Cosmetic sheet, transfer sheet, and decorated molded article

Abstract

To provide a decorative sheet which achieves both irregular touch feeling and smooth touch feeling on a sheet surface.MEANS FOR SOLVING THE PROBLEM: A decorative sheet has a design layer, a protruded part provided in a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the protruded part, where the protruded part contains a resin component and particles having an average particle diameter of 25 μm or less, and the surface resin layer contains an organic lubricant component.SELECTED DRAWING: None

Description

Technical Field

[0001] The present disclosure relates to a decorative sheet, a transfer sheet, and a decorated molded article.

Background Art

[0002] Conventionally, a decorative sheet in which a grain pattern (wood grain pattern) similar to natural wood is printed on a base material layer is known. For example, providing convex portions partially on the decorative sheet has also been considered (see, for example, Patent Document 1). According to Patent Document 1, the convex portions can impart a natural touch like natural wood.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Conventional decorative sheets having convex portions on the surface exhibit a rough touch due to the convex portions. One problem of the present disclosure is to provide a decorative sheet that achieves both a concavo-convex touch and a smooth touch on the sheet surface. One problem of the present disclosure is to provide a transfer sheet capable of transferring a transfer layer exhibiting the above touch to an adherend. One problem of the present disclosure is to provide a decorated molded article exhibiting the above touch.

Means for Solving the Problems

[0005] The decorative sheet of the present disclosure includes a design layer, convex portions provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portions. The convex portions may contain a resin component and particles having an average particle diameter of 25 μm or less. The surface resin layer may contain an organic lubricant component. The transfer sheet of the present disclosure has a release support and a transfer layer. The transfer layer may have a design layer, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion. The convex portion may contain a resin component and particles having an average particle diameter of 25 μm or less. The surface resin layer may contain an organic lubricant component. The release support may be disposed on the surface resin layer in the transfer layer. The decorated molded article of the present disclosure has a molded article, a design layer provided on at least a partial region of the molded article, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion. The convex portion may contain a resin component and particles having an average particle diameter of 25 μm or less. The surface resin layer may contain an organic lubricant component.

Advantages of the Invention

[0006] According to the present disclosure, it is possible to provide a decorative sheet that combines a concave and convex touch feeling and a smooth touch feeling on the sheet surface. According to the present disclosure, it is possible to provide a transfer sheet capable of transferring a transfer layer exhibiting the above touch feeling to an adherend. According to the present disclosure, it is possible to provide a decorated molded article exhibiting the above touch feeling.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0008] Hereinafter, embodiments of the present disclosure will be described in detail. The present disclosure can be implemented in many different forms and should not be construed as being limited to the description of the embodiments exemplified below. For the sake of clarity in the explanation, the drawings may schematically represent the width, thickness, shape, etc. of each layer as compared with the embodiments, but this is merely an example and does not limit the interpretation of the present disclosure. In this specification and each figure, elements that are the same as those already described with respect to the previously shown figures may be given the same reference numerals, and detailed descriptions may be omitted as appropriate.

[0009] In the following description, each component that appears (for example, resin components, various resins, particles, colorants, and additives) may be used alone or in combination of two or more.

[0010] The decorative sheet of the present disclosure has a design layer, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion. In one embodiment, the decorative sheet of the present disclosure further has a base material layer. In this embodiment, the design layer and the convex portion may be provided between the base material layer and the surface resin layer.

[0011] Films and sheets are often referred to as films and sheets in order from those with relatively small thicknesses. However, in the present disclosure, unless otherwise specified, a sheet includes a film.

[0012] FIG. 1 shows a schematic cross-sectional view of an embodiment of the cosmetic sheet of the present disclosure. The cosmetic sheet 1 includes a base material layer 10 including a first surface 11 and a second surface 12 facing the first surface 11, a design layer 20 provided on the first surface 11 of the base material layer 10, a plurality of convex portions 30 provided on a partial region of the design layer 20, and a surface resin layer 40 provided on the design layer 20 so as to cover the plurality of convex portions 30, in this order in the thickness direction. That is, the base material layer 10, the design layer 20, the convex portions 30, and the surface resin layer 40 are stacked in the thickness direction that is the vertical direction in the plane of FIG. 1. The convex portions 30 contain particles having an average particle diameter of 25 μm or less as will be described later, but the display of the particles is omitted in FIG. 1. The display of the particles is also omitted in other drawings. The cosmetic sheet 1 may further have an adhesive layer (not shown) on the second surface 12 of the base material layer 10.

[0013] Examples of the base material layer include a paper base material, a resin base material, a nonwoven fabric, and a woven fabric. Examples of the paper base material include kraft paper, titanium paper, linter paper, coated paper, art paper, glassine paper, parchment paper, paraffin paper, sulfuric acid paper, tissue paper, high-quality paper, Japanese paper, and resin-impregnated paper.

[0014] Examples of the resin component constituting the resin substrate include thermoplastic resins. Examples of the thermoplastic resin include polyolefins such as polyethylene, polypropylene, and polymethylpentene; vinyl chloride-based resins such as polyvinyl chloride, polyvinylidene chloride, and vinyl chloride-vinyl acetate copolymer; styrene-based resins such as polystyrene, acrylonitrile-styrene copolymer, and acrylonitrile-butadiene-styrene copolymer; (meth)acrylic resins such as polymethyl (meth)acrylate, polybutyl (meth)acrylate, and methyl (meth)acrylate-butyl (meth)acrylate copolymer; polyesters such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and ethylene glycol-terephthalic acid-isophthalic acid copolymer; polycarbonate; polyamide; polyimide; cellulose resin; and ionomer resin. The resin substrate may be composed of a single resin layer or may be composed of two or more resin layers of the same or different types. (Meth)acrylate means acrylate or methacrylate. (Meth)acrylic means acrylic or methacrylic.

[0015] The nonwoven fabric or woven fabric is composed of, for example, inorganic fibers and / or organic fibers. Examples of the inorganic fibers include glass fibers, alumina fibers, silica fibers, and carbon fibers. Examples of the organic fibers include synthetic fibers such as polyolefin fibers, polyester fibers, and (meth)acrylic fibers, and natural fibers such as silk, cotton, and hemp.

[0016] The base material layer may have the above base materials alone or in combination of multiple types. For example, the base material layer may have a plurality of paper base materials, may have a paper base material and a nonwoven fabric or woven fabric, may have a paper base material and a resin base material, may have a resin base material and a nonwoven fabric or woven fabric, or may have a paper base material, a nonwoven fabric or woven fabric, and a resin base material.

[0017] The base material layer may contain additives. Examples of the additives include ultraviolet absorbers, light stabilizers, antioxidants, fillers, foaming agents, flame retardants, plasticizers, lubricants, and colorants. Examples of the ultraviolet absorbers include benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, triazine-based ultraviolet absorbers, and hydroxyphenyltriazine-based ultraviolet absorbers. Examples of the light stabilizers include hindered amine light stabilizers such as piperidinyl sebacate-based light stabilizers.

[0018] The base material layer may contain a colorant. For example, when the surface hue of the adherend to which the decorative sheet is attached varies, if it is desired to conceal the surface hue and improve the stability of the color tone of the design layer, the base material layer may contain an inorganic pigment such as a white pigment.

[0019] The thickness of the base material layer is preferably 20 μm or more and 1,000 μm or less, more preferably 30 μm or more and 500 μm or less, and even more preferably 50 μm or more and 200 μm or less. In the case of a paper base material, nonwoven fabric, or woven fabric, the basis weight is preferably 20 g / m 2 or more and 150 g / m 2 or less, more preferably 30 g / m 2 or more and 100 g / m 2 or less.

[0020] The one or both surfaces of the base material layer may be subjected to a surface treatment. Examples of the surface treatment include physical surface treatments such as oxidation methods and roughening methods, and chemical surface treatments. Examples of the oxidation methods include corona discharge treatment methods, chromium oxidation treatment methods, flame treatment methods, hot air treatment methods, and ozone-ultraviolet treatment methods. Examples of the roughening methods include sandblasting methods and solvent treatment methods. The base material layer may have an easy adhesion layer on one or both of its surfaces. Thereby, for example, the interlayer adhesion between the base material layer and other layers can be improved.

[0021] The decorative sheet of the present disclosure has a design layer. In one embodiment, the design layer is provided on the base material layer. In other words, in this embodiment, the decorative sheet has a design layer that is stacked with the base material layer in the thickness direction. The base material layer and the design layer may be in contact with each other, or other layers may be present between the base material layer and the design layer.

[0022] The decorative sheet of the present disclosure having a design layer, a convex portion, and a surface resin layer is excellent in touch and design. In one embodiment, the design layer is provided between the base material layer and the convex portion or the surface resin layer for the purpose of imparting decorativeness to the decorative sheet. The design layer is provided to display the design expressed by the decorative sheet. That is, the design layer displays the design.

[0023] The design layer has, for example, a pattern. Examples of the pattern include a wood grain pattern imitating annual rings or conduit grooves on the surface of a wood board, a stone grain pattern imitating the surface of rocks such as marble and granite, a fabric pattern imitating a cloth texture or a cloth-like pattern, a leather grain pattern imitating the surface of leather, a matte pattern, a tile pasting pattern, a brick stacking pattern, a geometric pattern, and an abstract pattern such as letters, figures, symbols, polka dots, and floral patterns. The pattern may be a single-color solid color (so-called solid image). The pattern may be a composite pattern including two or more of these. The design layer may have two or more layers. For example, the design layer may have a colored first layer and a second layer provided on the first layer to form a pattern. Among these, a wood grain pattern imitating annual rings or conduit grooves on the surface of a wood board is preferable.

[0024] The design layer can be formed, for example, by a printing method or a coating method. Examples of the printing method include gravure printing, offset printing, silk screen printing, printing by transfer from a transfer sheet, and inkjet printing. Examples of the coating method include gravure coating, gravure reverse coating, gravure offset coating, spinner coating, roll coating, and reverse roll coating. Each layer described below can also be formed, for example, by these methods.

[0025] In one embodiment, the design layer contains a resin component and a colorant. Examples of the resin component include vinyl chloride-vinyl acetate copolymer, vinyl chloride-vinyl acetate-(meth)acrylic copolymer, chlorinated polyethylene, chlorinated polypropylene, urethane-(meth)acrylic copolymer, (meth)acrylic resin, polystyrene, polyurethane, polyester, polyamide, butyral resin, nitrocellulose, and cellulose acetate.

[0026] Examples of the colorant include pigments and dyes. Specifically, inorganic pigments such as carbon black, iron black, titanium white, antimony white, lead yellow, titanium yellow, chrome yellow, cadmium red, ultramarine, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, azomethine azo black, and nickel azo complex; metal pigments composed of flaky foil pieces such as aluminum and brass; and pearl (pearlescent) pigments composed of flaky foil pieces such as titanium dioxide-coated mica and basic lead carbonate.

[0027] The content of the colorant in the design layer is preferably 10 parts by mass or more and 500 parts by mass or less, more preferably 30 parts by mass or more and 300 parts by mass or less, and still more preferably 50 parts by mass or more and 200 parts by mass or less with respect to 100 parts by mass of the resin component contained in the design layer.

[0028] The design layer may contain an additive. Examples of the additive include an ultraviolet absorber, a light stabilizer, an antioxidant, a filler, an antifoaming agent, a flame retardant, a plasticizer, and a lubricant.

[0029] The thickness of the design layer is preferably 0.5 μm or more and 20 μm or less, more preferably 1 μm or more and 15 μm or less, and still more preferably 2 μm or more and 10 μm or less. Thereby, for example, the design property of the decorative sheet can be improved.

[0030] The design layer may have a metal thin film. Examples of the metal constituting the metal thin film include tin, indium, chromium, aluminum, nickel, iron, cobalt, copper, silver, gold, platinum, and zinc, and alloys containing at least one selected from these metals. Examples of the alloys include brass, bronze, and stainless steel. Examples of the method for forming the metal thin film include vacuum evaporation, sputtering, and ion plating. The thickness of the metal thin film is, for example, 0.1 μm or more and 1 μm or less.

[0031] The decorative sheet of the present disclosure may have a concealment layer between the base material layer and the design layer. By providing the concealment layer, for example, it is possible to suppress the base material layer from having an adverse effect on the color tone or pattern of the decorative sheet.

[0032] The concealment layer may be a layer of an opaque color. In one embodiment, the concealment layer contains a resin component and a colorant. Since the resin component and the colorant in the concealment layer can be appropriately selected from the resin component and the colorant in the design layer respectively, the description here is omitted. The concealment layer may contain the above additives. The thickness of the concealment layer is, for example, 1 μm or more and 20 μm or less.

[0033] The decorative sheet of the present disclosure has convex portions provided on a part of the region of the design layer. In other words, the decorative sheet has convex portions overlapped with a part of the design layer in the thickness direction. A plurality of convex portions may be provided on a plurality of regions of the design layer. By the decorative sheet having convex portions, for example, unevenness is formed on the surface of the decorative sheet, and a tactile sensation with unevenness can be imparted. The convex portions are provided, for example, at locations corresponding to the pattern of the design layer.

[0034] In one embodiment, the convex portion is composed of an aggregate of a plurality of protrusions separated from each other with a gap therebetween, for example, a group of protrusions in a reticular pattern in a plan view. In one embodiment, the convex portion is composed of a convex body in which a plurality of protrusions are leveled and fused together. The average outer diameter of one protrusion is, for example, about 100 μm or more and 500 μm or less. The interval between adjacent protrusions is, for example, about 20 μm or more and 150 μm or less.

[0035] The shape of one protrusion that can constitute the convex portion in a plan view may be a regular shape such as a circular shape, a square shape, and a hexagonal shape, or an irregular shape such as a shape formed by linearly extending.

[0036] The convex portion contains particles having an average particle diameter of 25 μm or less. By the convex portion containing particles having such an average particle diameter, fine irregularities due to the particles are formed on the surface of the convex portion. Thereby, a tactile sensation with finer irregularities can be imparted to the surface of the decorative sheet corresponding to the convex portion. When particles having an average particle diameter exceeding 25 μm are used, the rough tactile sensation becomes too strong, and the smooth tactile sensation based on the surface resin layer may relatively decrease. By the convex portion containing particles having an average particle diameter of 25 μm or less and the surface resin layer containing an organic lubricant component, both a tactile sensation with irregularities and a smooth tactile sensation can be achieved.

[0037] The particles may be either resin particles or inorganic particles. The convex portion may contain resin particles, may contain inorganic particles, or may contain both resin particles and inorganic particles. Examples of the resin material constituting the resin particles include (meth)acrylic resins, vinyl chloride-based resins, styrene-based resins, polyurethanes, polyesters, polyamides, polycarbonates, melamine resins, benzoguanamine resins, and benzoguanamine-formaldehyde condensation resins. By using the resin particles, for example, fine irregularities due to the resin particles can be formed more favorably and stably on the surface of the convex portion. Among these, from the viewpoint of imparting an excellent tactile sensation by the convex portion and increasing the strength of the convex portion, (meth)acrylic resins are preferred. That is, as the resin particles, (meth)acrylic resin particles are preferred.

[0038] From the viewpoints of imparting an excellent tactile sensation by the convex portion and increasing the strength of the convex portion, crosslinked resin particles are preferred. Examples of the crosslinked resin particles include crosslinked (meth)acrylic resin particles and crosslinked polyurethane particles.

[0039] The average particle diameter of the resin particles is preferably 5 μm or more and 25 μm or less, more preferably 10 μm or more and 25 μm or less, and even more preferably 15 μm or more and 25 μm or less. When the average particle diameter is below the upper limit value, for example, the above-described effects can be improved. When the average particle diameter is above the lower limit value, for example, the tactile sensation by the convex portion can be improved.

[0040] In the present disclosure, the average particle diameter means the average value (arithmetic mean diameter) of the particle diameters measured for 100 randomly selected non-aggregated particles observed by a scanning electron microscope (SEM) in the cross-section in the thickness direction of each layer.

[0041] In one embodiment, the content of the resin particles in the convex portion is preferably 5 parts by mass or more and 50 parts by mass or less, more preferably 10 parts by mass or more and 45 parts by mass or less, and even more preferably 15 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin component contained in the convex portion. When the content is below the upper limit value, for example, a decrease in the strength of the convex portion can be suppressed. When the content is above the lower limit value, for example, the tactile sensation by the convex portion can be improved.

[0042] The inorganic particles are particles formed of an inorganic compound. Examples of the inorganic compound include silica, kaolinite, antimony oxide, calcium carbonate, barium sulfate, alumina, zirconia, titania, glass, and ceramics. Among these, silica is preferable. That is, as the inorganic particles, silica particles are preferable. By using the inorganic particles, for example, while maintaining a matte feeling, fine irregularities due to the inorganic particles can be formed better on the surface of the convex portion.

[0043] The average particle diameter of the inorganic particles is preferably 5 μm or more and 20 μm or less, more preferably 8 μm or more and 15 μm or less. When the average particle diameter is at or below the upper limit value, for example, the above-described effects can be improved. When the average particle diameter is at or above the lower limit value, for example, the tactile sensation due to the convex portion can be improved.

[0044] In one embodiment, the content of the inorganic particles in the convex portion is, for example, 0 parts by mass or more and 40 parts by mass or less, preferably 5 parts by mass or more and 40 parts by mass or less, more preferably 7 parts by mass or more and 35 parts by mass or less, still more preferably 10 parts by mass or more and 30 parts by mass or less with respect to 100 parts by mass of the resin component contained in the convex portion. When the content is at or below the upper limit value, for example, a decrease in the strength of the convex portion can be suppressed. When the content is at or above the lower limit value, for example, the tactile sensation due to the convex portion can be improved.

[0045] In one embodiment, the convex portion contains resin particles and inorganic particles, and preferably contains resin particles having an average particle diameter of 15 μm or more and 25 μm or less and inorganic particles having an average particle diameter of 8 μm or more and 15 μm or less. Thereby, for example, the tactile sensation can be further improved while maintaining a matte feeling.

[0046] The convex portion contains a resin component. The resin component functions as a binder in the convex portion, for example. Examples of the resin component include a thermoplastic resin and a cured product of a curable compound. Examples of the cured product of the curable compound include a cured product of an ionizing radiation curable compound and a cured product of a thermosetting resin. The surface resin layer may contain two or more of these resin components.

[0047] From the viewpoint of suppressing deformation of the convex portion, it preferably contains a cured product of a curable compound, and more preferably contains a cured product of a thermosetting resin.

[0048] Examples of the thermoplastic resin include polyolefin, vinyl chloride resin, styrene resin, (meth)acrylic resin, polyester, polycarbonate, polyamide, and polyimide.

[0049] Examples of the thermosetting resin include unsaturated group-containing (meth)acrylic resin, unsaturated polyester, urethane resin, epoxy resin, phenol resin, aminoalkyd resin, urea resin, melamine resin, melamine-urea co-condensation resin, guanamine resin, diallyl phthalate resin, and silicone resin.

[0050] A curing agent is used as necessary together with the thermosetting resin. In the case of unsaturated group-containing (meth)acrylic resin and unsaturated polyester, for example, peroxides such as methyl ethyl ketone peroxide or radical initiators such as azoisobutyronitrile are used. In the case of urethane resin, for example, isocyanate-based curing agents are used. In the case of epoxy resin, for example, organic amine-based curing agents are used.

[0051] Examples of the thermosetting resin include two-component curable urethane resins using polyol as the main component and isocyanate compound as the curing agent. Examples of the polyol include (meth)acrylic polyol, polyether polyol, polyester polyol, polyethylene glycol, and polypropylene glycol. The isocyanate compound is a polyvalent isocyanate having two or more isocyanate groups, and examples thereof include aromatic isocyanates such as 4,4-diphenylmethane diisocyanate; aliphatic (or alicyclic) isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, and hydrogenated diphenylmethane diisocyanate.

[0052] The convex portion contains, in one embodiment, a cured product of a thermosetting resin, and for example, contains a crosslinked cured product of a (meth)acrylic polyol with an isocyanate-based curing agent.

[0053] The radiation curable compound means a compound that crosslinks and cures by irradiation with ionizing radiation and has a radiation curable functional group. The radiation curable functional group is a group that crosslinks upon irradiation with ionizing radiation, and examples thereof include functional groups having an ethylenic double bond (ethylenically unsaturated group) such as a (meth)acryloyl group, a vinyl group, and an allyl group. Ionizing radiation means those having energy quanta capable of polymerizing or crosslinking molecules among electromagnetic waves or charged particle beams. Examples of ionizing radiation include electron beam (EB) and ultraviolet ray (UV), electromagnetic waves such as X-ray and γ-ray, and charged particle beams such as α-ray and ion beam.

[0054] Examples of the radiation curable compound include polymerizable monomers and polymerizable oligomers that have been conventionally used as radiation curable compounds. As the polymerizable monomer, a (meth)acrylate monomer having a (meth)acryloyl group in the molecule is preferable, and a polyfunctional (meth)acrylate monomer having two or more (meth)acryloyl groups in the molecule is more preferable. The number of (meth)acryloyl groups in the polyfunctional (meth)acrylate monomer is 2 or more, preferably 8 or less, and more preferably 6 or less.

[0055] Examples of the polymerizable monomers include bifunctional (meth)acrylates such as ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, bisphenol A tetraethoxydi(meth)acrylate, and bisphenol A tetrapropoxydi(meth)acrylate; trifunctional or higher functional (meth)acrylates such as trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, and dipentaerythritol hexa(meth)acrylate; and ethylene oxide-modified products, propylene oxide-modified products, caprolactone-modified products, isocyanuric acid-modified products, or propionic acid-modified products of these (meth)acrylates.

[0056] Examples of the polymerizable oligomers include (meth)acrylate oligomers having two or more (meth)acryloyl groups in the molecule. Examples of the (meth)acrylate oligomers include urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, polycarbonate (meth)acrylate, polycaprolactone urethane (meth)acrylate, and polycaprolactone diol urethane (meth)acrylate. The number of (meth)acryloyl groups in the polymerizable oligomer is 2 or more, preferably 8 or less, more preferably 6 or less.

[0057] The weight average molecular weight of the polymerizable oligomer is preferably 500 or more and 100,000 or less, more preferably 1,000 or more and 50,000 or less. The weight average molecular weight is measured by gel permeation chromatography (GPC) analysis and is the average molecular weight converted with standard polystyrene.

[0058] As the ionizing radiation curable compound, a monofunctional (meth)acrylate may be appropriately used in combination with a polyfunctional (meth)acrylate for purposes such as reducing viscosity. Examples of the monofunctional (meth)acrylate include methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, pentyl (meth)acrylate, hexyl (meth)acrylate, cyclohexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, and isobornyl (meth)acrylate.

[0059] When the ionizing radiation curable compound is an ultraviolet curable compound, it is preferable to use at least one selected from a photopolymerization initiator and a photopolymerization accelerator together with the ultraviolet curable compound.

[0060] The convex portion may contain an additive. Examples of the additive include an ultraviolet absorber, a light stabilizer, an antioxidant, an antiwear property improver, an infrared absorber, an antistatic agent, an adhesion improver, a leveling agent, a thixotropic agent, a coupling agent, an antifoaming agent, a flame retardant, a plasticizer, a lubricant, and a colorant.

[0061] The average height of the convex portion is preferably 5 μm or more and 25 μm or less, more preferably 10 μm or more and 25 μm or less, and still more preferably 15 μm or more and 25 μm or less. Thereby, for example, the touch feeling and the design property of the decorative sheet can be further improved.

[0062] The average height of the convex portion is a value calculated as the average value of each measured value by observing the cross section of the decorative sheet with a scanning electron microscope (SEM). The average height of the convex portion can be calculated, for example, by the following steps (X1) and (X2). By replacing the "height of the convex portion" in the following steps (X1) and (X2) with the "thickness of the surface resin layer", the average thickness of the surface resin layer can also be calculated. Prepare 10 cross-sectional photographs taken when the width of the cosmetic sheet (X1) is in the range of 500 μm or more and 1500 μm or less. In each cross-sectional photograph, measure the height of the convex portion every 5 μm in the width direction of the cosmetic sheet. For example, when the width of the cosmetic sheet in each cross-sectional photograph is 500 μm, measure the height of 100 convex portions in each cross-sectional photograph. (X2) Calculate the average height of the convex portion from the measured total height data.

[0063] The average height of the convex portion is preferably greater than the average thickness of the surface resin layer. Thereby, even if the surface resin layer is present on the cosmetic sheet, a high tactile sensation due to the convex portion can be obtained. The average height of the convex portion is preferably 1.5 times or more, more preferably 2 times or more, and even more preferably 4 times or more the average thickness of the surface resin layer. The average height of the convex portion is, for example, 20 times or less, preferably 10 times or less the average thickness of the surface resin layer.

[0064] The ratio (average particle diameter / average height) of the average particle diameter of the particles contained in the convex portion to the average height of the convex portion is preferably 0.3 or more and 1.5 or less, more preferably 0.4 or more and 1.3 or less, and even more preferably 0.5 or more and 1.2 or less. Thereby, for example, the uneven tactile sensation due to the convex portion and the smooth tactile sensation due to the surface resin layer can be further improved.

[0065] When the cosmetic sheet is viewed in plan view from the surface resin layer side (viewed from the normal direction of the cosmetic sheet), it is preferable that 70% or more of the area of the convex portion is covered with the surface resin layer, and more preferably 75% or more, 80% or more, 85% or more, 90% or more, or 95% or more of the area of the convex portion is covered with the surface resin layer, and even more preferably the entire surface of the convex portion is covered with the surface resin layer. Thereby, for example, the uneven tactile sensation due to the convex portion and the smooth tactile sensation due to the surface resin layer can be further improved.

[0066] In the cosmetic sheet of the present disclosure, the ratio of the area where the convex portion is provided is, for example, 5% or more and 90% or less with respect to 100% of the area of the base material layer. Thereby, for example, the above tactile sensation can be further improved.

[0067] According to the pattern of the design layer, the convex portion is preferably provided on the design layer. With such a configuration, a decorative sheet excellent in tactile sensation and design can be obtained. For example, when the decorative sheet is viewed in plan view, there are modes in which convex portions are provided in regions where the pattern of the design layer is provided, and modes in which convex portions are provided in regions where the pattern of the design layer is not provided.

[0068] For example, when the design layer has a wood grain pattern including a conduit portion, it is preferable that convex portions are provided on at least a part of the region other than the conduit portion in the design layer. The conduit portion is a pattern imitating the conduit groove of the wood grain pattern. In the above wood grain pattern, the pattern region other than the conduit portion is, for example, a wood texture portion. The wood texture portion is a pattern imitating the wood fibers of the wood grain pattern. Thereby, the surface of the region corresponding to the conduit portion in the decorative sheet becomes relatively concave compared to the surface of the region corresponding to the wood texture portion, and the visually low gloss can improve the visual unevenness. Therefore, excellent tactile sensation and design similar to natural wood can be obtained.

[0069] FIG. 2 shows a schematic cross-sectional view according to an embodiment of the decorative sheet of the present disclosure. In the decorative sheet 1 of FIG. 2, the design layer 20 has a wood grain pattern including a conduit portion 22 and a wood texture portion 24. The convex portion 30 is provided on at least a part of the region other than the conduit portion 22 in the design layer 20, that is, on the wood texture portion 24.

[0070] For example, when the design layer has a wood grain pattern including an early wood portion and a late wood portion, it is preferable that convex portions are provided on at least a part of the region of the late wood portion in the design layer. Thereby, excellent tactile sensation and design similar to natural wood can be obtained.

[0071] The cosmetic sheet of the present disclosure has a surface resin layer. The surface resin layer is provided on the design layer so as to cover the convex portions. In other words, the surface resin layer is overlapped with the design layer in the thickness direction. The convex portions are located between the surface resin layer and the design layer in the thickness direction. The surface resin layer spreads along the surfaces of the design layer and the convex portions. The surface resin layer forms a bulge corresponding to the arrangement of the convex portions. In one embodiment, the surface resin layer is provided on the entire surface of the design layer. The surface resin layer is overlapped with the design layer in the thickness direction. By providing the surface resin layer, for example, the heat resistance, scratch resistance, and stain resistance of the cosmetic sheet can be improved. The surface resin layer constitutes the outermost layer on one side of the cosmetic sheet.

[0072] The surface resin layer contains an organic lubricant component. Thereby, for example, a smooth touch can be imparted to the cosmetic sheet. A cosmetic sheet having such a surface resin layer and the above convex portions exhibits, for example, a smooth touch and a touch with irregularities, and in one embodiment, exhibits a touch like that of wood subjected to a soap finish treatment.

[0073] The soap finish treatment is a treatment in which soap foam is applied to the wood surface to form a coating film. This treatment is performed, for example, to improve the smooth touch while maintaining the texture of the wood. In the soap finish treatment, the heat resistance, scratch resistance, and stain resistance of the formed coating film tend to be low. On the other hand, the surface resin layer in the cosmetic sheet of the present disclosure is excellent in these physical properties. For example, by attaching the cosmetic sheet of the present disclosure to the surface of a recycled material of wood, the touch of wood can be reproduced, and thus the amount of natural wood used can be reduced.

[0074] Examples of the organic lubricant component include silicone polymers, fluororesins, organic particle-based lubricants, hydrocarbon-based lubricants, fatty acid-based lubricants, higher alcohol-based lubricants, fatty acid ester-based lubricants, fatty acid amide-based lubricants, phosphate ester-based lubricants, and metal soap-based lubricants. In the present disclosure, the organic lubricant component includes organic-inorganic hybrid polymers such as silicone polymers.

[0075] Examples of silicone polymers include silicone resins, modified silicone resins, silicone oils, modified silicone oils, and silicone-modified polymers. The silicone polymer may be linear, or may have a branched or three-dimensional structure.

[0076] Examples of silicone resins include straight silicone resins such as methyl silicone resin and methylphenyl silicone resin. Examples of modified silicone resins include alkyd-modified silicone resins, epoxy-modified silicone resins, (meth)acrylic-modified silicone resins, and polyester-modified silicone resins.

[0077] Examples of silicone oils include straight silicone oils such as dimethyl silicone oil and methylphenyl silicone oil. Examples of modified silicone oils include polyether-modified silicone oils (such as polyether-modified dimethyl silicone oil), alkyl-modified silicone oils (such as alkyl-modified dimethyl silicone oil), aralkyl-modified silicone oils (such as aralkyl-modified dimethyl silicone oil), higher fatty acid ester-modified silicone oils (such as higher fatty acid ester-modified dimethyl silicone oil), and fluoroalkyl-modified silicone oils (such as fluoroalkyl-modified dimethyl silicone oil).

[0078] Examples of silicone-modified polymers include silicone-modified (meth)acrylic resins, silicone-modified polyesters, silicone-modified polyethers, and silicone-modified polyurethanes.

[0079] Examples of the fluororesin include polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluorovinyl ether copolymer, tetrafluoroethylene-ethylene copolymer, vinylidene fluoride polymer, vinylidene fluoride-hexafluoropropylene copolymer, tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymer, and vinyl fluoride polymer.

[0080] Examples of the organic particle-based lubricant include silicone particles and fluororesin particles. In the present disclosure, the organic particle-based lubricant includes organic-inorganic hybrid particles such as silicone particles.

[0081] The average particle diameter of the organic particle-based lubricant is preferably 0.5 μm or more and 15 μm or less, more preferably 1 μm or more and 12 μm or less, and still more preferably 2 μm or more and 10 μm or less. Thereby, for example, the smooth touch of the surface resin layer can be improved.

[0082] Examples of the hydrocarbon-based lubricant include liquid paraffin, paraffin wax, microcrystalline wax, and synthetic polyethylene wax. Examples of the fatty acid-based lubricant include stearic acid and montanic acid. Examples of the higher alcohol-based lubricant include stearyl alcohol. Examples of the fatty acid ester-based lubricant include stearic acid ester-based lubricants such as monoglyceryl stearate and stearyl stearate. Examples of the fatty acid amide-based lubricant include stearic acid amide, oleic acid amide, erucic acid amide, methylene bisstearic acid amide, and ethylene bisstearic acid amide. Examples of the phosphate ester-based lubricant include polyoxyethylene tridecyl ether phosphate ester. Examples of the metal soap-based lubricant include lead stearate, zinc stearate, calcium stearate, and magnesium stearate.

[0083] Examples of the lubricant component include waxes derived from animals such as beeswax, spermaceti wax, and wool wax; and waxes derived from plants such as carnauba wax, candelilla wax, rice wax, and wood wax.

[0084] The organic lubricant component may be, for example, a non-reactive lubricant or a reactive lubricant having a crosslinkable functional group or a polymerizable functional group. The reactive lubricant is preferable from the viewpoint that the lubricant component is less likely to fall off from the surface resin layer and it is possible to suppress a decrease in the excellent touch feeling over time.

[0085] Specific examples of the reactive lubricant include the above silicone polymer or the above fluororesin, and polymers having a crosslinkable functional group or a polymerizable functional group. Examples of the crosslinkable functional group or the polymerizable functional group include functional groups having an ethylenic double bond (ethylenically unsaturated group) such as (meth)acryloyl group, vinyl group, and allyl group, hydroxyl group, mercapto group, isocyanate group, and epoxy group. Among these, the ethylenically unsaturated group is preferable. In the reactive lubricant, the number of the above functional groups per molecule is, for example, 1 or more and 3 or less.

[0086] The reactive lubricant having an ethylenically unsaturated group can react with a radiation curable compound by irradiation with ionizing radiation such as electron beam and ultraviolet ray. Thereby, the dropout of the above reactive lubricant can be suppressed. When the reactive lubricant is incorporated into the curing system of the surface resin layer, the content ratio of the reactive lubricant (including the reactive lubricant incorporated into the curing system) can be calculated, for example, from the solid content ratio of the reactive lubricant in the resin composition forming the surface resin layer.

[0087] In one embodiment, the content ratio of the organic lubricant component excluding the organic particle-based lubricant in the surface resin layer is preferably 2% by mass or more and 40% by mass or less, more preferably 5% by mass or more and 30% by mass or less with respect to 100% by mass of the resin component. Thereby, for example, the smooth touch feeling of the surface resin layer can be improved. The resin component includes polymer-based lubricants such as silicone polymer and fluororesin.

[0088] Among the organic lubricant components, silicone polymers, fluororesins, and organic particle-based lubricants are preferred, silicone polymers, fluororesins, silicone particles, and fluororesin particles are more preferred, and silicone polymers and silicone particles are even more preferred.

[0089] In one embodiment, the surface resin layer contains a silicone polymer as an organic lubricant component, preferably contains a silicone polymer and an organic particle-based lubricant, and more preferably contains a silicone polymer and silicone particles. These organic lubricant components are excellent in compatibility with the resin components that can form the surface protection layer. With such a configuration, for example, a smooth touch like that of the wood subjected to the above-described soap finish treatment can be more easily obtained.

[0090] In one embodiment, the content of the organic particle-based lubricant in the surface resin layer is preferably 10 parts by mass or more and 50 parts by mass or less, more preferably 12 parts by mass or more and 40 parts by mass or less, and even more preferably 15 parts by mass or more and 30 parts by mass or less with respect to 100 parts by mass of the resin component. Thereby, for example, the smooth touch of the surface resin layer can be improved. The resin component includes polymer-based lubricants such as silicone polymers and fluororesins.

[0091] In one embodiment, the surface resin layer contains additional resin components other than silicone polymers and fluororesins. For example, from the viewpoint of further improving the heat resistance, scratch resistance, and stain resistance of the surface resin layer, it is preferable that the surface resin layer contains additional resin components.

[0092] The resin component functions as a binder in the surface resin layer, for example. Examples of the resin component include thermoplastic resins and cured products of curable compounds. Examples of the cured product of the curable compound include cured products of radiation-curable compounds and cured products of thermosetting resins. The surface resin layer may contain two or more of these resin components. The details of the thermoplastic resin, radiation-curable compound, and thermosetting resin are as described above.

[0093] From the viewpoints of excellent heat resistance, scratch resistance, and stain resistance, the surface resin layer preferably contains a cured product of a curable compound, and more preferably contains a cured product of an ionizing radiation curable compound. Among ionizing radiation curable compounds, electron beam curable compounds are preferred as components for forming the surface resin layer because they can be solvent-free, do not require a photoinitiator, and stable curing characteristics can be obtained. Among ionizing radiation curable compounds, polymerizable oligomers are preferred, (meth)acrylate oligomers having two or more (meth)acryloyl groups in the molecule are more preferred, and urethane (meth)acrylate is even more preferred.

[0094] In one embodiment, the surface resin layer further contains inorganic particles. By the surface protective layer containing inorganic particles, for example, a matte feeling can be imparted to the decorative sheet.

[0095] Examples of the inorganic particles include silica, alumina, kaolinite, clay, aluminosilicate, heavy calcium carbonate, light calcium carbonate, magnesium carbonate, barium sulfate, and calcium silicate. Among these, silica particles are preferred from the viewpoint of improving the matte feeling. The shape of the inorganic particles is, for example, spherical, polyhedral, or scaly.

[0096] The average particle diameter of the inorganic particles is preferably 0.5 μm or more and 15 μm or less, more preferably 1 μm or more and 12 μm or less, and even more preferably 2 μm or more and 10 μm or less. Thereby, for example, the matte feeling of the decorative sheet can be improved.

[0097] The content ratio of the inorganic particles in the surface resin layer is preferably 2% by mass or more and 40% by mass or less, more preferably 5% by mass or more and 30% by mass or less. Thereby, for example, the matte feeling of the decorative sheet can be improved.

[0098] The surface resin layer may contain additives. Examples of the additives include ultraviolet absorbers, light stabilizers, antioxidants, wear resistance improvers, infrared absorbers, antistatic agents, adhesion improvers, leveling agents, thixotropic agents, coupling agents, defoaming agents, flame retardants, plasticizers, and antiblocking agents. Among these, ultraviolet absorbers and light stabilizers are preferred.

[0099] In one embodiment, the surface resin layer can be formed by preparing a curable composition, applying the composition to a design layer provided with convex portions to form an uncured resin layer, and crosslinking and curing the uncured resin layer. The mode of crosslinking and curing is curing by heat treatment when a thermosetting resin is used, and curing by irradiation with ionizing radiation such as electron beams and ultraviolet rays when an ionizing radiation curable compound is used.

[0100] When using an electron beam as the ionizing radiation, the irradiation dose is, for example, 5 kGy or more and 300 kGy or less (0.5 Mrad or more and 30 Mrad or less), preferably 10 kGy or more and 100 kGy or less (1 Mrad or more and 10 Mrad or less). When using ultraviolet rays as the ionizing radiation, light rays containing ultraviolet rays with a wavelength of 190 nm or more and 380 nm or less may be emitted.

[0101] The average thickness of the surface resin layer is preferably 1 μm or more and 10 μm or less, more preferably 1.5 μm or more and 9 μm or less, and even more preferably 2 μm or more and 8 μm or less. When the average thickness is at least the lower limit value, for example, the shedding of particles and the like can be suppressed, and the scratch resistance can be improved. When the average thickness is at most the upper limit value, for example, the unevenness due to the convex portions is well formed on the surface of the decorative sheet, and the above-mentioned tactile sensation can be improved. The average thickness of the surface resin layer may be smaller than the average height of the convex portions. According to this example, the unevenness due to the convex portions can be well formed on the surface of the decorative sheet.

[0102] The ratio (average particle diameter / average thickness) of the average particle diameter of the particles contained in the surface resin layer to the average thickness of the surface resin layer is preferably 1.0 or more and 2.5 or less, more preferably 1.2 or more and 2.3 or less, and even more preferably 1.3 or more and 2.0 or less. The particles contained in the surface resin layer are, for example, organic particle-based lubricants and inorganic particles. Thereby, for example, the tactile sensation by the organic particle-based lubricant can be further improved, or the above-described effect by the inorganic particles can be further improved.

[0103] The average particle diameter of the organic particle-based lubricant contained in the surface resin layer is preferably smaller than the average particle diameter of the particles contained in the convex portion. Thereby, for example, the smooth tactile sensation and the uneven tactile sensation can be further improved.

[0104] The cosmetic sheet of the present disclosure may have a primer layer between the design layer and the convex portion and between the design layer and the surface resin layer. The primer layer is provided as necessary for the purpose of improving the adhesion of the convex portion and the surface resin layer and the like.

[0105] In one embodiment, the primer layer contains a resin component. Examples of the resin component include vinyl chloride-vinyl acetate copolymer, vinyl chloride-vinyl acetate-(meth)acrylic copolymer, chlorinated polyethylene, chlorinated polypropylene, urethane-(meth)acrylic copolymer, (meth)acrylic resin, polystyrene, polyurethane, polyester, polyamide, butyral resin, nitrocellulose, and cellulose acetate. The resin component may be a crosslinked cured product of these resins with a curing agent. The resin component may be, for example, a cured product of the two-component curable urethane resin described above.

[0106] The primer layer may contain the above-described additives. The thickness of the primer layer is preferably 0.1 μm or more and 10 μm or less, more preferably 0.5 μm or more and 8 μm or less, and even more preferably 1 μm or more and 6 μm or less.

[0107] The cosmetic sheet of the present disclosure may have an adhesive layer on the surface opposite to the surface resin layer side of the base material layer. The adhesive layer is provided as necessary for the purpose of enhancing the adhesion to the adherend (molded product) in the decorative molded product.

[0108] The adhesive layer is composed of, for example, an adhesive. Examples of the adhesive include (meth)acrylic resin, (meth)acrylic modified polyolefin, chlorinated polyolefin, vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer, styrene-(meth)acrylic copolymer, polyester, polyurethane, and polyamide. A two-component curable polyurethane-based adhesive or polyester-based adhesive using an isocyanate compound or the like as a curing agent can also be applied. Examples of the adhesive also include (meth)acrylic-based, urethane-based, silicone-based, or rubber-based pressure-sensitive adhesives.

[0109] From the viewpoint of obtaining excellent adhesiveness, the thickness of the adhesive layer is preferably 1 μm or more and 100 μm or less, more preferably 5 μm or more and 50 μm or less, and still more preferably 10 μm or more and 30 μm or less.

[0110] The transfer sheet of the present disclosure has a release support and a transfer layer. The transfer layer is provided so as to be peelable from the release support. The transfer layer has a design layer, convex portions provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portions. The convex portions contain a resin component and particles having an average particle diameter of 25 μm or less. The surface resin layer contains an organic lubricant component.

[0111] The transfer layer may have a primer layer between the design layer and the convex portions and between the design layer and the surface resin layer. The transfer layer may have a concealment layer on the surface opposite to the surface resin layer side of the design layer.

[0112] The design layer, convex portion, surface resin layer, concealment layer, and primer layer in the transfer layer are the same as the design layer, convex portion, surface resin layer, concealment layer, and primer layer in the above-described decorative sheet, respectively, so the description here is omitted.

[0113] The release support is disposed on the surface resin layer in the transfer layer. Examples of the release support include the resin base material described above. A known release treatment may be performed on the surface of the release support on the transfer layer side as necessary, or a release layer such as a silicone resin may be provided. Thereby, for example, the releasability between the release support and the transfer layer when transferring the transfer layer to the surface of an adherend (molded product) can be improved.

[0114] In one embodiment, the transfer layer further has an adhesive layer on the surface opposite to the surface resin layer side of the design layer. Thereby, the adhesion of the transfer layer to the adherend can be improved. Since the adhesive layer in the transfer layer is the same as the adhesive layer in the above-described decorative sheet, the description here is omitted. In one embodiment, the transfer layer further has a base material layer between the adhesive layer and the design layer. Since the base material layer in the transfer layer is the same as the base material layer in the above-described decorative sheet, the description here is omitted.

[0115] FIG. 3 shows a schematic cross-sectional view of an embodiment of the transfer sheet of the present disclosure. The transfer sheet 2 has a release support 50 and a transfer layer 52. The transfer layer 52 has, in this order in the thickness direction, an adhesive layer 60, a design layer 20, a plurality of convex portions 30 provided on a partial region of the design layer 20, and a surface resin layer 40 provided on the design layer 20 so as to cover the plurality of convex portions 30. In the illustrated example, a partial gap is provided between the release support 50 and the transfer layer 52, but the gap may not be provided.

[0116] The decorated molded product of the present disclosure has a molded product, a design layer provided on at least a partial region of the molded product, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion.

[0117] The decorated molded article may have a primer layer between the design layer and the convex portion, and between the design layer and the surface resin layer. The decorated molded article may have a concealing layer on the surface of the design layer opposite to the surface resin layer side. The decorated molded article may have a base material layer between the molded article and the design layer. The decorated molded article may have an adhesive layer between the molded article and the base material layer.

[0118] The base material layer, design layer, convex portion, surface resin layer, primer layer, concealing layer, and adhesive layer in the decorated molded article are the same as those in the above-mentioned decorative sheet, respectively, so the description here is omitted.

[0119] Examples of the molded article include resin members, wooden members, and inorganic members. Examples of the resin member include sheets, plates, or three-dimensional shaped articles composed of, for example, polyolefin, vinyl chloride-based resin, styrene-based resin, (meth)acrylic resin, polyester, polycarbonate, polyamide, polyimide, cellulose resin, phenolic resin, rubber, etc.

[0120] Examples of the wooden member include sheets or three-dimensional shaped articles composed of, for example, wood veneer, plywood, particle board, medium density fiberboard (MDF), and laminated wood such as laminated wood. In one embodiment, the decorated molded article is a decorative board in which the molded article is a wooden member.

[0121] Examples of the inorganic member include metal members and other inorganic members. Examples of the metal member include sheets, plates, or three-dimensional shaped articles composed of, for example, iron, aluminum, copper, tin, titanium, alloys containing at least one of these metals (for example, carbon steel, stainless steel, duralumin, brass, and bronze), etc. Examples of the other inorganic members include sheets or three-dimensional shaped articles composed of, for example, ceramics such as glass and porcelain, non-cement ceramic industry materials such as gypsum, and lightweight cellular concrete (ALC) plates.

[0122] The decorative molded article of the present disclosure can be used, for example, for furniture such as desks, chairs, cupboards, and chests; interior members such as walls, ceilings, and floors in buildings; exterior members such as exterior walls, roofs, eaves, fences, and doors in buildings; various doors such as entrance doors, handrails, moldings, baseboards, window frames, door frames, and moldings; housings of home appliances or OA equipment, and surface decorative panels in kitchen equipment or kitchen furniture; interior or exterior members of vehicles.

[0123] FIG. 4 shows a schematic cross-sectional view according to an embodiment of the decorative molded article of the present disclosure. The decorative molded article 3 has, in this order in the thickness direction, a molded article 70, an adhesive layer 60, a base material layer 10, a design layer 20 provided on the base material layer 10, a plurality of convex portions 30 provided on a partial region of the design layer 20, and a surface resin layer 40 provided on the design layer 20 so as to cover the plurality of convex portions 30.

[0124] The decorative molded article of the present disclosure can be obtained, for example, by disposing the decorative sheet of the present disclosure on the surface of an adherend (molded article). The decorative molded article of the present disclosure can be obtained, for example, by transferring the transfer layer of the transfer sheet of the present disclosure to the surface of an adherend (molded article) using the transfer sheet of the present disclosure.

[0125] In one embodiment, the sheet is affixed to at least a partial region of the surface of the adherend so that the base material layer or the adhesive layer in the decorative sheet of the present disclosure is in contact with the surface of the adherend (molded article). In one embodiment, the sheet is affixed to at least a partial region of the surface of the adherend so that the adhesive layer in the transfer sheet of the present disclosure is in contact with the surface of the adherend (molded article). Then, the release support in the transfer sheet is peeled off. In this way, a decorative molded article is obtained. The affixing may be performed under heating and pressure. As the transfer, for example, known roll transfer or press transfer can be employed.

[0126] The decorative molded article of the present disclosure may be produced, for example, by various injection molding methods such as an insert molding method and an injection molding simultaneous decoration method using the decorative sheet or the transfer sheet of the present disclosure.

[0127] The present disclosure relates to, for example, the following [1] to

[14] . [1] A decorative sheet having a design layer, a convex portion provided on a part of the area of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion, wherein the convex portion contains a resin component and particles having an average particle diameter of 25 μm or less, and the surface resin layer contains an organic lubricant component. [2] The decorative sheet according to [1] above, wherein the organic lubricant component is at least one selected from silicone polymers, fluororesins, organic particle-based lubricants, hydrocarbon-based lubricants, fatty acid-based lubricants, higher alcohol-based lubricants, fatty acid ester-based lubricants, fatty acid amide-based lubricants, phosphate ester-based lubricants, and metal soap-based lubricants. [3] The decorative sheet according to [1] or [2] above, wherein the surface resin layer contains a silicone polymer and an organic particle-based lubricant as the organic lubricant component. [4] The decorative sheet according to any one of [1] to [3] above, wherein the average thickness of the surface resin layer is 1 μm or more and 10 μm or less. [5] The decorative sheet according to any one of [1] to [4] above, wherein the convex portion contains at least one selected from resin particles having an average particle diameter of 15 μm or more and 25 μm or less and inorganic particles having an average particle diameter of 8 μm or more and 15 μm or less as the particles. [6] The convex portion contains the resin particles or the resin particles and the inorganic particles, the content of the resin particles in the convex portion is 5 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the resin component, and the content of the inorganic particles in the convex portion is 0 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin component. The decorative sheet according to [5] above. [7] The decorative sheet according to any one of [1] to [6] above, wherein the average height of the convex portion is 10 μm or more and 25 μm or less. [8] The decorative sheet according to any one of [1] to [7] above, wherein the design layer has a wood grain pattern. [9] The decorative sheet according to any one of [1] to [8] above, wherein the design layer has a wood grain pattern including a conduit portion, and the convex portion is provided on at least a part of the region other than the conduit portion.

[10] The decorative sheet further has a base material layer, and a design layer and a convex portion are located between the base material layer and the surface resin layer. The decorative sheet according to any one of [1] to [9] above.

[11] The decorative sheet according to

[10] above, further having an adhesive layer on the surface of the base material layer opposite to the surface resin layer side.

[12] A transfer sheet having a release support and a transfer layer, the transfer layer having a design layer, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion. The convex portion contains a resin component and particles having an average particle diameter of 25 μm or less, the surface resin layer contains an organic lubricant component, and the release support is disposed on the surface resin layer in the transfer layer. Transfer sheet.

[13] The transfer sheet according to

[12] above, wherein the transfer layer further has an adhesive layer on the surface opposite to the surface of the design layer on the surface resin layer side.

[14] A decorated molded article having a molded article, a design layer provided on at least a partial region of the molded article, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion. The convex portion contains a resin component and particles having an average particle diameter of 25 μm or less, and the surface resin layer contains an organic lubricant component.

Example

[0128] Hereinafter, the decorative sheet of the present disclosure will be described in more detail based on examples, but the decorative sheet of the present disclosure is not limited by the examples at all. In the following description, "parts by mass" is simply expressed as "parts".

[0129] [Example 1] As a base material, colored base paper for building materials ("CHPS45 (model number)", basis weight: 45 g / m 2, prepared from Tenjin Special Paper Co., Ltd.). The resin composition (1) was applied by the gravure printing method onto the easily adherent surface of the base material to form a first design layer with a thickness of 5 μm. The resin composition (1) contains a binder composed of a mixed resin of (meth)acrylic resin and polyurethane, and a colorant containing titanium white, cadmium red, and lead yellow. Using the resin composition (2), a second design layer having a wood grain pattern was formed on the first design layer. The resin composition (2) contains a binder composed of nitrocellulose and a colorant mainly composed of cadmium red. The wood grain pattern has a conduit part.

[0130] A resin composition for a primer layer containing a two-component curable resin (main component: (meth)acrylic polyol, curing agent: hexamethylene diisocyanate) was applied and dried over the entire surface of the design layer to form a primer layer with a thickness of 2 μm.

[0131] In a partial region of the primer layer, a resin composition for convex portions with the following composition was applied and dried by the gravure printing method to form convex portions with an average height of 20 μm. The convex portions were formed in a region where the conduit part in the wood grain pattern is not formed (the wood texture part region in plan view).

[0132] So as to cover the convex portions, a resin composition for a surface resin layer with the following composition was applied onto the primer layer by the roll coating method to form an uncured resin layer. The uncured resin layer was irradiated with an electron beam (3 Mrad (30 kGy)) for curing to form a surface resin layer with an average thickness of 4 μm. Thereafter, heat curing was performed at 70 °C for 24 hours. In the above manner, a decorative sheet was obtained.

[0133] <Resin composition for convex portions> · Two-component curable resin: 100 parts (Main component: (meth)acrylic polyol, curing agent: hexamethylene diisocyanate) · Resin particles: 19 parts ((Meth)acrylic resin particles, average particle diameter: 20 μm) · Inorganic particles: 14 parts (Silica particles, average particle diameter: 12 μm) · Solvent: appropriate amount

[0134] <Resin composition for surface resin layer> · Urethane (meth) acrylate: 80 parts · Reactive silicone polymer: 20 parts · Silica particles: 15 parts (average particle diameter: 6 μm) · Silicone particles: 15 parts (average particle diameter: 6 μm)

[0135] [Example 2, Comparative Example 1 and Comparative Example 3] A decorative sheet was obtained in the same manner as in Example 1, except that the blending composition of the resin composition in the convex portion and / or the surface resin layer and the average height of the convex portion were changed as described in Table 1.

[0136] [Comparative Example 2] A decorative sheet was obtained in the same manner as in Example 1, except that no convex portion was formed.

[0137] [Evaluation of the touch feeling of the decorative sheet] Regarding the obtained decorative sheet, the surface of the surface resin layer was touched with a finger, and the touch feeling was evaluated according to the following criteria. The evaluation results are shown in Table 1. A: Clear unevenness is felt, and it has a smooth touch feeling, similar to the touch feeling of wood with a soap finish treatment. B: It has a smooth touch feeling, but the unevenness feeling is not sufficient. C: Unevenness is felt, but the smoothness is not sufficient. D: Unevenness is felt, but the smoothness is low.

[0138]

Table 1

Explanation of symbols

[0139] 1 ··· Decorative sheet 2 ··· Transfer sheet 3 ··· Decorative molded product 10 ··· Base material layer 20... Design layer 22... Conduit part 24... Wood grain part 30... Convex part 40... Surface resin layer 50... Release support 52... Transfer layer 60... Adhesive layer 70... Adherend (molded product)

Claims

1. A design layer, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion are provided, the convex portion contains a resin component and particles having an average particle diameter of 5 μm or more and 25 μm or less, the surface resin layer contains an organic lubricant component, the surface resin layer is provided on the entire surface of the design layer, a decorative sheet.

2. The decorative sheet according to claim 1, wherein the organic lubricant component is at least one selected from a silicone polymer, a fluororesin, an organic particle-based lubricant, a hydrocarbon-based lubricant, a fatty acid-based lubricant, a higher alcohol-based lubricant, a fatty acid ester-based lubricant, a fatty acid amide-based lubricant, a phosphate ester-based lubricant, and a metal soap-based lubricant.

3. The decorative sheet according to claim 1 or 2, wherein the surface resin layer contains a silicone polymer and an organic particle-based lubricant as the organic lubricant component.

4. The decorative sheet according to any one of claims 1 to 3, wherein the average thickness of the surface resin layer is 1 μm or more and 10 μm or less.

5. The decorative sheet according to any one of claims 1 to 4, wherein the convex portion contains at least one selected from resin particles having an average particle diameter of 15 μm or more and 25 μm or less and inorganic particles having an average particle diameter of 8 μm or more and 15 μm or less as the particles.

6. The convex portion contains the resin particles or the resin particles and the inorganic particles, the content of the resin particles in the convex portion is 5 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the resin component, the content of the inorganic particles in the convex portion is 0 parts by mass or more and 40 parts by mass or less with respect to 100 parts by mass of the resin component, The decorative sheet according to claim 5.

7. The decorative sheet according to any one of claims 1 to 6, wherein the average height of the convex portion is 10 μm or more and 25 μm or less.

8. The decorative sheet according to any one of claims 1 to 7, wherein the design layer has a wood grain pattern.

9. The decorative sheet according to any one of claims 1 to 8, wherein the design layer has a wood grain pattern including a conduit portion, and the convex portion is provided on at least a part of a region other than the conduit portion.

10. The decorative sheet according to any one of claims 1 to 9, further having a base material layer, wherein the design layer and the convex portion are located between the base material layer and the surface resin layer.

11. The decorative sheet according to claim 10, further having an adhesive layer on the surface of the base material layer opposite to the surface resin layer side.

12. A transfer sheet having a release support and a transfer layer, wherein the transfer layer has a design layer, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion and has, the convex portion contains a resin component and particles having an average particle diameter of 5 μm or more and 25 μm or less, the surface resin layer contains an organic lubricant component, the release support is disposed on the surface resin layer in the transfer layer, the surface resin layer is provided on the entire surface of the design layer, transfer sheet.

13. The transfer sheet according to claim 12, wherein the transfer layer further has an adhesive layer on the surface of the design layer opposite to the surface resin layer side.

14. A molded article, a design layer provided on at least a partial region of the molded article, a convex portion provided on a partial region of the design layer, and a surface resin layer provided on the design layer so as to cover the convex portion and has, the convex portion contains a resin component and particles having an average particle diameter of 5 μm or more and 25 μm or less, the surface resin layer contains an organic lubricant component, the surface resin layer is provided on the entire surface of the design layer, decorated molded article.

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