Laminated resin sheet including resin sheet body having hair-like bodies and protective sheet, production method therefor, and molded article thereof

Abstract

The purpose of the present invention is to provide: a laminated resin sheet in which whitening and loss of tactile properties are suppressed even when secondary molding is performed, and with which mold contamination due to contact with a mold during secondary molding is also suppressed; a production method therefor; and a molded article thereof.　The present invention provides a laminated resin sheet including: a resin sheet body having a plurality of hair-like bodies regularly arranged on one surface of a base layer, the base layer and the hair-like bodies forming a continuous phase; and a protective sheet including a protective layer that fills gaps between the hair-like bodies and that covers a surface of the resin sheet body on the side having the hair-like bodies, and a surface layer positioned on the outermost surface of the resin sheet body on the side having the hair-like bodies. The present invention also provides a production method for the laminated resin sheet, including: laminating the surface layer and the protective layer to form a protective sheet; and laminating the resin sheet body and the protective sheet such that a surface of the protective sheet on the protective layer side is directly laminated on the surface of the resin sheet body on the side having the hair-like bodies.

Description

Laminated resin sheet including a resin sheet body having hair-like bodies and a protective sheet, its manufacturing method, and molded product

[0001] The present invention relates to a laminated resin sheet including a resin sheet body having hair-like bodies and a protective sheet, a method for producing the same, and a molded product thereof.

[0002] Conventionally, sheets made of paper or polymeric materials have been used as interior materials for automobiles, housings for accessories, housings for electronic devices and home appliances, sheets for building materials such as wallpaper, housings for toys and game consoles, and sheets for components of daily necessities. Furthermore, as a method for imparting a good tactile feel to a sheet surface, for example, Patent Document 1 proposes a resin sheet having regularly arranged hairs on its surface. On the other hand, when such a resin sheet is used as an interior part such as a dashboard or seat of an automobile, it needs to be subjected to secondary molding and attached to the surface of the object.

[0003] International Publication No. 2018 / 016562

[0004] However, it has been found that such a resin sheet may be subject to deformation of the hairs or tilting of the hairs, causing the hairs to fall down during the process of secondary molding and attaching the resin sheet to the surface of an object, resulting in whitening of the appearance of the sheet and loss of good tactile feel.The problem to be solved by the present invention is to provide a laminated resin sheet that is suppressed from whitening and loss of tactile feel even when secondary molding is performed, and that is suppressed from staining the mold due to contact with the mold during secondary molding, a method for manufacturing the same, and a molded product thereof.

[0005] That is, after examining various means, the inventors have found that by forming a laminated resin sheet comprising a resin sheet body having regularly arranged hairs on one side of a base layer, with the base layer and the hairs forming a continuous phase, a protective layer filling the gaps between the hairs and covering the surface of the resin sheet body on the side having the hairs, and a protective sheet including a surface layer located on the outermost surface of the resin sheet body on the side having the hairs, it is possible to obtain a laminated resin sheet that is suppressed from whitening and loss of tactile feel even when subjected to secondary molding, and that is suppressed from staining the mold due to contact with the mold during secondary molding, and have thus completed the present invention.

[0006] The present invention, which solves the above problems, includes the following aspects: [1] A laminated resin sheet comprising a resin sheet body having a plurality of regularly arranged hair-like bodies on one surface of a base layer, the base layer and the hair-like bodies forming a continuous phase, a protective layer filling the gaps between the hair-like bodies and covering the surface of the resin sheet body on the side having the hair-like bodies, and a protective sheet including a surface layer located on the outermost surface of the resin sheet body on the side having the hair-like bodies. [2] A method for manufacturing a laminated resin sheet, comprising: a resin sheet main body having a plurality of hair-like bodies regularly arranged on one side of a base layer, the base layer and the hair-like bodies forming a continuous phase; a protective sheet including a protective layer that fills the gaps between the hair-like bodies and covers the surface of the resin sheet main body on the side having the hair-like bodies; and a surface layer located on the outermost surface of the resin sheet main body on the side having the hair-like bodies, the method comprising: laminating the surface layer and the protective layer to form the protective sheet; and laminating the resin sheet main body and the protective sheet so that the surface of the protective sheet on the protective layer side is directly laminated on the surface of the resin sheet main body on the side having the hair-like bodies.

[0007] According to the present invention, it is possible to provide a laminated resin sheet in which whitening and loss of tactile feel are suppressed even when secondary molding is performed, and in which mold contamination due to contact with the mold during secondary molding is suppressed, a method for producing the same, and a molded product thereof.

[0008] 1 is a schematic vertical cross-sectional view showing a laminate resin sheet according to a first embodiment of the present invention; FIG. 2 is a schematic plan view of a resin sheet main body; FIG. 3 is a schematic vertical cross-sectional view showing a laminate resin sheet according to a second embodiment of the present invention; FIG. 4 is a schematic vertical cross-sectional view showing a laminate resin sheet according to an embodiment of the present invention;

[0009] An embodiment of the present disclosure will be described in detail below. However, the scope of the present disclosure is not limited to the embodiment described herein, and various modifications can be made without departing from the spirit of the present disclosure. Each aspect disclosed in this specification can be combined with any other feature disclosed in this specification. When multiple upper and lower limit values ​​are described for a specific parameter, any of these upper and lower limit values ​​can be combined to form a suitable numerical range. The lower and / or upper limit values ​​of a numerical range described in this disclosure are numerical values ​​within that numerical range and may be replaced with numerical values ​​shown in the examples. The expression "X to Y" indicating a numerical range means "X or more and Y or less." If a specific description described for one embodiment also applies to other embodiments, that description may be omitted in other embodiments.

[0010] [First embodiment] The laminated resin sheet according to the first embodiment of the present invention is a laminated resin sheet comprising a resin sheet body having regularly arranged hair-like bodies on one side of a base layer, the base layer and the hair-like bodies forming a continuous phase, a protective layer filling the gaps between the hair-like bodies and covering the surface of the resin sheet body on the side having the hair-like bodies, and a protective sheet including a surface layer located on the outermost surface of the resin sheet body on the side having the hair-like bodies. That is, the layer structure of the laminated resin sheet according to this embodiment is, from bottom to top, hair-like bodies and base layer (1), protective layer (2), and surface layer (3).

[0011] <Base Layer> The base layer (1a) is a layer underlying the hair-like bodies, and refers to the portion of the reference symbol 1 in FIG. 1 other than the surface hair-like bodies (1b). The thickness of the base layer refers to the thickness from the base of the hair-like bodies to the surface opposite the base layer. The average thickness of the base layer is preferably 20 μm or more and less than 540 μm, more preferably 30 μm or more and less than 520 μm, and even more preferably 40 μm or more and less than 500 μm. By making the thickness 20 μm or more, the height of the hair-like bodies can be sufficiently expressed. Furthermore, by making the thickness less than 540 μm, the hair-like bodies can be efficiently formed. The average thickness of the base layer can be determined by measuring the thickness from the base of the hair-like bodies to the interface with the other layer at 10 points on a sample cut into cross-sections at any three points using a microtome, and then using the arithmetic mean value of the 30 measurements. The base layer and the hair-like bodies form a continuous phase. Furthermore, there need not be a structural boundary between the base layer and the hair-like bodies. "Structurally boundaryless" means that the base layer and hairy bodies are integrally formed, with no clear structural boundary between them. "Forming a continuous phase" refers to a state in which there is no seam between the base layer and hairy bodies, and they are not discontinuous (continuous phase). In this respect, it differs from a structure in which hairy bodies are implanted on a base layer. The base layer and hairy bodies may have the same composition, and the bond between the base layer and hairy bodies may include a covalent bond. A covalent bond refers to a chemical bond formed by the sharing of an electron pair between two atoms. In thermoplastic resins, which are chain molecules formed by linked monomers, individual polymers are bonded by covalent bonds, which are stronger than the van der Waals bonds or hydrogen bonds that act between polymer molecules. Furthermore, the base layer and hairy bodies may be derived from the same solid thermoplastic resin sheet, rather than from separate components. "Derived from the same solid thermoplastic resin sheet" means, for example, that the hairy bodies and base layer are obtained based on the same resin sheet. Furthermore, the base layer and hairy bodies may be formed from the same solid thermoplastic resin sheet. Formed from the same solid thermoplastic resin sheet means that the hairs and the underlayer are directly formed by processing one resin sheet.The base layer and the hairs form a continuous phase, which prevents the hairs from separating from the base layer due to external stimuli, resulting in a sheet with a good feel to the touch. Furthermore, the sheet can be manufactured with fewer steps than when the hairs are implanted.

[0012] The base layer and the hair-like bodies are made of the same thermoplastic resin composition, with a thermoplastic resin as the main component. Here, "mainly composed" means that the thermoplastic resin is contained in an amount of 50% by mass or more. "Mainly composed" preferably means that the thermoplastic resin is contained in an amount of 60% by mass or more, 70% by mass or more, 80% by mass or more, or 90% by mass or more. In one embodiment of the present invention, it is preferable to use a resin containing at least one selected from the group consisting of urethane elastomer (TPU), styrene resin, polyolefin resin, polyvinyl chloride resin, thermoplastic elastomer, and fluorine-based resin.

[0013] Urethane elastomers are resins made from diisocyanates and polyols as reaction raw materials. The combination of diisocyanates is as follows: diphenylmethane diisocyanate (MDI) type, H １２ Any combination of MDI-based or hexamethylene diisocyanate (HDI)-based polyol and polyether-based, polyester-based, or polycarbonate-based polyol may be selected, or a combination of two or more thereof may be used. In one embodiment of the present invention, a combination of an MDI-based or HDI-based diisocyanate and a carbonate-based polyol is preferably used.

[0014] Examples of styrene-based resins that can be used include homopolymers or copolymers of styrene-based monomers such as styrene, α-methylstyrene, p-methylstyrene, dimethylstyrene, p-t-butylstyrene, and chlorostyrene, copolymers of these styrene-based monomers with other monomers, such as styrene-acrylonitrile copolymers (AS resins), and graft polymers obtained by graft polymerizing the styrene-based monomers with other polymers, such as diene rubber polymers such as polybutadiene, styrene-butadiene copolymers, polyisoprene, and polychloroprene, such as polystyrenes such as high impact polystyrene (HIPS resins) and styrene-acrylonitrile graft polymers (ABS resins). Also usable are styrene-based thermoplastic elastomers.

[0015] The term "polyolefin resin" refers to a resin made of a polymer containing an α-olefin as a monomer, and examples thereof include polyethylene resins and polypropylene resins. Examples of polyethylene resins that can be used include high-density polyethylene, low-density polyethylene, linear low-density polyethylene, and linear medium-density polyethylene. Not only simple polyethylene but also copolymers, graft compounds, and blends having these structures can be used. Examples of the latter resins include copolymers and blends of resins having polar groups in the polyethylene chain, such as ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-acrylic acid ester copolymers, ethylene-methacrylic acid ester copolymers, ethylene-vinyl acetate-vinyl chloride copolymers, and terpolymers with acid anhydrides.

[0016] Furthermore, examples of polypropylene resins that can be used include homopolypropylene, random polypropylene, and block polypropylene. When homopolypropylene is used, the structure of the homopolypropylene may be isotactic, atactic, or syndiotactic. When random polypropylene is used, the α-olefin copolymerized with propylene preferably has 2 to 20 carbon atoms, more preferably 4 to 12 carbon atoms, such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, and 1-decene. When block polypropylene is used, a block copolymer (block polypropylene), a block copolymer containing a rubber component, or a graft copolymer can be used. In addition to using these olefin-based resins alone, other olefin-based resins can also be used in combination.

[0017] The polyvinyl chloride resin can be a vinyl chloride homopolymer or a copolymer of vinyl chloride and other comonomers. When polyvinyl chloride is a copolymer, it can be a random copolymer or a graft copolymer. Examples of graft copolymers include those in which vinyl chloride is graft-polymerized onto an ethylene-vinyl acetate copolymer or a thermoplastic urethane polymer as the backbone polymer. The polyvinyl chloride resin is preferably a flexible polyvinyl chloride that can be extruded, and may also be a composition containing additives such as a polymeric plasticizer. Known polymeric plasticizers can be used, but preferred examples include ethylene copolymer polymeric plasticizers such as ethylene-vinyl acetate-carbon monoxide copolymer, ethylene-(meth)acrylate-carbon monoxide copolymer, and ethylene-vinyl acetate copolymer with a high vinyl acetate content.

[0018] Thermoplastic elastomers include those having a structure combining a soft polymeric substance and a hard polymeric substance. Specific examples include styrene-based elastomers, olefin-based elastomers, vinyl chloride-based elastomers, polyester-based elastomers, polyamide-based elastomers, etc. These elastomers can be selected from commercially available products.

[0019] Examples of the fluorine-based resin that can be used include a vinylidene fluoride homopolymer and a vinylidene fluoride copolymer containing vinylidene fluoride as a main component. Polyvinylidene fluoride (PVDF) resin is a crystalline resin that exhibits various crystal structures such as α-type, β-type, γ-type, and αp-type. Examples of the vinylidene fluoride copolymer include a vinylidene fluoride-hexafluoropropylene copolymer, a vinylidene fluoride-tetrafluoroethylene copolymer, a vinylidene fluoride-chlorotrifluoroethylene copolymer, a vinylidene fluoride-trifluoroethylene copolymer, a vinylidene fluoride-tetrafluoroethylene-hexafluoropropylene terpolymer, a vinylidene fluoride-chlorotrifluoroethylene-hexafluoropropylene terpolymer, and a mixture of two or more of these.

[0020] The melt mass flow rate of the thermoplastic resin composition at 190°C to 300°C is preferably 4 g / 10 min or more. By making it 4 g / 10 min or more, the transferability of the shape of the capillaries can be improved. The melt mass flow rate is a value measured according to JIS K 7210 under conditions of a test temperature range of 190°C to 300°C and a load (2.16 kg to 10.0 kg).

[0021] The thermoplastic resin composition may be an alloy of the above thermoplastic resins in any ratio, provided that the effects of the present invention are not impaired. Furthermore, other additives may be added. Examples of other additives that may be added, provided that the effects of the present invention are not impaired, include water / oil repellents, colorants such as pigments and dyes, lubricants / mold release agents such as silicone oils and alkyl esters, fibrous reinforcing agents such as glass fiber, fillers such as granular fine particles such as talc, clay, and silica, and scaly fine particles such as mica, low-molecular-weight antistatic agents such as salt compounds of sulfonic acid and alkali metals, polymeric antistatic agents such as polyether ester amides, and additives such as flame retardants, antibacterial agents, antiviral agents, and heat stabilizers. Scrap resin generated during the resin sheet manufacturing process may also be added.

[0022] Examples of water- and oil-repellents include silicone-based water- and oil-repellents, carnauba wax, and fluorine-based water- and oil-repellents. Examples of silicones include organopolysiloxane, dimethylpolysiloxane, methylphenylpolysiloxane, and methylhydrogenpolysiloxane, with dimethylpolysiloxane being particularly preferred. Commercially available products include "Clinbell CB-50PP," "Clinbell CB-30PE," "Clinbell CB-1," and "Clinbell CB-50AB" (manufactured by Fuji Chemical Co., Ltd.), which are silicone-resin alloys. Commercially available carnauba wax products include "Carnauba No. 1" (manufactured by Nikko Rica Corporation). Fluorine-based water- and oil-repellents include surfactants having perfluoroalkyl groups, such as "Surflon KT-PA" (manufactured by AGC Seimi Chemical Co., Ltd.). The amount of water- and oil-repellent added is preferably 0.5% to 25% by mass. If the content is less than 0.5% by mass, there is a risk that sufficient water and oil repellency may not be obtained, and if the content exceeds 25% by mass, there is a risk that moldability may deteriorate.

[0023] Examples of antistatic agents include polyether ester amide-based polymer antistatic agents and ionomer-based polymer antistatic agents. Commercially available polyether ester amide-based polymer antistatic agents include "Pelestat 230," "Pelestat 6500," "Pelectron AS," and "Pelectron HS" (manufactured by Sanyo Chemical Industries, Ltd.). Commercially available ionomer-based polymer antistatic agents include "Entira SD100" and "Entira MK400" (manufactured by DuPont-Mitsui Polychemicals). The amount of antistatic agent added is preferably 5% to 30% by mass. If the amount is less than 5% by mass, sufficient antistatic properties may not be obtained, and if the amount is more than 30% by mass, production costs increase.

[0024] The antibacterial agent may be either inorganic or organic. In terms of dispersibility, inorganic agents are preferred. Specific examples include inorganic antibacterial agents based on metal ions (Ag, Zn, Cu) and calcined shell calcium antibacterial agents. Commercially available inorganic antibacterial agents based on metal ions include "Bactekiller BM102VT" (manufactured by Fuji Chemical Co., Ltd.), "Novalon VZF200," "Novalon (AG300)" (manufactured by Toagosei Co., Ltd.), "KM-10D-G," and "IM-10D-L" (manufactured by Sinanen Zeomic Co., Ltd.). Examples of calcined shell calcium antibacterial agents include "Scallow" (manufactured by FID). The amount of antibacterial agent added is preferably 0.5% to 5% by mass. Less than 0.5% by mass may result in insufficient antibacterial activity, while more than 5% by mass increases production costs.

[0025] Examples of lubricants and release agents that can be used include alkyl-based lubricants and release agents such as aliphatic hydrocarbon compounds, higher fatty acid compounds, higher aliphatic alcohol compounds, and fatty acid amide compounds, as well as silicone-based lubricants and release agents and fluorine-based lubricants and release agents. When a lubricant and release agent is used, the amount added is preferably 0.01 to 5 parts by mass, more preferably 0.05 to 3 parts by mass, and even more preferably 0.1 to 2 parts by mass, based on a total of 100 parts by mass of the lubricant and release agent and the resin composition. By adding an amount of 0.01 parts by mass or more, the risk of a decrease in the release effect is reduced, and by adding an amount of 5 parts by mass or less, the risk of bleeding out onto the sheet surface is reduced.

[0026] It is also possible to use a masterbatch in which a lubricant and a release agent are pre-alloyed with a thermoplastic resin. For example, a commercially available masterbatch based on a urethane-based thermoplastic elastomer is "Wax Master V" (manufactured by BASF), and in consideration of production efficiency, it is preferable to use a masterbatch. The amount of masterbatch added is preferably 1 to 8 parts by mass, more preferably 2 to 7 parts by mass, and even more preferably 3 to 6 parts by mass, out of a total of 100 parts by mass including the resin composition.

[0027] <Hair-like bodies> The hair-like bodies (1b) refer to the portions extending in a hair-like manner from the surface of the base layer (1a) as shown in FIG. 1. The hair-like bodies are regularly arranged on the surface of the base layer. Here, "regularly arranged" means that the hairs are not randomly arranged, i.e., arranged in an orderly manner (e.g., at regular intervals) in one or two directions. The orderly arrangement of the hair-like bodies is determined based on the arrangement of the hair-like bodies' roots. In one embodiment, the hair-like bodies are located on the base layer at a predetermined interval, and the positions of the base surface of the hair-like bodies are regularly arranged in the longitudinal and lateral directions of the base layer. The arrangement of the hair-like bodies is not particularly limited, and a checkerboard arrangement or a staggered arrangement, in which the hairs are arranged vertically and horizontally, can be selected. The regular arrangement of the hair-like bodies on the surface of the base layer facilitates the development of a uniform, consistent, and good tactile feel. The hair-like bodies may collapse when subjected to a load, such as when traced with a finger, resulting in a finger mark that appears to have a different gloss and color tone from the surrounding area. The hairy material can also provide a suede-like feel to the touch.

[0028] The average height (h) of the hairs is preferably 60 μm or more and less than 330 μm, more preferably 80 μm or more and less than 250 μm, even more preferably 80 μm or more and less than 200 μm, and particularly preferably 90 μm or more and less than 180 μm. By setting the average height to 60 μm or more, a good tactile feel can be sufficiently ensured, and by setting the average height to less than 330 μm, it is easy to prevent the hairs from falling over. When the hairs are almost upright with respect to the base layer, the length from the base to the tip of the hairs represents the height of the hairs. On the other hand, when the hairs are inclined with respect to the base layer or have a wound portion, the distance from the surface of the base layer at the point where the hairs are furthest from the surface of the base layer is defined as the height h of the hairs. In addition, the total value of the intervals subdivided by multi-point measurement from the tip to the center of the base of the hairs is defined as the length L of the hairs. The average height and length of the hairs can be determined by measuring the height and length of the hairs at any number of locations on the resin sheet using an electron microscope and image processing software, and then calculating the arithmetic mean value of the measured values.

[0029] The average diameter (d) of the hairs is preferably 1 μm to 50 μm, more preferably 5 μm to 50 μm, and even more preferably 5 μm to 40 μm. By setting the average diameter of the hairs to 1 μm or more, a good tactile feel can be ensured, while by setting the average diameter of the hairs to 50 μm or less, good tactile feel such as a moist, soft, and fluffy feel can be obtained. The average diameter of the hairs is determined by measuring the diameter of the hairs at the mid-height (h / 2) from several locations on the resin sheet body using an electron microscope and image processing software, and calculating the arithmetic mean value of the measured values. The aspect ratio of the hairs can be expressed as (average height of hairs / average diameter of hairs). The aspect ratio of the hairs is preferably 2 to 20, more preferably 2 to 10, and even more preferably 2 to 5. By setting the aspect ratio to 2 or more, a good tactile sensation can be ensured, while by setting the aspect ratio to 20 or less, not only can good tactile sensations such as a moist feel, soft feel, and fluffy feel be obtained, but also the risk of the ratio of height to length of the hairs falling below a certain level can be reduced. Meanwhile, the aspect ratio can also be based on the average basal diameter of the hairs. The average basal diameter of the hairs is preferably 10 μm to 150 μm, more preferably 20 μm to 120 μm, and even more preferably 30 μm to 100 μm. The average basal diameter of the hairs is determined by measuring the distance between adjacent hairs at several locations on the resin sheet body and calculating the arithmetic mean value of the measured values. When based on the basal diameter of the hairs, the aspect ratio is preferably 1.0 to 10, more preferably 1.0 to 5, and even more preferably 1.0 to 2.5. By setting the aspect ratio to 1.0 or more, a good tactile feel can be ensured, and by setting the aspect ratio to 10 or less, not only can good tactile feel such as a moist, soft, and fluffy feel be obtained, but also the risk of the ratio of height to length of the hair-like body falling below a certain level can be reduced.

[0030] The average spacing (t) of the hairs is preferably 20 μm to 200 μm, more preferably 40 μm to 150 μm, and even more preferably 40 μm to 100 μm. The spacing of the hairs refers to the distance between the center of the base of a hair and the center of the base of an adjacent hair, as shown in FIG. 2, for example. By setting the average spacing to 20 μm or more, a good tactile sensation is ensured, while by setting it to 200 μm or less, good tactile sensations such as a moist feel, a soft feel, and a fluffy feel are obtained. The average spacing of the hairs is determined by measuring the spacing between adjacent hairs at several locations on the resin sheet body and calculating the arithmetic mean value of the measured values.

[0031] The shape of the hairs is not particularly limited, but may be such that they extend in a direction away from the base layer and become thinner as they approach the tip, or may have a bulge at the tip. In other words, the cross-sectional area may gradually decrease with increasing distance from the base layer, then increase once and terminate. The tip of the hair may be bud- or mushroom-shaped. The hair may have a base-end portion extending away from the base layer, a portion extending from the base-end portion and bending with a constant curvature or a gradually changing curvature, or even a spiral or spiral-shaped portion. In this case, the tip of the hair may be folded inward. Such a shape provides a good tactile sensation. Having the bud- or mushroom-shaped portion hollow provides a more favorable tactile sensation. When a bud or mushroom shape is formed at the tip of the hair, the ratio of the average diameter of the bud or mushroom shape to the average diameter of the hair is preferably 1.1 or more. The height of the bud or mushroom shape is preferably 7 μm or more. The average diameter of the hair, the average diameter of the width of the bud or mushroom shape, and the height are measured using an electron scanning microscope photograph, and the values ​​are calculated using the arithmetic mean values. The hair is made of a thermoplastic resin. The thermoplastic resin may be the same as the resin that can be used in the base layer.

[0032] The thermoplastic resin contained in the base layer and hairs may at least partially form a three-dimensional crosslinked structure (e.g., a three-dimensional network structure). For example, in one embodiment, at least a portion of the hairs may be crosslinked; in another embodiment, the entire surface of the hairs may be crosslinked; and in yet another embodiment, the entire hairs (from the boundary with the base layer to the tip) may be crosslinked. The method for forming the three-dimensional crosslinked structure is not particularly limited, and may be formed by chemical crosslinking or physical crosslinking. Examples of methods for forming a crosslinked structure include a method in which a resin sheet is molded and then the surface having the hairs is irradiated with an electron beam, and a method in which an organic peroxide is added and then heated and humidified during or after molding of the resin sheet. Commercially available resins containing added organic peroxide include "Linkron" manufactured by Mitsubishi Chemical Corporation. In this embodiment, it is preferable to form a crosslinked structure (electron beam crosslinked structure) by irradiation with an electron beam.

[0033] In one embodiment, the average increase in the angle of the hairs due to heat molding is preferably 0 to 10°, assuming that the angle of the hairs when extending perpendicular to the surface of the base layer is 0°. More preferably, it is 0 to 9°, and even more preferably, it is 0 to 8°. The angle can be calculated by measuring the angle of the hairs on the resin sheet body before heat molding and the resin sheet body from which the protective layer has been peeled off after heat molding, using, for example, a laser microscope, and subtracting the angle of the hairs before heat molding from the angle of the hairs after heat molding. Here, heat molding refers to placing the laminate resin sheet in a mold, injecting an injection resin such as polycarbonate resin into the mold to obtain an insert-molded product in which the laminate resin sheet is decorated, and finally peeling off the protective layer. When placing the laminate resin sheet in the mold, the laminate resin sheet may be placed directly, or it may be preformed in advance to impart a three-dimensional shape before placing it. Preforming methods include vacuum forming, pressure forming, vacuum-pressure forming, and TOM molding. The temperature conditions for the preform can be a sheet surface temperature of 100 to 150°C and a heating time of 40 to 300 seconds. In addition to polycarbonate (PC) resin, ABS resin, AES resin, polyester resin, acrylic resin, or an alloy resin combining these can be used as the injection resin. The temperature conditions for injection can be a mold temperature of 40°C, an injection resin temperature of 280°C, and a holding pressure of 30 MPa. Specific heat molding can be performed under the following conditions. A vacuum / compressed air molding machine is used to perform preforming on the laminated resin sheet under the following conditions, imparting a three-dimensional shape. The three-dimensional shape can be imparted by using a convex cover panel mold that is gently curved 10 mm from the end to the center on a surface measuring 200 mm long and 100 mm short, and the surface of the laminated resin sheet opposite the surface layer is brought into contact with the convex surface of the mold.Sheet surface temperature: 100-150°C Heating time: 40-300 seconds Mold shape: 200 mm long, 100 mm short. The three-dimensionally shaped laminated resin sheet is then removed from the mold, and the excess is trimmed. Using an insert molding machine, polycarbonate resin is injected under the following conditions to obtain a secondary molded product (insert molded product). Insert molding is performed by placing the surface layer side of the three-dimensionally shaped laminated resin sheet against the injection mold, and injecting the resin into the side opposite the surface layer using a side gate method. Mold temperature: 40°C Injected resin temperature: 280°C Holding pressure: 30 MPa. After cooling, the molded product is removed from the mold, and the protective sheet is peeled off to obtain the final secondary molded product. The average angle increase due to heat molding can be adjusted by adjusting the composition of the resin sheet itself, the shape of the hairs, the composition and average thickness of the protective layer, etc.

[0034] <Resin Sheet Main Body> The resin sheet main body according to this embodiment has a base layer and hair-like bodies regularly arranged on one side of the base layer. The base layer and the hair-like bodies form a continuous phase. In this embodiment, "tactile sensation" refers to the texture and feel of the surface of the resin sheet main body. The surface of the resin sheet main body is judged to feel comfortable when touched, and if so, a good tactile sensation is defined as a specific feel of comfortable touch, such as moist, soft, or fluffy.

[0035] In this embodiment, the average thickness of the resin sheet body refers to the combined thickness of the average height of the hair-like bodies and the average thickness of the base layer. The average thickness of the resin sheet body is preferably 80 μm or more and less than 600 μm, preferably 90 μm or more and less than 580 μm, and preferably 150 μm or more and less than 580 μm. By setting the average thickness at a certain level or more, good tactile feel can be sufficiently ensured, and by setting it at a certain level or less, it becomes easy to use in insert molding. The average thickness of the resin sheet body can be measured according to Method A of JIS L 1913:2010.

[0036] <Protective Layer> The protective layer (2) is a layer that fills the gaps between the hairs and covers the surface of the resin sheet main body on the side having the hairs. "Filling the gaps" means filling the spaces between adjacent hairs, more preferably filling the spaces between adjacent hairs from the base to the tip. In one embodiment, the protective layer covers the entire surface of the resin sheet main body on the side having the hairs.

[0037] The average thickness of the protective layer is preferably 60 μm to 600 μm, more preferably 80 μm to 400 μm, even more preferably 80 μm to 300 μm, and even more preferably 80 μm to 200 μm. By making the thickness 60 μm or more, the hairs are more completely covered by the protective layer, making it easier to suppress tilting of the hairs due to molding. Furthermore, by making the thickness 600 μm or less, manufacturing costs can be reduced. In one embodiment, the average thickness of the protective layer is greater than the average height of the hairs. By making the average thickness of the protective layer greater than the average height of the hairs, the hairs are completely covered by the protective layer, thereby enhancing the effect of suppressing tilting of the hairs due to molding. The average thickness of the protective layer can be determined by cutting cross-sections from three arbitrary locations on a sample using a microtome, measuring the layer thickness at 10 locations on each sample, and then calculating the arithmetic mean value of the 30 measurements. The thickness of the protective layer is the shortest linear distance from the interface between the protective layer and the underlayer to the interface with the layer in contact with the surface of the protective layer opposite to the surface in contact with the underlayer.

[0038] The tensile modulus of the protective layer at 20°C is preferably 0.2 MPa or more and less than 2 MPa, more preferably 0.3 MPa or more and less than 1.9 MPa, even more preferably 0.3 MPa or more and less than 1.8 MPa, and particularly preferably 0.4 MPa or more and less than 1.7 MPa. The tensile modulus of the protective layer can be measured, for example, by cutting out a 115 mm x 6 mm, dumbbell-shaped No. 5 test piece (longer side in the CMD direction) of the protective layer, setting the test piece in a small tabletop testing machine ("EZTest / CE" manufactured by Shimadzu Corporation), and conducting a tensile test at room temperature (20°C) (chuck distance 25 mm, tensile speed 500 mm / min), and determining the tensile modulus in the elastic region (slope at 0-4% strain) from the obtained stress-strain (S-S) curve.

[0039] In one embodiment, the tensile strength of the protective layer is preferably 1.0 to 30 MPa, more preferably 1.5 to 30 MPa, and even more preferably 1.5 to 30 MPa. The tensile strength of the protective layer can be determined from the maximum value of the obtained stress-strain (S-S) curve, for example, by cutting out a test piece of the protective layer (115 mm x 6 mm, dumbbell-shaped No. 5, with the long side in the CMD direction), setting the test piece in a small tabletop testing machine ("EZTest / CE", manufactured by Shimadzu Corporation), and conducting a tensile test at room temperature (20°C) (chuck distance 25 mm, tensile speed 500 mm / min).

[0040] A resin composition primarily composed of a silicone resin can be used as the raw material for the protective layer. The protective layer can be formed, for example, by coating and curing the resin composition on the hair-like surface of a resin sheet using a comma coater, slot die, or the like. Alternatively, a hot-melt film can be laminated on the hair-like surface of the resin sheet and heated to conform to the uneven shape of the hairs. Silicone resins that can be used include peroxide-curable, condensation-curable, addition-reaction-curable, and ultraviolet-curable silicone resins. A curing agent and a curing retarder can be used in curing the silicone resin. Examples of curing agents that can be used include radical polymerization initiators, cationic polymerization initiators, and anionic polymerization initiators. The amount of curing agent is preferably 1 to 30 parts by weight, more preferably 3 to 20 parts by weight, and even more preferably 5 to 15 parts by weight per 100 parts by weight of the silicone resin. A curing retarder is a compound that temporarily captures reactive species involved in the reaction, thereby suppressing the rapid increase in viscosity due to the curing reaction and extending the usable life. The curing retarder is preferably a curing retarder selected from the group consisting of phosphoric acid-based curing retarders and ether-based curing retarders. One type of curing retarder can be used alone, or two or more types can be used in combination. The amount of curing retarder is preferably 0.1 to 5 parts by mass, more preferably 0.5 to 5 parts by mass, and even more preferably 0.5 to 3 parts by mass, per 100 parts by mass of silicone-based resin. Hot-melt films such as olefin-based, polyamide-based, polyurethane-based, and polyester-based hot-melt films can be used. Furthermore, the resin composition used as the raw material for the protective layer, like the thermoplastic resin composition forming the underlayer and the hair-like bodies, may contain other additives to the extent that they do not impair the effects of the present invention.

[0041] <Surface Layer> The surface layer (3) is a layer that constitutes the surface of the laminated resin sheet opposite to the surface of the base layer that does not have hair-like bodies. The average thickness of the surface layer is preferably 10 μm or more but less than 100 μm, more preferably 10 μm or more but less than 90 μm, and even more preferably 15 μm or more but less than 80 μm. By making it 10 μm or more, a certain level of rigidity can be easily obtained. Furthermore, by making it less than 100 μm, mold followability can be easily obtained during secondary molding. The average thickness of the surface layer can be measured by cutting cross-sections from three arbitrary locations using a microtome, measuring the layer thickness at 10 locations for each sample, and using the arithmetic average of the 30 measurements. The thickness of the surface layer is the distance from the layer interface with the intermediate layer to the surface of the surface layer.

[0042] The melting point of the resin composition used as the raw material for the surface layer is preferably 100 to 350°C, more preferably 100 to 340°C, and even more preferably 110 to 340°C, from the viewpoint of ensuring heat resistance and formability. A melting point of 100°C or higher prevents the resin from melting upon contact with the mold during secondary molding, making it difficult to peel from the mold and preventing the mold from becoming dirty. Furthermore, a melting point of 350°C or lower prevents the rigidity from becoming too high, making it easier to obtain mold followability during secondary molding. In this specification, the melting point refers to the melting peak temperature measured by differential scanning calorimetry (DSC) using a thermal analyzer (e.g., "DSC8500" (manufactured by PerkinElmer Co., Ltd.)) in the temperature range of 30 to 350°C, heated at a heating rate of 10°C / min.

[0043] The tensile strength of the surface layer is preferably 80 to 500 MPa, more preferably 90 to 500 MPa, and even more preferably 100 to 500 MPa. By making the tensile strength of the surface layer 80 MPa or more, it is possible to prevent the protective sheet from tearing when peeling it from the resin sheet body. The tensile strength of the surface layer can be determined, for example, by cutting out a test piece of the surface layer measuring 10 x 150 mm (longer side in the CMD direction), setting the test piece in a small tabletop testing machine ("EZTest / CE" manufactured by Shimadzu Corporation), and conducting a tensile test at room temperature (20 ° C) (chuck distance 50 mm, tensile speed 50 mm / min), and determining the maximum value of the obtained stress-strain (S-S) curve.

[0044] The surface layer can be made from a resin composition primarily composed of a polypropylene resin, a polyethylene resin, a polyester resin, or the like. Polypropylene resins are resins containing 50% by mass or more of propylene monomer units. Examples of polypropylene resins include propylene homopolymers such as isotactic homopolypropylene, syndiotactic homopolypropylene, and atactic homopolypropylene; ethylene-propylene random copolymers; ethylene-propylene block copolymers; and α-olefin-propylene copolymers, such as soft olefins blended with elastomer components (either compound or reactor type). These polypropylene resins can be used alone or in combination of two or more. Examples of polyethylene resins that can be used include high-density polyethylene, low-density polyethylene, linear low-density polyethylene, and linear medium-density polyethylene. These resins can be used alone or in combination with copolymers, graft copolymers, or blends of these structures. Examples of the latter resin include copolymers and blends of resins having polar groups in the polyethylene chain, such as blends with ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-acrylic acid ester copolymers, ethylene-methacrylic acid ester copolymers, ethylene-vinyl acetate-vinyl chloride copolymers, and terpolymers with acid anhydrides. Examples of polyester-based resins include polyethylene terephthalate, polybutylene terephthalate, polyethylene-2,6-naphthalate, and polymethylene terephthalate. Examples of copolymerizable components include polyester resins copolymerized with diol components such as diethylene glycol, neopentyl glycol, and polyalkylene glycol, and dicarboxylic acid components such as adipic acid, sebacic acid, phthalic acid, isophthalic acid, and 2,6-naphthalenedicarboxylic acid. Examples of polyethylene terephthalate include polyesters containing terephthalic acid as the primary acid component and ethylene glycol as the primary glycol component, with 90 mol % or more of repeating units of ethylene terephthalate.Furthermore, other copolymerizable components capable of forming ester bonds may be included within a range that does not impair the effects of the present invention. Examples of copolymerizable compounds include dicarboxylic acids containing substituents such as isophthalic acid, cyclohexanedicarboxylic acid, adipic acid, dimer acid, sebacic acid, and sulfonic acid groups. Furthermore, the resin composition that serves as the raw material for the surface layer may contain other additives within a range that does not impair the effects of the present invention, similar to the thermoplastic resin composition that forms the base layer and the hair-like bodies. The surface layer can be formed by a conventional method.

[0045] <Intermediate Layer> In one embodiment, the laminate resin sheet may have an intermediate layer between the protective layer and the surface layer. The average thickness of the intermediate layer is preferably 0.01 μm or more and less than 15 μm, more preferably 0.01 μm or more and less than 10 μm, and even more preferably 0.01 μm or more and less than 8 μm. By making the thickness 0.02 μm or more, the adhesion strength with the protective layer is easily improved. The average thickness of the intermediate layer can be determined by measuring the layer thickness at 10 points on each sample, which is obtained by cutting cross-sections at three arbitrary points using a microtome, and then using the arithmetic mean value of the 30 measurements. The thickness of the intermediate layer is defined as the distance from the layer interface with the protective layer to the layer interface with the surface layer.

[0046] The raw material for the intermediate layer is preferably one that can be laminated with the protective layer and the surface layer with sufficient peel strength, and for example, a composition containing an adhesive as a main component can be used. Examples of adhesives include silicone-based adhesives, (meth)acrylic resin-based adhesives, natural rubber adhesives, urethane resin-based adhesives, ethylene-vinyl acetate resin emulsion adhesives, ethylene-vinyl acetate resin-based adhesives, epoxy resin-based adhesives, vinyl chloride resin solvent-based adhesives, chloroprene rubber-based adhesives, cyanoacrylate-based adhesives, styrene-butadiene rubber solvent-based adhesives, nitrile rubber-based adhesives, nitrocellulose-based adhesives, phenolic resin-based adhesives, modified silicone-based adhesives, polyester-based adhesives, polyamide-based adhesives, polyimide-based adhesives, olefin resin-based adhesives, vinyl acetate resin emulsion-based adhesives, polystyrene resin solvent-based adhesives, polyvinyl alcohol-based adhesives, polyvinylpyrrolidone resin-based adhesives, polyvinyl butyral-based adhesives, polybenzimidazole adhesives, polymethacrylate resin solvent-based adhesives, melamine resin-based adhesives, urea resin-based adhesives, and resorcinol-based adhesives. The adhesives can be used alone or in combination of two or more. Among these, a silicone adhesive is preferably used. The intermediate layer can be formed, for example, by applying a composition serving as a raw material for the intermediate layer onto the surface of the surface layer.

[0047] <Protective Sheet> The protective sheet in this embodiment has a protective layer and a surface layer. By having the surface layer in addition to the protective layer, the protective sheet is less likely to tear when peeled off from the resin sheet body, compared to when only the protective layer is included. In one embodiment, the protective sheet further has an intermediate layer between the protective layer and the surface layer.

[0048] The tensile modulus of the protective sheet at 23°C is preferably 100 MPa or more and less than 500 MPa, more preferably 100 MPa or more and less than 480 MPa, even more preferably 110 MPa or more and less than 480 MPa, and particularly preferably 110 MPa or more and less than 470 MPa. The tensile modulus of the protective sheet can be measured, for example, by cutting out a 115 mm x 6 mm, dumbbell-shaped No. 5 test piece (longer side in the CMD direction) from the protective sheet, setting the test piece in a small tabletop testing machine ("EZTest / CE", manufactured by Shimadzu Corporation), and conducting a tensile test at room temperature (20°C) (chuck distance 25 mm, tensile speed 500 mm / min), and determining the tensile modulus in the elastic region (slope at 0-4% strain) from the obtained stress-strain (S-S) curve.

[0049] The tensile strength of the protective sheet is preferably 10 to 150 MPa, more preferably 15 to 150 MPa, and even more preferably 20 to 150 MPa, from the viewpoints of improving mold conformability during secondary molding, being less likely to tear when peeled from the resin sheet main body, etc. The tensile strength of the protective sheet can be determined, for example, by cutting out a 115 mm x 6 mm, dumbbell-shaped No. 5 (long side in the CMD) test piece from the protective sheet, setting the test piece in a small tabletop testing machine ("EZTest / CE" manufactured by Shimadzu Corporation), and conducting a tensile test (25 mm, tensile speed 500 mm / min) at room temperature (20°C), and then determining the maximum value of the obtained stress-strain (S-S) curve.

[0050] <Laminate Resin Sheet> The laminate resin sheet in this embodiment includes hair-like bodies and a base layer (1), a protective layer (2), and a surface layer (3). In one embodiment, an intermediate layer is further provided between the protective layer and the surface layer. The average thickness of the laminate resin sheet is preferably 100 μm or more and less than 1200 μm, more preferably 100 μm or more and less than 1100 μm, and even more preferably 110 μm or more and less than 1000 μm. The thickness of the laminate resin sheet can be measured in accordance with JIS K 7130:1999. In this embodiment, the average thickness of the laminate resin sheet refers to the combined average thickness of all layers constituting the laminate resin sheet, and in this embodiment, refers to the combined average thickness of the base layer, the protective layer, and the surface layer.

[0051] In one embodiment, the peel strength between the resin sheet main body and the protective sheet is preferably 0.01 to 1.6 N / mm. The peel strength between the resin sheet main body and the protective sheet is more preferably 0.01 to 1.3 N / mm, even more preferably 0.02 to 1.1 N / mm, and particularly preferably 0.02 to 1.0 N / mm. By setting the peel strength to 0.01 N / mm or more, it is possible to prevent the protective sheet from peeling off during molding, causing hair collapse and resulting in poor appearance. Furthermore, by setting the peel strength to 1.6 N / mm or less, it is possible to prevent the shape of the hair-like bodies from deforming after peeling, resulting in poor appearance. The peel strength between the resin sheet main body and the protective sheet in a laminated resin sheet can be determined as follows: a laminated resin sheet consisting of a resin sheet main body and a protective sheet is cut to a width of 25 mm, and the resin sheet main body is placed horizontally below the gripping jig of a universal testing machine using a 90-degree peeling jig so that the protective sheet faces upward.The protective layer peeled from the lower resin sheet is sandwiched above the gripping jig, and the gripping jig with the protective sheet sandwiched above is pulled in the normal direction to the sheet surface at a tensile speed of 100 mm / min to measure.

[0052] [Second Embodiment] An example of a laminate resin sheet according to a second embodiment of the present invention is a laminate resin sheet having a base layer formed on the side of the base layer opposite the side having the hair-like bodies, as shown in Figure 3. That is, the layer structure of the laminate resin sheet according to the second embodiment is, from bottom to top, a base layer (4), hair-like bodies and base layer (1), a protective layer (2), and a surface layer (3). In one embodiment, an intermediate layer is further provided between the protective layer and the surface layer. The average thickness of the base layer is preferably 50 μm or more and less than 500 μm, more preferably 50 μm or more and less than 280 μm, and even more preferably 60 μm or more and less than 280 μm. By setting the average thickness of the base layer to 500 μm or less, production costs can be reduced. Here, the hair-like bodies and base layer, protective layer, intermediate layer, and surface layer are the same as those described in the first embodiment, so their description will be omitted. The base layer in the resin sheet according to the second embodiment is preferably made of a thermoplastic resin that can adhere to the base layer. For example, the same thermoplastic resin composition as the underlayer, polycarbonate-based resins, polyester-based resins, or polymer alloy resins thereof can be suitably used. The mass ratio of polycarbonate-based resin to polyester-based resin in the polymer alloy resin is preferably 50:50 to 90:10, more preferably 60:40 to 80:20, and even more preferably 65:35 to 75:25. Here, the polymer alloy resin refers to a polymer multicomponent system, and may be a polymer blend having a certain degree of compatibility through mixing, a block copolymer or graft copolymer obtained by copolymerization, or a mixture of incompatible resins. Examples of polycarbonate-based resins include those derived from aliphatic dihydroxy compounds and those derived from aromatic dihydroxy compounds. For example, those derived from aromatic dihydroxy compounds can be suitably used, and those derived from aromatic dihydroxy compounds (bisphenols) in which two aromatic dihydroxy compounds are bonded via a certain type of bonding group are particularly preferred. These resins can be produced by a known method of polycondensation of a dihydroxy compound with phosgene or a carbonate ester, but are not limited to this method, and commercially available resins can also be used.Examples of polyester resins that can be used include polyethylene terephthalate, polybutylene terephthalate, polyethylene-2,6-naphthalate, and polymethylene terephthalate. Examples of copolymerizable components include polyester resins copolymerized with diol components such as diethylene glycol, neopentyl glycol, and polyalkylene glycol, and dicarboxylic acid components such as adipic acid, sebacic acid, phthalic acid, isophthalic acid, and 2,6-naphthalenedicarboxylic acid. The base layer may contain other additives as needed. Examples of such additives include water repellents, oil repellents, colorants such as pigments and dyes, lubricants and release agents such as silicone oils and alkyl esters, fibrous reinforcing agents such as glass fiber, fillers such as granular microparticles such as talc, clay, and silica, and scaly microparticles such as mica, low-molecular-weight antistatic agents such as salt compounds of sulfonic acids and alkali metals, and high-molecular-weight antistatic agents such as polyether ester amides. Flame retardants, antibacterial agents, antiviral agents, and heat stabilizers may also be added, provided they do not impair the effects of the present invention. Scrap resin generated in the resin sheet manufacturing process can also be mixed in. The base layer may have a partially crosslinked structure within the range that does not impair the effects of the present invention.

[0053] [Manufacturing of Resin Sheet Body] The manufacturing method of the resin sheet body according to the present invention is not limited and may be any method, but typically includes a step of melt-extruding a raw resin and providing regularly arranged hair-like bodies on at least one surface of the resulting sheet. For example, a feed block or a multi-manifold die can be used during the manufacturing process. The layer structure of each embodiment is basically as described above, but other layers, such as scrap raw materials generated during the manufacturing process, may also be laminated as an additional layer as long as the physical properties are not deteriorated.

[0054] The method for providing the hair-like bodies is not particularly limited, and any method known to those skilled in the art can be used. For example, a method using an extrusion molding method, a method using a roll-to-roll method, a method using a photolithography method, a method using a heat press method, a method using a pattern roll and a UV-curable resin, a method using a 3D printer, a method in which the hair-like bodies are embedded in a resin layer and then covalently bonded by a polymerization reaction, etc.

[0055] For example, when using an extrusion molding method, a sheet can be extruded using a T-die method and cast between a transfer roll and a touch roll that have been textured to impart a capillary shape. As a textured transfer roll, a roll surface with fine irregularities ranging from several μm to several hundred μm in size and formed in a regular pattern by laser engraving, electroforming, etching, mill engraving, or the like can be used. Here, "regular" refers to a non-random arrangement of the irregularities, i.e., a state in which the irregularities are arranged in an orderly manner in one or two directions. In some embodiments, the arrangement of the irregularities can be selected from a checkerboard arrangement or a staggered arrangement, with the irregularities arranged lengthwise and widthwise. Examples of the shape of the irregularities include cones (e.g., cones, square pyramids, triangular pyramids, hexagonal pyramids), semicircles, and rectangles (square prisms). The size of the recesses, including the opening diameter, depth, and spacing between the recesses, ranges from several μm to several hundred μm. The transfer roll can be made of a material such as metal or ceramic. The spacing between the hairs can be adjusted by adjusting the spacing between the recesses on the transfer roll, and the height of the hairs can be adjusted by adjusting the depth of the recesses on the transfer roll, thereby adjusting the tactile feel. It is also preferable to process the transfer roll surface into concaves and convexes with a high aspect ratio. For example, when processing the recesses on the transfer roll surface, the aspect ratio (recess depth / recess opening diameter) is preferably 1.0 to 9.0 or 1.0 to 2.0. To process the transfer roll surface into concaves and convexes with a high aspect ratio, laser engraving or electroforming is particularly suitable for precise processing in the depth direction compared to etching, blasting, mill engraving, etc., and is therefore particularly preferred. Examples of materials that can be used for the transfer roll include metal and ceramic. On the other hand, various materials can be used for the touch roll, including rolls made of silicone rubber, NBR rubber, EPT rubber, butyl rubber, chloroprene rubber, and fluororubber. In certain embodiments, a touch roll with a rubber hardness (JIS K 6253) of 40 to 100 can be used. A Teflon (registered trademark) layer may be formed on the surface of the touch roll.The touch roll can be made of various materials, including silicone rubber, NBR rubber, EPT rubber, butyl rubber, chloroprene rubber, and fluororubber. In one embodiment, a touch roll having a rubber hardness (JIS K 6253) of 40 to 100 can be used. A Teflon (registered trademark) layer may also be formed on the surface of the touch roll. The resin sheet body of this embodiment can be manufactured using the above-described roll set including the transfer roll and touch roll. In one embodiment, the temperature of the transfer roll is adjusted to a temperature near the crystalline melting temperature, glass transition point, or melting point of the thermoplastic resin (e.g., 100 to 150°C when random polypropylene is used), and the pinch pressure between the transfer roll and the touch roll is 30 to 120 kg / cm. ２ The resin sheet main body of this embodiment can be manufactured by casting the resin sheet as follows: The cast resin sheet is taken up at a line speed of 0.5 to 30 m / min using a pinch roll or the like.

[0056] [Manufacturing of Laminated Resin Sheet] The manufacturing method of a laminated resin sheet according to this embodiment includes laminating a surface layer and a protective layer to form a protective sheet, and laminating the resin sheet main body and the protective sheet so that the surface of the protective sheet on the protective layer side is directly laminated on the surface of the resin sheet main body on the side having hair-like bodies. According to the manufacturing method of this embodiment, the raw material resin composition of the protective layer is laminated on the surface of the surface layer, which is a flat surface, rather than on the surface of the resin sheet main body on the side having hair-like bodies, and then laminated on the resin sheet main body. This not only makes it possible to manufacture a laminated resin sheet that is suppressed from whitening and loss of tactile feel even when secondary molding is performed, but also makes it easier to suppress the intrusion of air bubbles into the protective layer or between the protective layer and the resin sheet main body, even if the raw material resin composition of the protective layer has a high viscosity when laminating the resin sheet main body and the protective sheet, and further makes it easier to suppress the occurrence of wrinkles in the surface layer.

[0057] A method for forming the protective sheet according to this embodiment can be exemplified by a method in which a composition serving as a raw material for the protective layer is applied to a surface layer formed in a sheet form. When the laminated resin sheet has an intermediate layer between the protective layer and the surface layer, a method in which a composition serving as a raw material for the intermediate layer is applied to the surface layer formed in a sheet form, and then a composition serving as a raw material for the protective layer is applied to the intermediate layer. As a method for applying the composition serving as a raw material for the protective layer or the composition serving as a raw material for the intermediate layer, a coating method using a comma coater, a slot die, or the like can be used.

[0058] Examples of methods for laminating the resin sheet body and the protective sheet so that the surface of the protective sheet on the protective layer side is directly laminated on the surface of the resin sheet body on the side having the hair-like bodies include lamination (e.g., thermal lamination).

[0059] The viscosity of the raw resin composition of the protective layer when laminating the resin sheet main body and the protective sheet is preferably 1100 mPa·s or more and 41000 mPa·s or less, more preferably 1100 mPa·s or more and 4000 mPa·s or less, and even more preferably 2000 mPa·s or more and 4000 mPa·s or less. By setting the viscosity of the raw resin composition of the protective layer to 1100 mPa·s or more, it is possible to form a protective layer having a certain thickness or more. By setting the viscosity to 41000 mPa·s or less, the generation of bubbles in the raw resin composition of the protective layer is suppressed, and even if bubbles are generated, the bubbles are easily removed. Furthermore, the raw resin composition of the protective layer is easily inserted into the gaps between the hairs of the resin sheet main body, and even if bubbles are generated between the resin sheet main body and the protective sheet when laminating the resin sheet main body and the protective sheet, the bubbles are easily removed. The effect of suppressing the generation of bubbles increases as the viscosity of the raw resin composition decreases. The viscosity of the raw material resin composition for the protective layer can be measured using a Brookfield viscometer in accordance with JIS Z8803, for example, using a spindle under conditions of a rotation speed of 5 rpm, 23±3° C., and humidity of 45 to 70%.

[0060] The viscosity of the raw resin composition of the protective layer when laminating the resin sheet main body and the protective sheet can be adjusted by adding a solvent to the resin composition that is the raw material for the protective layer. The solvent volatilizes and does not remain in the formed protective layer, but a small amount may remain depending on the type of solvent used. As the solvent, a volatile organic solvent can be suitably used, for example, hydrocarbon solvents such as n-butane, n-hexane, n-heptane, n-octane, cyclopentane, cyclohexane, and cyclobutane; aromatic solvents such as toluene and xylene; ketone solvents such as methyl isobutyl ketone; ether solvents such as n-butyl ether, dioxane, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, and diethylene glycol; ethyl acetate, n-butyl acetate, isobutyl acetate, ethylene glycol monomethyl ether, diethylene glycol monoethyl ... Examples of suitable solvents include ester-based solvents such as methyl ether acetate and butyl carbitol acetate; ketone-based solvents such as methyl ethyl ketone, methyl isobutyl ketone, and diisobutyl ketone; alcohol-based solvents such as ethanol, isopropanol, n-butanol, sec-butanol, and isobutanol; and amide-based solvents such as Equamide (trade name, manufactured by Idemitsu Kosan Co., Ltd., an amide-based solvent), N,N-dimethylformamide, N,N-dimethylacetamide, N-methylformamide, N-methylacetamide, N-methylpropioamide, and N-methyl-2-pyrrolidone. These solvents may be used alone or in combination. Among these, aromatic solvents and hydrocarbon solvents are preferred. When a solvent is used, the mass ratio of the resin composition to the solvent can be in the range of 90:10 to 50:50. The mass ratio of the resin composition to the solvent is more preferably 80:20 to 50:50, and even more preferably 80:20 to 55:45. In this case, the resin composition and the solvent preferably account for 90% by mass or more of the raw materials of the protective layer.

[0061] [Molded Product] The molded product of this embodiment is a molded product using the laminated resin sheet of this embodiment. The laminated resin sheet of this embodiment can be used in general molding processes. Examples of molding methods include insert molding, in-mold molding, general vacuum molding, pressure molding, and applications of these methods, such as heating and softening a resin sheet under vacuum and then releasing it under atmospheric pressure to overlay (molde) it onto the surface of an existing molded product. This method is not limited to these. Furthermore, known sheet heating methods, such as non-contact radiant heating using an infrared heater, can also be used to heat and soften the sheet before molding. In one embodiment of vacuum pressure molding, for example, a resin sheet is heated to a surface temperature of 60°C to 220°C for 20 to 480 seconds, and then molded onto the surface of an existing molded product. Depending on the surface shape, the resin sheet can be stretched 1.05 to 2.50 times.

[0062] The laminated resin sheet of this embodiment can be used in applications requiring the above-described good tactile feel. For example, the laminated resin sheet can be used as an automobile interior material, an electronic device exterior material, or a surface material for cosmetic containers.

[0063] Examples of automotive interior materials include steering wheels, dashboards, levers, switches, and other parts of an automobile that are touched by the hands. For example, an interior material can be made by molding and laminating the above-described resin sheet onto the surface of a known instrument panel or pillar (for example, JP 2009-184421 A). By laminating a resin sheet, an interior material with a good tactile feel can be obtained. Considering light resistance and chemical resistance, olefin-based resins, vinyl chloride-based resins, and urethane-based elastomers are preferred as the material for the resin sheet to be laminated. The method for laminating the resin sheet and the interior material is not particularly limited.

[0064] Examples of exterior materials for electronic devices include transmitter housings for keyless entry systems, smartphone housings, smartphone cases, music player cases, game console housings, digital camera housings, electronic organizer housings, calculator housings, tablet housings, mobile personal computer housings, keyboards, mice, etc. For example, a portable transmitter can be exemplified in which the resin sheet of the present invention is molded and bonded to the surface of a portable transmitter housing for a known keyless entry system (e.g., JP 2005-228911 A). Bonding the resin sheet can provide a portable transmitter with a good tactile feel. Olefin-based resins and urethane-based elastomers are preferred as the material for the resin sheet to be bonded. The method for bonding the resin sheet to the housing is not particularly limited.

[0065] Examples of cosmetic containers include containers for face cream, pack cream, foundation, and eye shadow, such as a cosmetic container in which the resin sheet of the present invention is molded and attached to the surface of the lid of a known foundation container (JP 2017-29608 A). By attaching the resin sheet, a cosmetic container with a good tactile feel can be obtained. The resin sheet to be attached is preferably made of an olefin-based resin or a urethane-based elastomer. The method for attaching the resin sheet is not particularly limited.

[0066] Furthermore, a hairy sheet can be produced by printing letters or patterns on the surface of the hairy material using a common printing method (offset printing, gravure printing, flexographic printing, screen printing, foil stamping, etc.), and can be used for the above-mentioned applications. The material of the resin sheet to be printed is not particularly limited, but it is preferable to consider the printability with the ink used for printing.

[0067] Furthermore, a laminate can be produced by laminating (dry laminating, extrusion laminating) a printed material (paper, metal thin film, etc.) on which letters, pictures, etc. have been printed, a nonwoven fabric, etc., and then laminating the laminate onto the printed surface of a business card, for example, to produce a business card with a tactile feel. The material of the resin sheet to be laminated is not particularly limited.

[0068] A non-limiting list of exemplary embodiments and combinations of exemplary embodiments of the present disclosure is disclosed below. [1] A laminate resin sheet comprising: a resin sheet body having a plurality of regularly arranged hairs on one surface of a base layer, the base layer and the hairs forming a continuous phase; and a protective sheet including: a protective layer filling the gaps between the hairs and covering the surface of the resin sheet body on the side having the hairs; and a surface layer located on the outermost surface of the resin sheet body on the side having the hairs. [2] The laminate resin sheet according to [1], wherein the resin sheet body has an average thickness of 80 μm or more and less than 600 μm. [3] The laminate resin sheet according to [1] or [2], wherein the protective layer comprises a silicone-based resin. [4] The laminate resin sheet according to any one of [1] to [3], wherein the surface layer comprises one or more resins selected from the group consisting of polypropylene-based resins, polyethylene-based resins, and polyester-based resins. [5] The laminated resin sheet according to any one of [1] to [4], wherein the average height of the hairs is 60 μm or more and 330 μm or less, the average diameter of the hairs is 1 μm or more and 50 μm or less, and the average spacing of the hairs is 20 μm or more and 200 μm or less. [6] A molded product of the laminated resin sheet according to any one of [1] to [5]. [7] The molded product according to [6], which is an insert-molded product or a vacuum-molded product. [8] The molded product according to [6] or [7], which is an automobile interior material, an electronic device exterior material, or a cosmetic container exterior material. [9] A method for manufacturing a laminated resin sheet, comprising: a resin sheet main body having a plurality of hair-like bodies regularly arranged on one side of a base layer, the base layer and the hair-like bodies forming a continuous phase; a protective sheet including a protective layer that fills the gaps between the hair-like bodies and covers the surface of the resin sheet main body on the side having the hair-like bodies, and a surface layer located on the outermost surface of the resin sheet main body on the side having the hair-like bodies, the method comprising: laminating the surface layer and the protective layer to form a protective sheet; and laminating the resin sheet main body and the protective sheet so that the surface of the protective sheet on the protective layer side is directly laminated on the surface of the resin sheet main body on the side having the hair-like bodies.

[10] The manufacturing method according to [9], wherein laminating the resin sheet body and the protective sheet includes laminating the protective sheet including the protective layer having a viscosity of 41,000 mPa s or less on the surface of the resin sheet body having the hair-like bodies. Each configuration and combination thereof in each embodiment is an example, and additions, omissions, substitutions, and other modifications of the configurations are possible as appropriate within the scope of the present disclosure.

[0069] EXAMPLES The present invention will be explained in more detail below with reference to examples and comparative examples, but the present invention is not limited to the contents of the examples.

[0070] The various raw materials used in the examples and their manufacturing methods are as follows: (1) Hair-like body and underlayer: TPU (urethane elastomer) "A3086A17J" (manufactured by BASF Japan Ltd.) (2) Base material layer: PC / polyester "SP-3012" (manufactured by Sumika Polycarbonate Co., Ltd.) (3) Protective layer: Resin: Silicone resin "KE-1316" (manufactured by Shin-Etsu Chemical Co., Ltd.) + Curing agent "CAT-1316" (manufactured by Shin-Etsu Chemical Co., Ltd.) + Curing retarder "Seigyozai No. 6 10" (manufactured by Shin-Etsu Chemical Co., Ltd.) Solvent 1: Toluene (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) Solvent 2: n-heptane (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) Solvent 3: MEK (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) Solvent 4: Ethyl acetate (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) (4) Intermediate layer + surface layer・ "NS-40+A-1180(P)" (manufactured by Nakamoto Packs Co., Ltd. (middle layer: silicone adhesive, surface layer: polypropylene resin film (average thickness 40 μm, tensile strength: MD 158 MPa, TD 360 MPa)) (5) Surface layer ・ Polyester resin film "E5100" (manufactured by Toyobo Co., Ltd. (polyethylene terephthalate (PET), average thickness 50 μm, tensile strength: MD 160 MPa, TD 220 MPa)) ・ Polypropylene resin film "P2108" (manufactured by Toyobo Co., Ltd., average thickness 40 μm, tensile strength: MD 156 MPa, TD 346 MPa)

[0071] The methods for evaluating various properties of the resin sheet bodies, laminated resin sheets, and molded articles of the laminated resin sheets produced in the examples and comparative examples are as follows.

[0072] (1) Average height of hairs, average diameter of hairs, average spacing of hairs, average thickness of base layer The height (h), diameter (d), spacing (t), and thickness of the base layer of the hairs of the resin sheet body were measured using a laser microscope (VK-X100, manufactured by Keyence Corporation). The measured samples were cross-sectional slices cut out from any three locations of the resin sheet using a microtome. For the average height of hairs, the height of 10 hairs was measured for each sample, and the arithmetic mean value of 30 measured values ​​was used. For the average diameter of hairs, the diameter at the midpoint height (h / 2) of 10 hairs was measured for each sample, and the arithmetic mean value of 30 measured values ​​was used. For the average spacing of hairs, the distance between the center of the base of a hair and the center of the base of an adjacent hair was measured at 10 locations for each sample, and the arithmetic mean value of 30 measured values ​​was used. The average thickness of the primer layer was determined by measuring the thickness of each layer at 10 points on each sample and calculating the arithmetic mean value of the 30 measurements. The thickness of the primer layer is defined as the distance from the base of the hair to the interface with the other layer.

[0073] (2) Confirmation of Whitening The appearance of the resin sheet body (and base layer) before secondary molding and the secondary molded product of the laminated resin sheet was judged by a total of 10 external panelists, 5 men and 5 women. Regarding the difference in color when comparing the two and the difference in color within the secondary molded product, if no difference was observed, it was judged as "no whitening," and if a difference was observed in at least one of them, it was judged as "whitening." If 8 or more panelists judged it as "no whitening," the overall evaluation was "good," if 4 to 7 out of 10 panelists judged it as "no whitening," the overall evaluation was "fair," and if 3 or less out of 10 panelists judged it as "no whitening," the overall evaluation was "poor."

[0074] (3) Sensory Evaluation of Good Tactile Sensation For the good tactile sensation, a total of 10 external panelists, 5 men and 5 women, were asked to touch the resin sheet main body (and base layer) after the protective sheet was peeled off after the laminated resin sheet was secondary molded. The specific tactile sensation (smooth, moist, dry, rough, etc.) when touching the surface of the resin sheet main body was evaluated on a scale of 10 points, and the tactile sensation with the highest score was taken as the tactile sensation of the resin sheet main body surface. In Table 2, "Good" indicates that the score for smoothness or moistness was high, and a good tactile sensation like a suede-like raised sheet was obtained even after secondary molding. "Fair" indicates that the score for smoothness or moistness was high, but the tactile sensation with the highest score was reduced by 3 points or more due to secondary molding. "Poor" indicates that the score for dryness or roughness was high, and a good tactile sensation was not obtained after secondary molding.

[0075] (4) Check for mold contamination When the laminated resin sheet was subjected to secondary molding, contamination of the mold on the side that came into contact with the protective sheet was evaluated according to the following criteria: Good: No resin adhesion Fair: Resin adhesion in some areas Poor: Resin adhesion throughout

[0076] (5) Checking for Air Bubbles If air bubbles get into the protective layer or between the protective layer and the resin sheet body, traces of the air bubbles may be transferred during secondary molding, causing poor appearance. Therefore, the occurrence of air bubbles was visually confirmed and evaluated according to the following criteria: 1: No air bubbles were generated 2: A small amount of air bubbles were generated, but no poor appearance occurred 3: Air bubbles were generated, causing poor appearance 4: Air bubbles were generated, causing severe poor appearance

[0077] (6) Checking for wrinkles If wrinkles occur on the surface layer, the wrinkle marks may be transferred during secondary molding, causing poor appearance. Therefore, the occurrence of wrinkles was visually confirmed and evaluated according to the following criteria: 1: No wrinkles occurred 2: Slight wrinkles occurred, but no poor appearance occurred 3: Wrinkles occurred, causing poor appearance 4: Wrinkles occurred, causing severe poor appearance

[0078] (Production of Laminated Resin Sheet) [Example 1] A urethane-based elastomer for the capillaries and base layer was poured from one 40 mm single-screw extruder, and a PC / polyester resin for the base layer was poured from one 65 mm single-screw extruder. The resin sheet extruded by the coextrusion multilayer T-die method was then subjected to texture processing using chromium oxide spraying and laser engraving, and a transfer roll with a textured surface adjusted to 60°C to 150°C, and a touch roll made of silicone rubber with a rubber hardness of 70 adjusted to 10°C to 90°C. The resin sheet was then cast using a pinch roll at a line speed of 1 m / min to 15 m / min. This resulted in a resin sheet body laminated with the base layer, having the composition, thickness, and surface shape shown in Table 1. Next, a silicone-based adhesive for the intermediate layer was applied to the polypropylene-based resin film for the surface layer. Furthermore, a resin composition was prepared by mixing a silicone-based resin for the protective layer with a curing agent and a cure retarder in a ratio of resin:curing agent:cure retarder of 100:10:1. Toluene was used as a solvent, and the resin composition and solvent were mixed in a ratio of 68:32. The mixture was then applied to the surface of the intermediate layer using a comma coater and semi-cured by heating in a drying oven. The viscosity of the protective layer was measured immediately after mixing the resin composition and solvent using the method described above. A laminated resin sheet was obtained by laminating the resin composition and solvent with a pre-prepared resin sheet body (and substrate layer) so that the spaces between the hairs were filled in the semi-cured state.

[0079] Example 2 A laminated resin sheet was obtained in the same manner as in Example 1, except that toluene was used as the solvent and the resin composition and solvent were mixed in a ratio of 63:37.

[0080] Example 3 A laminated resin sheet was obtained in the same manner as in Example 1, except that toluene was used as the solvent and the resin composition and solvent were mixed in a ratio of 55:45.

[0081] Example 4 A laminated resin sheet was obtained in the same manner as in Example 1, except that n-heptane was used as the solvent and the resin composition and solvent were mixed in a ratio of 74:26.

[0082] Example 5 A laminated resin sheet was obtained in the same manner as in Example 1, except that n-heptane was used as the solvent and the resin composition and solvent were mixed in a ratio of 70:30.

[0083] Example 6 A laminated resin sheet was obtained in the same manner as in Example 1, except that a polyester resin film was used as the surface layer and no solvent was used.

[0084] Example 7 A laminated resin sheet was obtained in the same manner as in Example 1, except that no intermediate layer was provided and a polypropylene-based resin film was used as the surface layer.

[0085] Comparative Example 1 A resin sheet body (and substrate layer) having the composition, thickness and surface shape shown in Table 1 was obtained in the same manner as in Example 1. No protective layer, intermediate layer or surface layer was formed.

[0086] [Comparative Example 2] A resin sheet body (and substrate layer) with the composition, thickness, and surface shape shown in Table 1 was obtained using the same method as in Example 1. A resin composition was prepared by mixing a silicone resin to be used as a protective layer with a curing agent and a curing retarder in a ratio of 100:10:1. MEK was then added as a solvent to the resin composition and solvent in a ratio of 90:10. The mixture was then spread on the hair-like body surface of the resin sheet body with a brass rod to form a protective layer with the thickness shown in Table 1, resulting in a laminated resin sheet (the protective layer was applied to the resin sheet body). The viscosity of the protective layer was measured using the above-mentioned method after mixing the resin composition and solvent and immediately before application. No surface layer or intermediate layer was formed.

[0087] Comparative Example 3 A laminated resin sheet was obtained in the same manner as in Comparative Example 2, except that ethyl acetate was used as the solvent.

[0088] (Production of secondary molded product) Using a vacuum pressure molding machine (NGF-0406s manufactured by Fuse Vacuum Co., Ltd.), preforming was carried out on the laminated resin sheet under the following conditions to give it a three-dimensional shape. The three-dimensional shape was given using a convex cover panel mold that was gently curved by 10 mm from the end to the center on a surface of 200 mm long and 100 mm short, and the surface of the laminated resin sheet on the base layer side, i.e., the surface opposite the protective layer, was brought into contact with the convex surface of the mold. - Sheet surface temperature: 100 to 150°C - Heating time: 40 to 300 seconds - Mold shape: 200 mm long, 100 mm short The laminated resin sheet with the three-dimensional shape was then removed from the mold, and the excess was trimmed. Using an insert molding machine (Sumitomo Heavy Industries "SE315EV-A-HD"), polycarbonate resin (Mitsubishi Engineering Plastics "H3700UR") was injected under the following conditions to obtain a secondary molded product (insert molded product). Insert molding was performed by placing the protective layer side of the laminated resin sheet with the three-dimensional shape in contact with the injection mold, and injecting the resin into the base layer side using a side gate method. Mold temperature: 40°C Injection resin temperature: 260-310°C Holding pressure: 30 MPa After cooling, the molded product was removed from the mold, and the protective layer was peeled off to obtain the final secondary molded product.

[0089] Using the resin sheets obtained in each of the Examples and Comparative Examples, evaluation tests were carried out on various properties, and the results are shown in Table 2.

[0090]

[0091]

[0092] The results shown in Tables 1 and 2 revealed the following. The laminate resin sheets of Examples 1 to 5 and 7 were prevented from whitening and loss of tactile feel even after secondary molding, and there were no problems with mold fouling. Furthermore, there were no problems with bubbles or wrinkles. The laminate resin sheet of Example 6 was prevented from whitening and loss of tactile feel even after secondary molding, and there were no problems with mold fouling. A few bubbles were generated, but no poor appearance occurred. The laminate resin sheet of Comparative Example 1 was prevented from whitening and loss of tactile feel when secondary molding was performed. The resin sheet of Comparative Example 2 was prevented from whitening and loss of tactile feel when secondary molding was performed, and the resin constituting the protective layer adhered to the entire mold during secondary molding, resulting in mold fouling. Furthermore, bubbles were generated in the protective layer, resulting in severe poor appearance. The laminate resin sheet of Comparative Example 3 was prevented from whitening and loss of tactile feel even after secondary molding, but the resin constituting the protective layer adhered to the entire mold during secondary molding, resulting in mold fouling. Furthermore, bubbles were generated in the protective layer, resulting in severe poor appearance.

[0093] Although the present invention has been described above using various embodiments, it goes without saying that the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various modifications and improvements can be made to the above embodiments. Furthermore, it is clear from the claims that such modifications and improvements also fall within the technical scope of the present invention.

[0094] The resin sheet of this embodiment is industrially applicable as a resin sheet that can be secondary molded and as a molded product thereof, because whitening and loss of tactile feel are suppressed even when secondary molding is performed, and mold contamination due to contact with the mold during secondary molding is suppressed.

[0095] REFERENCE SIGNS LIST 1 Hairs and base layer 1a Base layer 1b Hairs d Hair diameter h Hair height t Hair spacing 2 Protective layer 3 Surface layer 4 Base layer 5 Intermediate layer

Claims

1. A laminated resin sheet comprising: a resin sheet body having a plurality of regularly arranged hair-like bodies on one side of a base layer, the base layer and the hair-like bodies forming a continuous phase; and a protective sheet including a protective layer that fills the gaps between the hair-like bodies and covers the surface of the resin sheet body on the side having the hair-like bodies, and a surface layer located on the outermost surface of the resin sheet body on the side having the hair-like bodies.

2. The laminated resin sheet according to claim 1, wherein the average thickness of the resin sheet body is 80 μm or more and less than 600 μm.

3. The laminated resin sheet according to claim 1 or 2, wherein the protective layer contains a silicone-based resin.

4. The laminated resin sheet according to claim 1 or 2, wherein the surface layer contains one or more resins selected from the group consisting of polypropylene-based resins, polyethylene-based resins, and polyester-based resins.

5. A laminated resin sheet according to claim 1 or 2, wherein the average height of the hairs is 60 μm or more and 330 μm or less, the average diameter of the hairs is 1 μm or more and 50 μm or less, and the average spacing of the hairs is 20 μm or more and 200 μm or less.

6. A molded article made from the laminated resin sheet according to claim 1 or 2.

7. The molded product according to claim 6, which is an insert molded product or a vacuum molded product.

8. The molded article according to claim 7, which is an automobile interior material, an electronic device exterior material, or a cosmetic container exterior material.

9. A method for producing a laminated resin sheet comprising a resin sheet body having a plurality of hair-like bodies regularly arranged on one side of a base layer, the base layer and the hair-like bodies forming a continuous phase, a protective sheet including a protective layer that fills the gaps between the hair-like bodies and covers the surface of the resin sheet body on the side having the hair-like bodies, and a surface layer located on the outermost surface of the resin sheet body on the side having the hair-like bodies, the method comprising: laminating the surface layer and the protective layer to form the protective sheet; and laminating the resin sheet body and the protective sheet so that the surface of the protective sheet facing the protective layer is directly laminated on the surface of the resin sheet body on the side having the hair-like bodies.

10. The manufacturing method described in claim 9, wherein laminating the resin sheet body and the protective sheet includes laminating the protective sheet, which includes the protective layer having a viscosity of 41,000 mPa·s or less, on the surface of the resin sheet body on the side having the hair-like bodies.

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