass. By setting the proportion of the polymerizable oligomer to 50% by mass or more, an excessive increase in hardness of the surface protective layer can be suppressed, and convex portions can be easily formed on the surface of the molded article.

[0066] In the ionizing radiation-curable resin composition, a monofunctional (meth)acrylate may be used in combination for the purpose of reducing the viscosity of the ionizing radiation-curable resin composition, etc. These monofunctional (meth)acrylates may be used alone or in combination of two or more kinds.

[0067] The number average molecular weight of the ionizing radiation-curable compound is, for example, from 300 to 10,000, or may be from 1,000 to 10,000, or may be from 2,000 to 10,000. The number average molecular weight is an average molecular weight measured by GPC analysis and converted into standard polystyrene.

[0068] For example, when the ionizing radiation-curable compound is an ultraviolet-curable compound, the ionizing radiation-curable compound preferably contains at least one of a photopolymerization initiator and a photopolymerization accelerator. Examples of photopolymerization initiators include acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, α-acyloxime ester, acylphosphine oxide, and thioxanthones. Examples of photopolymerization accelerators include p-dimethylaminobenzoic acid isoamyl ester and p-dimethylaminobenzoic acid ethyl ester.

[0069] A thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that cures when heated. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In a thermosetting resin composition, a curing agent is added to the curable resin as needed.

[0070] The surface protective layer may contain a weatherproofing agent. Examples of weatherproofing agents include an ultraviolet absorber and a light stabilizer. The surface protective layer preferably contains at least one of an ultraviolet absorber and a light stabilizer. The surface protective layer may contain one or more ultraviolet absorbers. Similarly, the surface protective layer may contain one or more light stabilizers.

[0071] Examples of the ultraviolet absorber contained in the surface protective layer include organic ultraviolet absorbers such as triazine-based ultraviolet absorbers, benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, oxybenzophenone-based ultraviolet absorbers, salicylic acid ester-based ultraviolet absorbers, and cyano(meth)acrylate-based ultraviolet absorbers, and inorganic ultraviolet absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based ultraviolet absorbers are more preferred.

[0072] Examples of triazine-based ultraviolet absorbers include hydroxyphenyltriazine-based ultraviolet absorbers. Examples of hydroxyphenyltriazine-based ultraviolet absorbers include 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2,4-bis[2-hydroxy-4-butoxyphenyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine, azine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5[2-(2-ethylhexanoyloxy)ethoxy]phenol.

[0073] The content of the ultraviolet absorber in the surface protective layer is, for example, 0.5 parts by mass to 10 parts by mass, alternatively 0.8 parts by mass to 8 parts by mass, or alternatively 1 part by mass to 5 parts by mass, relative to 100 parts by mass of the ionizing radiation-curable compound. If the content of the ultraviolet absorber is too high, bleeding out of the ultraviolet absorber may occur, whereas if the content of the ultraviolet absorber is too low, sufficient ultraviolet absorption performance may not be obtained.

[0074] Examples of the light stabilizer contained in the surface protective layer include hindered amine light stabilizers, such as 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, methyl(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine.

[0075] The content of the light stabilizer in the surface protective layer is, for example, 1 part by mass to 10 parts by mass, or alternatively 1.5 parts by mass to 8 parts by mass, or alternatively 2 parts by mass to 5 parts by mass, relative to 100 parts by mass of the ionizing radiation-curable compound. If the content of the light stabilizer is too high, bleed-out of the light stabilizer may occur, whereas if the content of the light stabilizer is too low, sufficient light stability may not be obtained.

[0076] The surface protective layer may contain additives such as silicone compounds, polymerization inhibitors, crosslinking agents, antistatic agents, adhesion improvers, antioxidants, leveling agents, thixotropy-imparting agents, coupling agents, plasticizers, antifouling agents, and antifoaming agents. The surface protective layer may or may not contain a filler. Examples of fillers include organic fillers and inorganic fillers. Examples of inorganic fillers include silica. Furthermore, the absence of a filler in the surface protective layer prevents a decrease in transparency. As a result, a decrease in designability is prevented.

[0077] The thickness of the surface protective layer is preferably 1.5 μm to 20 μm, more preferably 2 μm to 10 μm, and even more preferably 3 μm to 7 μm, in order to achieve a good balance between processing characteristics and scratch resistance.

[0078] (b) Primer layer The transfer layer of the present disclosure may have a primer layer. The primer layer contributes to, for example, improving adhesion between the surface protective layer and the design layer. The primer layer and the surface protective layer may be arranged so as to be in direct contact with each other, or may be arranged via another layer. For example, as shown in FIG. 4(a), a raised layer 3 may be provided between the primer layer 5 and the surface protective layer 4.

[0079] The primer layer preferably contains a resin, and the proportion of the resin relative to the total solid content of the primer layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0080] The primer layer preferably contains a cured product of a curable resin composition (particularly a cured product of a thermosetting resin composition) as the resin. The thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that cures when heated. Examples of thermosetting resins include (meth)acrylic resins, urethane resins, urethane acrylic resins, phenolic resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. The thermosetting resin composition may also be one in which a curing agent such as an isocyanate curing agent or an epoxy curing agent is added to these resins.

[0081] The cured product of the thermosetting resin composition is preferably a cured product of a thermosetting resin composition containing a (meth)acrylic resin, a urethane resin, or a urethane acrylic resin, and more preferably a cured product of a thermosetting resin composition containing a urethane acrylic resin. Furthermore, the thermosetting resin composition preferably contains an isocyanate-based curing agent or an epoxy-based curing agent, more preferably an isocyanate-based curing agent, in order to make the structure of the cured product more rigid. Among these, HDI (hexamethylene diisocyanate)-based curing agents are preferred from the viewpoint of suppressing yellowing.

[0082] Furthermore, when the primer layer contains a urethane acrylic resin, the urethane acrylic resin is preferably a urethane acrylic copolymer, more preferably a polycarbonate urethane acrylic copolymer. The polycarbonate urethane acrylic copolymer is a resin obtained by radically polymerizing an acrylic monomer with a polycarbonate polyurethane polymer obtained by reacting a polycarbonate diol with a (di)isocyanate.

[0083] Examples of the (di)isocyanate include aromatic isocyanates such as 4,4'-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 1,5-naphthalene diisocyanate, n-isocyanatophenylsulfonyl isocyanate, o-isocyanatophenylsulfonyl isocyanate, and p-isocyanatophenylsulfonyl isocyanate; aliphatic isocyanates such as 1,6-hexamethylene diisocyanate; and alicyclic isocyanates such as isophorone diisocyanate, hydrogenated xylylene diisocyanate, and hydrogenated diphenylmethane diisocyanate.

[0084] Examples of acrylic monomers include (meth)acrylic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, and isobutyl (meth)acrylate.

[0085] The mass ratio of the acrylic component to the urethane component in the polycarbonate-based urethane acrylic copolymer is preferably in the range of 95:5 to 30:70, more preferably 93:7 to 50:50, and even more preferably 90:10 to 60:40. By setting the mass ratio of the acrylic component to the urethane component within the above range, the primer layer does not become an excessively hard coating film, and sufficient processability is obtained. Furthermore, by setting the mass ratio of the acrylic component to the urethane component within the above range, when the surface protective layer is made of a urethane acrylic resin such as a urethane (meth)acrylate oligomer, interlayer adhesion with the surface protective layer is improved.

[0086] In addition, when the primer layer and the protrusion layer are adjacent to each other, it is also preferable that the resin component of the primer layer is the same as the resin component of the protrusion layer, which makes it easier to improve the adhesion between the primer layer and the protrusion layer.

[0087] The primer layer may contain a weathering agent. Examples of the weathering agent include an ultraviolet absorber and a light stabilizer. The preferred types and modes of the weathering agent are the same as those described above in "(a) Surface protective layer," and therefore will not be described here.

[0088] The primer layer may contain additives such as a silicone compound, a polymerization inhibitor, a crosslinking agent, an antistatic agent, an adhesion improver, an antioxidant, a leveling agent, a thixotropy-imparting agent, a coupling agent, a plasticizer, an antifouling agent, an antifoaming agent, a filler, etc. The primer layer may or may not contain a filler.

[0089] The thickness of the primer layer is preferably 1 μm or more, more preferably 2 μm or more, in order to improve the interlayer adhesion of the transfer layer, while the thickness of the primer layer is preferably 10 μm or less, more preferably 8 μm or less, and even more preferably 5 μm or less.

[0090] (c) Design layer The transfer layer in the present disclosure may have a design layer. When the transfer layer has a surface protective layer, it is preferable that the design layer be provided on the side of the surface protective layer opposite the release film. When the transfer layer has a primer layer, it is preferable that the design layer be provided on the side of the primer layer opposite the release film. Providing a design layer improves the design of the molded product. The design layer and the primer layer may be arranged so as to be in direct contact with each other, or may be arranged via another layer. For example, a raised layer may be provided between the design layer and the primer layer.

[0091] The design layer may have, for example, a pattern layer. The design layer may also have, in order from the release film side, a pattern layer and a solid layer. In the present disclosure, the pattern layer refers to a layer formed partially (particularly in a pattern) within the surface of the transfer layer. The solid layer refers to a layer formed over the entire surface of the transfer layer. A raised layer may be present between the pattern layer and the solid layer.

[0092] The design of the picture layer may be formed with one pattern, or may be formed with two or more patterns. In the present disclosure, it is preferable to synchronize at least a portion of the pattern of the picture layer with the pattern of the raised layer. By synchronizing at least a portion of the pattern of the picture layer with the pattern of the raised layer, it is possible to more easily achieve a textured surface of the molded product. Furthermore, it is preferable that the picture layer having a pattern that is synchronized with the pattern of the raised layer has a higher brightness than the picture layer having a pattern that is not synchronized with the pattern of the raised layer. This configuration makes it possible to more easily achieve a textured surface of the molded product. For example, by using the same pattern for the gravure plate used to form the raised layer and the gravure plate used to form the picture layer, it is possible to more easily synchronize the pattern of the raised layer with the pattern of the picture layer.

[0093] Examples of patterns for the design layer include organic patterns, inorganic patterns, and abstract patterns. Organic patterns are patterns derived from the life activities of living organisms such as animals and plants. Inorganic patterns are patterns that do not fall under the category of organic patterns. Abstract patterns are patterns that interpret objects (such as images found in nature) in an abstract manner and do not represent a clear shape. Examples of organic patterns include wood grain patterns, leather patterns, floral patterns, and botanical patterns. Examples of inorganic patterns include stone patterns, concrete patterns, sand patterns, fabric patterns, metal patterns, tile patterns, and brickwork patterns. Examples of abstract patterns include flickering patterns (such as ink flickering patterns), smoke patterns, and marble patterns.

[0094] The design layer (picture layer or solid layer) contains, for example, a colorant and a resin component. Examples of colorants include inorganic pigments such as carbon black, titanium white, zinc white, red iron oxide, Prussian blue, and cadmium red; organic pigments such as azo pigments, lake pigments, anthraquinone pigments, quinacridone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine pigments; metal powder pigments such as aluminum powder and bronze powder; pearlescent pigments such as titanium oxide-coated mica and bismuth oxide chloride; fluorescent pigments; and luminous pigments. Dyes may also be used as colorants.

[0095] Examples of resin components include acrylic resins, styrene resins, polyester resins, urethane resins, chlorinated polyolefin resins, vinyl chloride-vinyl acetate copolymer resins, polyvinyl butyral resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine-containing resins, silicone resins, cellulose derivatives, and rubber resins. The resin of the design layer may also be a cured product of the aforementioned resins. These resins may be used alone or in combination.

[0096] When a pattern layer and a raised layer are adjacent to each other, it is also preferable that the resin component of the pattern layer be the same as the resin component of the raised layer. By making the resin component of the pattern layer and the resin component of the raised layer the same, it is possible to easily improve the adhesion between the pattern layer and the raised layer. Similarly, when a solid layer and a raised layer are adjacent to each other, it is also preferable that the resin component of the solid layer be the same as the resin component of the raised layer. By making the resin component of the solid layer and the resin component of the raised layer the same, it is possible to easily improve the adhesion between the solid layer and the raised layer.

[0097] The design layer may contain additives such as fillers (e.g., silica), extender pigments (e.g., organic beads), neutralizers, surfactants, etc. The thickness of the design layer is not particularly limited, but is, for example, 0.1 μm or more and 20 μm or less.

[0098] Examples of the solvent (or dispersion medium) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and inorganic solvents such as water.

[0099] (d) Adhesive layer The transfer layer in the present disclosure may or may not have an adhesive layer. The adhesive layer is preferably a layer that contacts the substrate among the layers constituting the transfer layer in the transfer sheet. That is, the adhesive layer is preferably the outermost layer located farthest from the release film among the multiple layers constituting the transfer layer. In this case, the adhesive layer is arranged to improve adhesion between the transfer layer and the substrate.

[0100] The adhesive contained in the adhesive layer can be a moisture-curing adhesive, a dry-curing adhesive, a UV-curing adhesive, a heat-sensitive adhesive, a pressure-sensitive adhesive, or the like. The thickness of the adhesive layer is preferably 2 μm or more, more preferably 3 μm or more, because this improves adhesion between the substrate and the transfer layer. On the other hand, the thickness of the adhesive layer is preferably 80 μm or less, more preferably 50 μm or less, and even more preferably 30 μm or less, because this makes it easier to form convex portions on the surface of the molded article.

[0101] 2.Release film The transfer sheet of the present disclosure has a release film (first release film). The release film and the surface protective layer may be disposed so as to be in direct contact with each other, or may be disposed via another layer. In the case of (ii) above, it is preferable to have a raised layer between the release film and the surface protective layer.

[0102] The release film preferably contains a resin film. Examples of resin films include plastic films made of polyolefin resins such as polyethylene and polypropylene; vinyl resins such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymer, and ethylene-vinyl alcohol copolymer; polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate; acrylic resins such as polymethyl(meth)acrylate and polyethyl(meth)acrylate; styrene resins such as polystyrene; and polyamide resins typified by nylon 6 or nylon 66. The resin film may have a smooth or matte surface. Among these, polyester films are preferred. Among polyester films, biaxially oriented polyester films are preferred because of their excellent heat resistance and dimensional stability.

[0103] The resin film preferably has an upper yield point load of 150 MPa or less, more preferably 120 MPa or less, more preferably 90 MPa or less, more preferably 60 MPa or less, and more preferably 40 MPa or less. By setting the yield point of the resin film within the above range, it becomes easier to form convex portions on the surface of the molded product.

[0104] On the other hand, the upper yield point load of the resin film is preferably 15 MPa or more, more preferably 17 MPa or more, and even more preferably 20 MPa or more, because this improves strength and also makes it possible to prevent wrinkles from occurring during processes such as transfer.

[0105] The upper yield point load is a value measured as follows. First, a test piece is prepared by punching out a resin film into a dumbbell shape. Next, in accordance with JIS K7161-1:2014, the test piece is pulled using a tension-compression testing machine at a tension speed of 50 mm / min and a chuck distance of 80 mm, and a stress-strain curve is created to calculate the upper yield point load.

[0106] The stress-strain curve is a curve obtained by applying a tensile strain at a constant rate to a test specimen held at both ends, in accordance with JIS K7161-1:2014, with the elongation of the test specimen plotted on the horizontal axis and the tensile stress on the vertical axis, and the tensile stress at each elongation being plotted. In this specification, the upper yield point refers to the point on the curve where, as the stress gradually increases and exceeds the elastic limit, the strain begins to increase while the stress decreases or does not increase at all. An example of a tension-compression tester is the Tensilon RTC-1250A manufactured by Orientec Co., Ltd.

[0107] In this specification, the atmosphere in which various parameters such as the upper yield point load of a resin film are measured and various evaluations are performed is a temperature of 23°C ± 5°C and a relative humidity of 40% to 65%, unless otherwise specified. Furthermore, before performing various measurements or evaluations, the sample for measurement or evaluation is exposed to the above atmosphere for 30 minutes or more.

[0108] The thickness of the resin film is preferably 12 μm or more, more preferably 15 μm or more, and even more preferably 20 μm or more. When the thickness of the resin film is within the above range, the handleability of the release film is improved. On the other hand, the thickness of the resin film is preferably 100 μm or less, more preferably 80 μm or less, and even more preferably 40 μm or less. When the thickness of the resin film is within the above range, convex portions are easily formed on the surface of the molded product.

[0109] The release film may have a release layer on one side of the resin film. The surface of the resin film may be subjected to physical treatments such as corona discharge treatment and oxidation treatment to enhance adhesion to the release layer, or a coating film containing a material that enhances adhesion may be formed. The surface of the resin film opposite the transfer layer may have an antistatic layer to suppress charging when the release film is peeled off. The antistatic layer may be formed from a general-purpose antistatic agent, resin, etc.

[0110] The release layer preferably contains a resin. It is also preferable that the release layer contains a release agent in addition to the resin. The resin and release agent constituting the release layer can be general-purpose materials. The thickness of the release layer is preferably 0.2 μm or more and 50 μm or less, and more preferably 0.5 μm or more and 10 μm or less.

[0111] 3. Transfer sheet The transfer sheet in the present disclosure has a release film and a transfer layer (having at least a raised layer).

[0112] The transfer sheet of the present disclosure may have a second release film on the side of the transfer layer opposite to the release film. For example, when the transfer sheet is produced by winding it into a roll, the occurrence of blocking can be suppressed. The second release film is usually peeled off from the transfer sheet before the lamination step described below. Details of the second release film are the same as those described for the first release film above, so description here is omitted.

[0113] 4. Transfer sheet manufacturing method The method for producing a transfer sheet in the present disclosure can be modified as appropriate depending on the configuration of the transfer layer. When producing the transfer sheet shown in Figure 4(a), for example, a surface protective layer 4 is formed on the surface of a release film 1. Next, a raised layer 3 is formed on the surface of the surface protective layer 4 opposite the release film 1. Next, a primer layer 5 is formed on the raised layer 3 opposite the surface protective layer 4, and then a design layer 6 is formed on the surface of the primer layer 5 opposite the raised layer 3.

[0114] The surface protective layer can be formed, for example, by applying a composition for the surface protective layer and curing it. Examples of the coating method for the composition include gravure coating, die coating, bar coating, roll coating, reverse roll coating, comma coating, and inkjet coating. Examples of the curing method include irradiation with ionizing radiation such as electron beams and ultraviolet rays.

[0115] The primer layer can be formed, for example, by applying a primer layer composition and curing it as needed. Examples of methods for applying the composition include gravure coating, die coating, bar coating, roll coating, reverse roll coating, comma coating, and inkjet coating. Examples of curing methods include heat.

[0116] Examples of methods for forming the design layer include a coating method using a design layer-forming ink containing a colorant, a binder resin, and a solvent (or dispersion medium). For example, the design layer can be obtained by applying the design layer-forming ink and drying it. Examples of the coating method include various coating methods such as gravure coating, offset printing, screen printing, flexographic printing, electrostatic printing, inkjet coating, roll coating, knife coating, air knife coating, die coating, lip coating, comma coating, kiss coating, flow coating, and dip coating.

[0117] The transfer layer may also have the above-mentioned adhesive layer. The adhesive layer may be formed, for example, by coating a composition for forming the adhesive layer.

[0118] The method for forming the raised layer is as described above.

[0119] For example, in Patent Document 1, in the production of a transfer sheet having a surface protection layer, a primer layer, a design layer, and a raised layer on a release film in this order, each layer is formed by gravure coating. When the raised layer is formed and another layer (e.g., a high-coverage layer such as a solid layer constituting a design layer) is formed on top of it by gravure coating, the unevenness of the raised layer may hinder ink application, resulting in unintended voids (areas where the ink is not transferred) in the formed layer. For this reason, in Patent Document 1, the raised layer is positioned at the position of the transfer layer farthest from the release film. On the other hand, in the present disclosure, another layer is formed on the raised layer by a coating method other than gravure coating (e.g., die coating, inkjet coating, etc.), thereby making it possible to form a layer in which unintended voids are suppressed.

[0120] 5.Applications The transfer sheet of the present disclosure is used for producing a molded article. By using the transfer sheet of the present disclosure to transfer the above-mentioned transfer layer to a substrate by a transfer method, a molded article can be obtained in which the texture of the surface irregularities is easily perceived and the adhesion between the substrate and the transfer layer is good.

[0121] B. Manufacturing methods for molded products The present disclosure provides a method for producing a molded article, comprising the steps of: preparing the transfer sheet; laminating the transfer sheet onto a substrate so that the transfer layer side of the transfer sheet faces the substrate to obtain a laminate; pressing the transfer layer from the substrate side to form convex portions based on the raised portions on the surface of the transfer layer opposite the substrate; and peeling the release film from the laminate. The "transfer layer side of the transfer sheet" refers to the side of transfer sheet 10 (S1 in FIG. 1) that faces transfer layer 2 when release film 1 is used as a reference, as shown in FIG. 1, for example.

[0122] According to the present disclosure, by using the transfer sheet described above, a molded article can be obtained in which the texture of the surface irregularities is easily perceived and the adhesion between the substrate and the transfer layer is good.

[0123] 2 and 3 are schematic cross-sectional views illustrating a method for producing a molded article according to the present disclosure. Since Fig. 2 and Fig. 3 have been described above in "A. Transfer sheet," further description here will be omitted.

[0124] 1. Preparation process The preparation step in this disclosure is a step of preparing the transfer sheet described above. The transfer sheet is the same as the above-mentioned "A. Transfer sheet," so a description thereof will be omitted here.

[0125] 2.Lamination process The lamination step in the present disclosure is a step of obtaining a laminate by laminating a transfer sheet onto a substrate so that the surface of the transfer sheet on the transfer layer side faces the substrate.

[0126] (1) Base The substrate material in the present disclosure is not particularly limited, and examples thereof include wood, fiber, ceramics, metal, and resin. In the in-mold transfer method described below, the main component of the substrate is, for example, resin.

[0127] An example of a substrate in the present disclosure is a resin member. Examples of resins used in resin members include vinyl chloride resins, (meth)acrylic resins, ester resins, styrene resins, olefin resins, acrylonitrile-butadiene-styrene copolymers (ABS resins), phenolic resins, cellulose resins, and rubber. Other examples of substrates include wood members. Examples of wood members include wood veneers, wood plywood, particle boards, and wood fiberboards. Examples of wood materials used in wood members include cedar, cypress, pine, and lauan.

[0128] Another example of the substrate is a metal member. Examples of metals used for the metal member include iron and aluminum. Another example of the substrate is a ceramic member. The material of the ceramic member may be ceramics such as glass or porcelain, a non-cement ceramic material such as gypsum, or a non-ceramic ceramic material such as ALC (aerated lightweight concrete).

[0129] The shape of the substrate is not particularly limited, and examples thereof include a plate, a sheet, and a three-dimensional shape. The substrate may have a flat surface, a curved surface, or both a flat surface and a curved surface. The substrate may have at least one of a convex portion, a concave portion, a ridge portion, a groove portion, and a through portion.

[0130] In the case of laminate transfer, it is preferable that the adherend has a higher Martens hardness than the raised portion of the transfer sheet. By making the Martens hardness of the adherend higher than that of the raised portion, it becomes easier to form convex portions on the surface of the transfer layer. When a metal is used as the adherend, it is preferable because it is easier to make the Martens hardness of the adherend higher than that of the raised portion.

[0131] (2) Lamination method Regarding the lamination method, the transfer sheet is laminated on the substrate so that the surface of the transfer sheet on the transfer layer side faces the substrate, thereby obtaining a laminate.

[0132] For example, when the transfer sheet has the above-mentioned adhesive layer, it is preferable to laminate the transfer sheet to the substrate by adhering the adhesive layer of the transfer sheet to the substrate.

[0133] For example, if the transfer sheet does not have the above-mentioned adhesive layer, the transfer sheet and the substrate may be laminated via an adhesive layer. Specifically, the transfer sheet may be laminated to the substrate via an adhesive layer so that the transfer layer side of the transfer sheet faces the substrate. In this case, the interposed adhesive layer may be any of the types exemplified for the adhesive layer in the transfer layer. Among these, a heat-sensitive adhesive is preferred to achieve a good balance between adhesion, ease of handling, and ease of forming convex portions. In order to facilitate the formation of convex portions on the surface of the molded product, the thickness of the adhesive layer is preferably smaller than the height of the first convex portions of the transfer sheet. If the thickness of the adhesive layer is greater than the height of the first convex portions of the transfer sheet, the difference between the thickness of the adhesive layer and the height of the first convex portions is preferably 30 μm or less to facilitate the formation of convex portions on the surface of the molded product.

[0134] 3. Pressing process 2(b), the pressing step in the present disclosure is a step of pressing the transfer layer 2 from the substrate 20 side to form second convex portions R22 based on the raised portions 3p on the surface of the transfer layer 2 opposite the substrate 20. The lamination step and the pressing step described above may be performed simultaneously, or may be separate steps separated in time.

[0135] When lamination transfer is used as the transfer process, the pressure during pressing can be applied by the pressure of a pair of upper and lower lamination rolls.When in-mold transfer is used as the transfer process, the pressure during pressing can be applied by the pressure when the injected resin collides with the transfer layer.As shown in Figure 2(b), a convex portion R1 based on the raised portion is usually formed on the surface of the release film 1 as well.

[0136] After the pressing step, a peeling step of peeling the release film from the laminate may be performed.

[0137] 4. Molded products The molded article produced in this disclosure is the same as that described in "C. Molded article."

[0138] C. Molded product 6(a) and 6(b) are schematic cross-sectional views illustrating a molded article according to the present disclosure. The molded article 100 according to the present disclosure is a molded article having a substrate 20 and a transfer layer 2. The transfer layer 2 has multiple layers, and a raised layer 3 having a patterned raised portion 3p is disposed (i) inside the transfer layer 2 or (ii) on the surface S2 opposite to the substrate 20. On the surface S2 of the transfer layer 2, a convex portion (second convex portion) R22 based on the raised portion 3p is formed.

[0139] The molded article 100 according to the present disclosure has second convex portions R22 with reduced rounding of corners on the surface S2 of the transfer layer 2 opposite the substrate 20, making the unevenness easier to perceive. Furthermore, the adhesion between the substrate 20 and the transfer layer 2 is good.

[0140] The height of the second convex portions R22 in the molded article produced in the present disclosure is preferably 3.0 μm or more, more preferably 8.0 μm or more, and even more preferably 12.0 μm or more, in order to facilitate a good tactile feel of the unevenness. On the other hand, if the height of the second convex portions R22 is too high, when an object comes into contact with the surface of the molded article, it is likely to get caught on the second convex portions R22, making the surface of the molded article more likely to be scratched. For this reason, the height of the second convex portions R22 is preferably 50.0 μm or less, more preferably 25.0 μm or less, and even more preferably 20.0 μm or less.

[0141] The uses of the molded article are not particularly limited, but examples include architectural components such as walls, ceilings, floors, roofs, eaves ceilings, fences, and gates; fittings or fixtures such as window frames, doors, handrails, baseboards, moldings, and other building components; general furniture such as chests of drawers, shelves, and desks; kitchen furniture such as dining tables and sinks; various types of furniture used in wet areas such as kitchens, toilets, bathrooms, and washbasins; surface decorative panels such as cabinets for home appliances and office equipment; and interior or exterior components for vehicles. Furthermore, the molded article of the present disclosure may be a component used outdoors (exterior component) or a component used indoors (interior component).

[0142] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and anything that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits similar effects is included within the technical scope of the present disclosure. [Example]

[0143] [Example 1] (Preparation of transfer sheet) A matte polyester film (Mitsubishi Chemical Corporation, product name: Diafoil E130-26, thickness: 26 μm) that had not been subjected to an easy-adhesion treatment was prepared as a release film. The following surface protective layer composition was applied to one side of the release film by gravure coating to form an uncured resin layer, and the uncured resin layer was cured by irradiating with an electron beam (applied voltage: 175 kV, 5 Mrad (50 kGy)) to form a 5 μm thick surface protective layer. Corona irradiation was then performed on the surface protective layer. Next, a protrusion layer ink containing the following thermosetting resin as a resin component was applied to the corona-irradiated surface protective layer by gravure coating and dried to form a 30 μm thick protrusion layer having multiple protrusions. Next, the following primer layer composition was applied to the protrusion layer by die coating and dried to form a 3.5 μm thick primer layer. Next, the following ink for the pattern layer was applied onto the primer layer by inkjet coating and dried to form a pattern layer. Next, the following ink for the solid layer was applied onto the pattern layer by inkjet coating and dried to form a solid layer. This was then aged at room temperature for 24 hours. This resulted in a transfer sheet having a release film, a surface protective layer, a raised layer, a primer layer, a pattern layer, and a solid layer, in this order in the thickness direction. The surface protective layer, raised layer, primer layer, pattern layer, and solid layer form the transfer layer.

[0144] <Composition for surface protective layer> Ionizing radiation curable resin composition: 100 parts by mass (a mixture of a trifunctional urethane acrylate oligomer having a weight average molecular weight of 4000 and a trifunctional urethane acrylate oligomer having a weight average molecular weight of 2500 in a 30:70 (mass ratio)) UV absorber 1:1 mass part (product name: TINUVIN 479, BASF) UV absorber 2:1 by weight (product name: Adeka Stab LA-46, ADEKA Corporation) UV absorber 3:1 mass parts (product name: TINUVIN 477, BASF) Light stabilizer: 3 parts by weight (product name: LS3410, Nippon Nyukazai Co., Ltd.) ·solvent

[0145] <Ink for raised layer> A thermosetting resin containing acrylic resin and vinyl chloride-vinyl acetate copolymer in a mass ratio of 8:2. ·solvent

[0146] <Primer layer composition> A composition obtained by mixing composition X (a composition consisting of a polycarbonate-based urethane-acrylic copolymer and an acrylic polyol with hexamethylene diisocyanate in a mass ratio of 100:5) with a dilution solvent. The mass ratio of the urethane component to the acrylic component in the polycarbonate-based urethane-acrylic copolymer is 7:3.

[0147] <Ink for design layer> Pigment 1 A thermosetting resin containing acrylic resin and vinyl chloride-vinyl acetate copolymer in a mass ratio of 8:2. ·solvent

[0148] <Ink for solid layer> Pigment 2 A thermosetting resin containing acrylic resin and vinyl chloride-vinyl acetate copolymer in a mass ratio of 8:2. ·solvent

[0149] (manufacturing of molded products) An aluminum plate with a thickness of 0.8 mm was prepared as a substrate. A heat-sensitive adhesive (main agent: Toagosei Co., Ltd.'s trade name "Aronmelt PES-320SK", curing agent: Tosoh Corporation's trade name "Coronate L", the blending ratio of main agent to curing agent was 100:11) was applied to the aluminum plate and dried to form a heat-sensitive adhesive layer with a thickness of 5 μm, thereby obtaining a substrate with an adhesive layer. The substrate with the adhesive layer was then cured at 150°C for 1 minute. The adhesive layer side of the substrate with the adhesive layer facing the transfer layer side of the transfer sheet of Example 1 was made to face each other, and the substrate with the adhesive layer and the transfer sheet were passed between the rolls of a roll laminator to obtain a laminate in which the transfer layer side of the transfer sheet was in close contact with the substrate. The roll laminator used was a NAVITAS RT-300 product name, and the roll temperature was 160°C and the pressure was 49 Pa (5 kgf / m 2 ) Then, the release film was peeled off from the laminate to obtain the molded article of Example 1. The height of the second convex portions of the molded article of Example 1 was 20 μm.

[0150] [Example 2] (Preparation of transfer sheet) A matte polyester film (Mitsubishi Chemical Corporation, product name: Diafoil E130-26, thickness: 26 μm) that had not been subjected to an easy-adhesion treatment was prepared as a release film. The surface protective layer composition was applied to one side of the release film by gravure coating to form an uncured resin layer, and the uncured resin layer was cured by irradiating with an electron beam (applied voltage: 175 kV, 5 Mrad (50 kGy)) to form a 5 μm-thick surface protective layer. Corona irradiation was then performed on the surface protective layer. Next, the primer layer composition was applied to the corona-irradiated surface protective layer by gravure coating and dried to form a 3.5 μm-thick primer layer. Next, the raised layer ink was applied to the primer layer by gravure coating and dried to form a 30 μm-thick raised layer having multiple raised portions. Next, the design layer ink was applied to the raised layer by inkjet coating and dried to form a design layer. Next, the ink for the solid layer was applied to the pattern layer by inkjet coating and dried to form a solid layer. The sheet was then cured at room temperature for 24 hours. This resulted in a transfer sheet having a release film, a surface protective layer, a primer layer, a raised layer, a pattern layer, and a solid layer, in this order in the thickness direction. The surface protective layer, primer layer, raised layer, pattern layer, and solid layer constitute the transfer layer.

[0151] (manufacturing of molded products) An aluminum plate with a thickness of 0.8 mm was prepared as a substrate. A heat-sensitive adhesive (main agent: Toagosei Co., Ltd.'s trade name "Aronmelt PES-320SK", curing agent: Tosoh Corporation's trade name "Coronate L", the blending ratio of main agent to curing agent was 100:11) was applied to the aluminum plate and dried to form a heat-sensitive adhesive layer with a thickness of 5 μm, thereby obtaining a substrate with an adhesive layer. The substrate with the adhesive layer was then cured at 150°C for 1 minute. The adhesive layer side of the substrate with the adhesive layer facing the transfer layer side of the transfer sheet of Example 2 was made to face each other, and the substrate with the adhesive layer and the transfer sheet were passed between the rolls of a roll laminator to obtain a laminate in which the transfer layer side of the transfer sheet was in close contact with the substrate. The roll laminator used was a NAVITAS RT-300 product name, and the roll temperature was 160°C and the pressure was 49 Pa (5 kgf / m 2 ) Then, the release film was peeled off from the laminate to obtain a molded article of Example 2. The height of the second convex portions of the molded article of Example 2 was 15 μm.

[0152] [Example 3] (Preparation of transfer sheet) A matte polyester film (Mitsubishi Chemical Corporation, product name: Diafoil E130-26, thickness: 26 μm) that had not been subjected to an easy-adhesion treatment was prepared as a release film. The surface protective layer composition was applied to one side of the release film by gravure coating to form an uncured resin layer, and the uncured resin layer was cured by irradiating with an electron beam (applied voltage: 175 kV, 5 Mrad (50 kGy)) to form a 5 μm thick surface protective layer. Corona irradiation was then performed on the surface protective layer. Next, the primer layer composition was applied to the corona-irradiated surface protective layer by gravure coating and dried to form a 3.5 μm thick primer layer. Next, the design layer ink was applied to the primer layer by gravure coating and dried to form a design layer. Next, the raised layer ink was applied to the design layer by gravure coating and dried to form a 20 μm thick raised layer having multiple raised portions. Next, the ink for the solid layer was applied to the raised layer by inkjet coating and dried to form a solid layer. The sheet was then cured at room temperature for 24 hours. This resulted in a transfer sheet having a release film, a surface protective layer, a primer layer, a design layer, a raised layer, and a solid layer, in this order in the thickness direction. The surface protective layer, primer layer, design layer, raised layer, and solid layer constitute the transfer layer.

[0153] (manufacturing of molded products) An aluminum plate with a thickness of 0.8 mm was prepared as a substrate. A heat-sensitive adhesive (main agent: Toagosei Co., Ltd.'s trade name "Aronmelt PES-320SK", curing agent: Tosoh Corporation's trade name "Coronate L", the blending ratio of main agent to curing agent was 100:11) was applied to the aluminum plate and dried to form a heat-sensitive adhesive layer with a thickness of 5 μm, thereby obtaining a substrate with an adhesive layer. The substrate with the adhesive layer was then cured at 150°C for 1 minute. The adhesive layer side of the substrate with the adhesive layer facing the transfer layer side of the transfer sheet of Example 3 was made to face each other, and the substrate with the adhesive layer and the transfer sheet were passed between the rolls of a roll laminator to obtain a laminate in which the transfer layer side of the transfer sheet was in close contact with the substrate. The roll laminator used was a NAVITAS RT-300 product name, and the roll temperature was 160°C and the pressure was 49 Pa (5 kgf / m 2 ) Then, the release film was peeled off from the laminate to obtain a molded article of Example 3. The height of the second convex portions of the molded article of Example 3 was 12 μm.

[0154] [Comparative Example 1] (Preparation of transfer sheet) A matte polyester film (Mitsubishi Chemical Corporation, product name: Diafoil E130-26, thickness: 26 μm) that had not been subjected to an easy-adhesion treatment was prepared as a release film. The surface protective layer composition was applied to one side of the release film by gravure coating to form an uncured resin layer, and the uncured resin layer was cured by irradiating with an electron beam (applied voltage: 175 kV, 5 Mrad (50 kGy)) to form a 5 μm thick surface protective layer. Corona irradiation was then performed on the surface protective layer. Next, the primer layer composition was applied to the corona-irradiated surface protective layer by gravure coating and dried to form a 3.5 μm thick primer layer. Next, the design layer ink was applied to the primer layer by gravure coating and dried to form a design layer. Next, the solid layer ink was applied to the design layer by gravure coating and dried to form a solid layer. Next, the ink for the raised layer was applied to the solid layer by gravure coating and dried to form a raised layer with multiple raised portions and a thickness of 30 μm. The sheet was then cured at room temperature for 24 hours. This resulted in a transfer sheet having a release film, a surface protective layer, a primer layer, a design layer, a solid layer, and a raised layer, in this order in the thickness direction. The surface protective layer, primer layer, design layer, raised layer, solid layer, and raised layer constitute the transfer layer.

[0155] (manufacturing of molded products) An aluminum plate with a thickness of 0.8 mm was prepared as a substrate. A heat-sensitive adhesive (main agent: Toagosei Co., Ltd.'s trade name "Aronmelt PES-320SK", curing agent: Tosoh Corporation's trade name "Coronate L", the blending ratio of main agent to curing agent was 100:11) was applied to the aluminum plate and dried to form a heat-sensitive adhesive layer with a thickness of 5 μm, thereby obtaining a substrate with an adhesive layer. The substrate with the adhesive layer was then cured at 150°C for 1 minute. The adhesive layer side of the substrate with the adhesive layer facing the transfer layer side of the transfer sheet of Comparative Example 1 was made to face each other, and the substrate with the adhesive layer and the transfer sheet were passed between the rolls of a roll laminator to obtain a laminate in which the transfer layer side of the transfer sheet was in close contact with the substrate. The roll laminator used was a NAVITAS RT-300 product name, and the roll temperature was 160°C and the pressure was 49 Pa (5 kgf / m 2 ) Then, the release film was peeled off from the laminate to obtain a molded article of Comparative Example 1. The height of the second convex portions of the molded article of Comparative Example 1 was 10 μm.

[0156] [evaluation] The molded articles obtained in Examples 1 to 3 and Comparative Example 1 were evaluated as follows. 1.Tactile sensation The surfaces of the molded articles of the Examples and Comparative Examples were touched with the index finger to evaluate whether the unevenness could be clearly felt and whether the feel was good. Twenty healthy people aged between 20 and 50 were selected as evaluators. Evaluations by the 20 people were made according to the following criteria. A: More than 16 people answered that the feel was good. B: 13 to 15 people answered that the feel was good. C: 10 to 12 people answered that the feel was good. D: 9 or fewer people answered that the feel was good

[0157] 2. Adhesion The adhesion between the substrate and the transfer layer of the molded articles prepared in the Examples and Comparative Examples was evaluated according to the cross-cut method specified in JIS K 5600-5-6:1999. Specifically, the molded articles prepared in the Examples and Comparative Examples were stored for 24 hours at 23°C and 50% relative humidity, and then cross-cut into a grid of 10 squares (10 vertical x 10 horizontal) = 100 squares (number of cuts: 11 in each direction of the grid pattern, cut interval: 1 mm) so that the blade edge reached from the transfer layer to the substrate. Adhesive tape (manufactured by Nichiban Co., Ltd., product name "Cellotape (registered trademark)") was applied to the cross-cut surface of the cross-cut sample, and a peel test was performed according to the cross-cut method specified in JIS K 5600-5-6:1999. Based on the results of the peel test, adhesion was evaluated according to the following evaluation criteria. A: The cross-cut area where peeling is confirmed is 10 squares or less B: Cross-cut area with peeling confirmed to be 11 to 20 squares C: Cross-cut area with peeling confirmed between 21 and 30 squares D: Cross-cut areas with peeling confirmed are 31 or more squares

[0158] [Table 1]

[0159] As shown in Table 1, it was confirmed that the transfer sheets of each example produced molded products in which the surface irregularities were easily noticeable to the touch and in which the adhesion between the substrate and the transfer layer was good.

[0160] Thus, the present disclosure provides, for example, the following inventions.

[0161] [1] A transfer sheet, A release film and a transfer layer disposed on one surface of the release film and having a plurality of layers, The transfer sheet has a raised layer including a patterned raised portion inside or on the surface facing the release film.

[0162] [2] The transfer sheet according to [1], wherein the transfer layer has the raised layer inside.

[0163] [3] The transfer sheet according to [2], wherein the transfer layer has a surface protection layer between the release film and the raised layer.

[0164] [4] The transfer sheet according to [2] or [3], wherein the transfer layer has a high-coverage layer with a coverage rate of 90% or more on the surface opposite to the release film.

[0165] [5] The transfer sheet according to [4], wherein the high-coverage layer is a solid layer that constitutes a design layer.

[0166] [6] The transfer sheet according to [2], wherein the transfer layer does not have a pattern layer constituting a design layer on the surface opposite the release film.

[0167] [7] The transfer sheet according to [2], wherein the transfer layer has, from the release film side, a surface protection layer, the raised layer, and a design layer.

[0168] [8] the transfer layer has a primer layer between the surface protective layer and the design layer, The transfer sheet according to [7], wherein the raised layer is disposed between the surface protective layer and the primer layer.

[0169] [9] the transfer layer has a primer layer between the surface protective layer and the design layer, The transfer sheet according to [7], wherein the raised layer is disposed between the primer layer and the design layer.

[0170]

[10] The transfer sheet according to [2], wherein the transfer layer has, from the release film side, a pattern layer constituting a design layer, the raised layer, and a solid layer constituting a design layer.

[0171]

[11] The transfer sheet according to [1], wherein the transfer layer has the raised layer on the surface on the release film side.

[0172]

[12] The transfer sheet according to

[11] , wherein the transfer layer has, from the release film side, the raised layer, a surface protective layer, and a design layer.

[0173]

[13] The transfer sheet according to

[12] , wherein the transfer layer has a primer layer between the surface protection layer and the design layer.

[0174]

[14] The transfer sheet according to

[12] , wherein the design layer has, from the release film side, a picture layer and a solid layer.

[0175]

[15] A method for manufacturing a molded article, comprising: A preparation step of preparing a transfer sheet according to any one of [1] to

[14] ; a lamination step of laminating the transfer sheet onto the substrate so that the surface of the transfer sheet on the transfer layer side faces the substrate to obtain a laminate; and a pressing step of pressing the transfer layer from the substrate side to form convex portions based on the raised portions on the surface of the transfer layer opposite the substrate.

[0176]

[16]

[15] The method for producing a molded article according to

[15] , further comprising a peeling step of peeling the release film from the laminate after the pressing step.

[0177]

[17] A molded article, a substrate and a transfer layer having a plurality of layers; the transfer layer has a raised layer including a patterned raised portion inside or on the surface opposite to the substrate, A molded product, wherein convex portions based on the raised portions are formed on the surface of the transfer layer. [Explanation of symbols]

[0178] 1...Release film 2... Transfer layer 3... Raised layer 4 … Surface protective layer 5... Primer layer 6... Design layer 10... Transfer sheet 20 … Base 100…molded product

Claims

1. A transfer sheet, A release film and a transfer layer disposed on one surface of the release film and having a plurality of layers, The transfer sheet has a raised layer including a patterned raised portion inside or on the surface facing the release film.

2. The transfer sheet according to claim 1 , wherein the transfer layer has the raised layer in the interior thereof.

3. The transfer sheet according to claim 2 , wherein the transfer layer has a surface protection layer between the release film and the raised layer.

4. The transfer sheet according to claim 2 , wherein the transfer layer has a high-coverage layer having a coverage rate of 90% or more on the surface opposite to the release film.

5. The transfer sheet according to claim 4 , wherein the high-coverage layer is a solid layer that constitutes a design layer.

6. The transfer sheet according to claim 2 , wherein the transfer layer does not have a pattern layer constituting a design layer on the surface opposite to the release film.

7. The transfer sheet according to claim 2 , wherein the transfer layer has, from the release film side, a surface protection layer, the raised layer, and a design layer.

8. the transfer layer has a primer layer between the surface protective layer and the design layer, The transfer sheet according to claim 7 , wherein the raised layer is disposed between the surface protective layer and the primer layer.

9. the transfer layer has a primer layer between the surface protective layer and the design layer, The transfer sheet according to claim 7 , wherein the raised layer is disposed between the primer layer and the design layer.

10. The transfer sheet according to claim 2 , wherein the transfer layer has, from the release film side, a pattern layer constituting a design layer, the raised layer, and a solid layer constituting a design layer.

11. The transfer sheet according to claim 1 , wherein the transfer layer has the raised layer on a surface facing the release film.

12. The transfer sheet according to claim 11 , wherein the transfer layer has, from the release film side, the raised layer, a surface protective layer, and a design layer.

13. The transfer sheet according to claim 12 , wherein the transfer layer has a primer layer between the surface protection layer and the design layer.

14. The transfer sheet according to claim 12 , wherein the design layer has, from the release film side, a picture layer and a solid layer.

15. A method for manufacturing a molded article, comprising: a preparation step of preparing the transfer sheet according to any one of claims 1 to 14; a lamination step of laminating the transfer sheet onto the substrate so that the surface of the transfer sheet on the transfer layer side faces the substrate to obtain a laminate; and a pressing step of pressing the transfer layer from the substrate side to form convex portions based on the raised portions on the surface of the transfer layer opposite the substrate.

16. The method for producing a molded article according to claim 15, further comprising, after the pressing step, a peeling step of peeling the release film from the laminate.

17. A molded article, a substrate and a transfer layer having a plurality of layers; the transfer layer has a raised layer including a patterned raised portion inside or on the surface opposite to the substrate, A molded product, wherein convex portions based on the raised portions are formed on the surface of the transfer layer.

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