Method for producing article, and transfer sheet

Abstract

The present disclosure provides a method for producing an article having a metal member, said method comprising: a metal member preparation step in which a surface-treated metal member is prepared; a transfer sheet preparation step in which a transfer sheet that has a release film and a transfer layer provided to one surface of the release film is prepared, the transfer layer having a first protective layer and an adhesive layer in this order from the release film–side in the thickness direction; an attachment step in which a laminate is obtained by positioning the adhesive layer–side surface of the transfer sheet to face a transfer target surface of the metal member and attaching the two surfaces without gaps therebetween in a reduced-pressure atmosphere; and a heating step in which the transfer sheet and the metal member are adhered by heating the laminate, wherein, in the transfer sheet, the adhesive layer has a thickness of 1.5 μm or more, the release film has a thermal shrinkage of 3.4% or less, and the release film has a loop stiffness of 35.0 mN / 15 mm or less.

Description

ARTICLE MANUFACTURING METHOD AND TRANSFER SHEET

[0001] The present disclosure relates to a method for manufacturing an article having a metal member and a transfer sheet.

[0002] Conventionally, a sublimation transfer method using a sublimation transfer sheet having a colorant layer containing a sublimable dye provided on a substrate has been used as a method for decorating an adherend such as a metal member. In the sublimation transfer method, the dye is sublimated (thermally transferred) by heating, and the dye is thermally transferred onto the substrate.

[0003] Patent Document 1 discloses a process for painting and decorating an article, the process including the steps of subjecting the article to at least one pretreatment consisting of cleaning, degreasing, chemical conversion treatment, electrolytic chemical conversion treatment, and anodizing treatment, subjecting the article to at least one pre-painting cycle consisting of applying a primer coat with a fluid paint or powder paint of a predetermined color and optionally applying a layer of clear coat on the primer coat, wrapping or covering the article with a transfer support having a pattern obtained using a sublimation ink, further wrapping the article with a sheet of heat-shrinkable material made of polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), and heating the article at a predetermined temperature for a predetermined time to cause shrinkage of the heat-shrinkable material and transfer of the pattern from the transfer support to the surface of the article.

[0004] U.S. Patent No. 6,335,749

[0005] In addition to the above-mentioned sublimation transfer sheet, a transfer sheet having a release film and a transfer layer and transferring the transfer layer to an adherend is known as a transfer sheet. However, an article obtained by transferring the transfer layer to a metal member using such a transfer sheet has problems such as poor adhesion between the metal member and the transfer layer, the transfer sheet being prone to lifting at corners, and the transfer sheet being prone to wrinkling.

[0006] The present disclosure has been made in consideration of the above-mentioned situation, and has as its main object to provide a method for manufacturing an article having a metal member using a transfer sheet having a release film and a transfer layer, which has good adhesion between the metal member and the transfer layer, suppresses lifting of the transfer sheet at corner portions, and is capable of manufacturing an article in which wrinkles in the transfer sheet are suppressed.

[0007] The present disclosure provides a method for manufacturing an article having a metal member, the method comprising: a metal member preparation step of preparing the metal member that has been surface-treated; a transfer sheet preparation step of preparing a transfer sheet having a release film and a transfer layer disposed on one side of the release film, the transfer layer having a first protective layer and an adhesive layer in this order in the thickness direction from the release film side; a bonding step of placing the adhesive layer side of the transfer sheet opposite a transfer surface of the metal member and closely adhering them together under a reduced pressure atmosphere to obtain a laminate; and a heating step of heating the laminate to bond the transfer sheet and the metal member, wherein the transfer sheet has a thickness of the adhesive layer of 1.5 μm or more, the release film has a heat shrinkage rate of 3.4% or less, and the release film has a loop stiffness of 35.0 mN / 15 mm or less.

[0008] The present disclosure provides a transfer sheet for use in the manufacturing method of the above-mentioned article, which comprises a release film and a transfer layer arranged on one side of the release film, the transfer layer having, from the release film side, a first protective layer and an adhesive layer in this order in the thickness direction.

[0009] According to the method for manufacturing an article having a metal member disclosed herein, it is possible to produce an article in which the metal member and the transfer layer have good adhesion, lifting of the transfer sheet at the corners is suppressed, and wrinkles in the transfer sheet are suppressed.

[0010] Fig. 1 is a process diagram illustrating a method for manufacturing an article according to the present disclosure. Fig. 2 is a schematic cross-sectional view illustrating a transfer sheet according to the present disclosure. Fig. 3 is an explanatory view illustrating a method for measuring the loop stiffness of a release film. Fig. 4 is a schematic perspective view illustrating a bonding step according to the present disclosure. Fig. 5 is a schematic side view illustrating an example of an article according to the present disclosure.

[0011] Below, embodiments will be described with reference to the drawings etc. However, the present disclosure can be implemented in many different forms and should not be limited to the description of the embodiments exemplified below. Furthermore, to make the explanation clearer, the drawings may show the width, thickness, and shape of each part schematically compared to the actual form, but this is merely an example and should not be interpreted as limiting.

[0012] In this specification, when describing a mode in which another component is disposed on a certain component, the term "above" or "below" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified. Also, in this specification, when describing a mode in which another component is disposed on the surface of a certain component, the term "on the surface" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified.

[0013] The method for manufacturing an article and the transfer sheet according to the present disclosure will be described in detail below.

[0014] A. Manufacturing Method of an Article Figures 1(a) to 1(d) are process diagrams illustrating a manufacturing method of an article according to the present disclosure. First, as shown in Figure 1(a), a surface-treated metal member 20 is prepared (metal member preparation step). Next, as shown in Figure 1(b), a transfer sheet 10 is prepared, which includes a release film 1 and a transfer layer X disposed on one side of the release film 1 (transfer sheet preparation step). The transfer layer X in the transfer sheet 10 is formed by transferring a first protective layer 2 and an adhesive layer 3 from the release film 1 side in the thickness direction D. Ｔ1(c), the surface of the transfer sheet 10 on the adhesive layer 3 side is placed opposite the surface 20A of the metal member 20 to be transferred, and the two are brought into close contact under a reduced pressure atmosphere to obtain a laminate 50 (close contact process). Next, the laminate 50 is heated to bond the transfer sheet 10 and the metal member 20 together (heating process). This results in an article 100 (FIG. 1(d)).

[0015] The transfer sheet 10 used in the present disclosure has an adhesive layer 3 with a thickness within a predetermined range, a release film 1 with a thermal shrinkage rate within a predetermined range, and a loop stiffness within a predetermined range for the release film 1. As will be described later, in this specification, the "transfer-receiving surface of a metal member" refers to the surface of a metal member that has been surface-treated and on which a transfer sheet is placed.

[0016] Decorated metal components decorated with sublimation transfer film (sublimation transfer type thermal transfer film) may have poor surface properties such as weather resistance and solvent resistance. Therefore, the inventors of the present application investigated the use of a transfer sheet having a release film and a transfer layer, with a first protective layer (surface protective layer) provided on the transfer layer. However, because the metal component and the resin contained in the transfer layer are dissimilar materials, adhesion between them is likely to be poor. In particular, exterior products (items for outdoor use) are exposed to harsh environments, so high adhesion between the metal component and the transfer layer is desirable. Furthermore, when transferring the transfer layer of the transfer sheet to the metal component, the stiffness of the release film on the transfer sheet can cause the transfer sheet to not adhere sufficiently to the metal component at the corners of the metal component, resulting in the transfer sheet floating away from the metal component. The corners of the metal component are the boundaries between adjacent surfaces. Lifting of the transfer sheet at the corners can lead to product defects, so it is preferable to avoid this. Furthermore, the transfer sheet is required to be able to easily peel the release film from the transfer layer after the transfer sheet has been adhered to the metal member, but if the transfer sheet is wrinkled, it becomes difficult to peel the release film from the transfer layer.

[0017] According to the method for manufacturing an article of the present disclosure, the thickness of the adhesive layer of the transfer sheet is within a predetermined range, thereby improving the adhesion between the transfer layer and the metal member. Furthermore, the thermal shrinkage rate of the release film in the transfer sheet is within a predetermined range, thereby suppressing wrinkles in the transfer sheet, and the loop stiffness of the release film is within a predetermined range, thereby suppressing lifting of the transfer sheet at corners.

[0018] Furthermore, by providing the transfer layer of the transfer sheet with the first protective layer, an article can be obtained that has desired surface properties such as weather resistance, scratch resistance, solvent resistance, etc. Furthermore, according to the method for manufacturing an article of the present disclosure, a sublimation transfer device used in the sublimation transfer method can be repurposed, thereby reducing manufacturing costs.

[0019] 1. Metal Member Preparation Step This step is a step of preparing a metal member to be subjected to a surface treatment.

[0020] The metal member is a member containing a simple metal or a metal alloy. Examples of metals used for the metal member include aluminum, iron, steel, and copper. The metal member is preferably an aluminum member. This is because aluminum members are lightweight and have excellent corrosion resistance, making them useful as adherends for exterior components (items for outdoor use). The aluminum member is a member containing aluminum or an aluminum alloy.

[0021] The shape of the metal member is not particularly limited, and examples thereof include a plate, a sheet, and a three-dimensional shape, with a three-dimensional shape being preferred. The metal member preferably has multiple surfaces. The surfaces may be flat or curved. The metal member may also have at least one of a convex portion, a concave portion, a ridge portion, a groove portion, and a through portion.

[0022] The surface treatment is preferably at least one of degreasing, cleaning, chemical conversion treatment, anodizing, plating, and painting.

[0023] Degreasing is a process performed to remove oil from metal components, and examples of degreasing methods include solvent degreasing (solvent washing, solvent vapor cleaning), alkaline degreasing, electrolytic alkaline degreasing, and emulsion degreasing.

[0024] The cleaning treatment is a treatment carried out to remove dirt adhering to the metal member, and examples of the cleaning treatment include washing with hot water, pickling, and solvent cleaning.

[0025] Chemical conversion treatment is a process for forming a chemical conversion coating on the surface of a metal member. Chemical conversion treatment allows for the formation of thinner coatings than anodic oxidation treatments such as alumite treatment. Chemical conversion treatment may be either an electroless treatment or an electrolytic treatment. Examples of chemical conversion coatings include coatings containing at least one of phosphates, chromates, fluorides, triazine thiol compounds, and rare earth oxides. Chemical conversion treatments are preferably treatments capable of forming crystalline coatings, such as parkerizing treatments (phosphate coating treatments) and blunting treatments. Parkerizing treatment is a method for forming a phosphate coating on a metal member. A phosphate coating is a crystalline coating, and because the surface has irregularities due to the crystals, the anchor effect can improve adhesion to the adhesive layer of the transfer sheet. The zinc phosphate coating weight is, for example, 0.1 g / m. ２ Above, 4.0g / m ２ The following is the result.

[0026] Anodizing is a process in which the surface of a metal member is dissolved with a treatment agent to form an oxide film with excellent corrosion resistance. Examples of anodizing include alumite treatment.

[0027] Examples of plating treatments include nickel plating, electroless nickel plating, nickel-boron plating, hard chrome plating, and parker plating.

[0028] Examples of coating processes include powder coating and liquid coating. Coating processes provide anti-rust effects, etc. Powder coating is a baking coating method for metal members using powder paint. Specifically, powder paint containing resins such as epoxy resin, acrylic resin, and polyester is sprayed onto the metal member using a spray or the like, and the powder paint is baked and cured at a predetermined temperature. Liquid coating is a baking coating method for metal members using liquid paint. Specifically, a solvent-resistant liquid paint such as melamine resin paint, acrylic resin paint, or fluororesin paint is used, and the liquid paint is applied to the metal member, followed by baking and curing at a predetermined temperature. Examples of liquid coating methods include spray application and electrodeposition coating, in which the metal member is immersed in the liquid paint and an electric current is applied to apply the liquid paint to the metal member. Electrodeposition coating can form a uniform coating film.

[0029] It is preferable that the surface-treated aluminum member has an aluminum oxide coating on the surface, because this improves the corrosion resistance of the aluminum member. Methods for forming the aluminum oxide coating include, for example, anodizing (alumite treatment).

[0030] In the surface treatment of the present disclosure, a sanding treatment may be performed after at least one of the above-mentioned degreasing treatment, cleaning treatment, chemical conversion treatment, anodizing treatment, plating treatment, and painting treatment. By performing the sanding treatment, the surface of the metal component is polished, and scratches on the metal component can be flattened and made less noticeable.

[0031] The maximum height Sz of the transfer surface of the metal member is, for example, 1.0 μm or more, and may be 2.0 μm or more. When the maximum height Sz of the transfer surface of the metal member is within the above range, the anchor effect is fully exerted and adhesion to the transfer layer is likely to be good. The maximum height Sz is, for example, 4.0 μm or less, and may be 3.0 μm or less. In this specification, the "transfer surface of the metal member" refers to the surface of the metal member that has been surface-treated and on which the transfer sheet is placed. The maximum height Sz of the transfer surface of the metal member is measured using a shape analysis laser microscope in accordance with ISO 25178-2 2012. As the shape analysis laser microscope, a 3D shape measuring instrument VK-X1000 manufactured by Keyence Corporation can be used. Note that in this specification, the maximum height Sz is the average value of measurements at any 10 locations.

[0032] The arithmetic mean height Sa of the transferred surface of the metal member is, for example, 0.1 μm or more, and may be 0.2 μm or more. On the other hand, the arithmetic mean height Sa of the transferred surface of the metal member is, for example, 0.4 μm or less, and may be 0.3 μm or less. The arithmetic mean height Sa of the transferred surface of the metal member is measured in accordance with ISO 25178-2 2012 using a shape analysis laser microscope. As the shape analysis laser microscope, a 3D shape measuring instrument VK-X1000 manufactured by Keyence Corporation can be used. Note that in this specification, the arithmetic mean height Sa is the average value of measurements taken at any 10 locations.

[0033] In this step, it is not necessary to perform a base treatment for imparting color to the metal member. As will be described later, when the transfer sheet used in the present disclosure has a solid layer as a design layer, the solid layer can conceal the color of the metal member or impart color to the metal member. The base agent used for the base treatment contains, for example, the above-mentioned liquid paint or powder paint and a colorant.

[0034] 2. Transfer Sheet Preparation Step This step is a step of preparing a transfer sheet. FIGS. 2(a) to (d) are schematic cross-sectional views illustrating examples of transfer sheets in the present disclosure. As shown in FIG. 2(a), the transfer sheet 10 has a release film 1 and a transfer layer X disposed on one surface of the release film 1. The transfer layer X in the transfer sheet 10 is formed by attaching a first protective layer 2 and an adhesive layer 3 from the release film 1 side in the thickness direction D. Ｔ Each layer of the transfer sheet will be described in detail below.

[0035] (1) Release Film The transfer sheet in the present disclosure has a release film facing the transfer layer.

[0036] (a) Heat Shrinkage Ratio The heat shrinkage ratio of the release film in the present disclosure is usually 3.4% or less, may be 3.0% or less, or may be 2.5% or less. When the heat shrinkage ratio of the release film is within the above range, the thermal dimensional stability can be improved, and the occurrence of wrinkles in the transfer sheet after the heating step can be suppressed. On the other hand, the heat shrinkage ratio may be 0% or more, and may be 1.0% or more.

[0037] The heat shrinkage rate of a release film may have directional dependency, and the heat shrinkage rate of the release film in one direction may differ from the heat shrinkage rate of the release film in another direction. The heat shrinkage rate of a release film in the present disclosure refers to the heat shrinkage rate in the direction in which the heat shrinkage rate is greatest. Note that the heat shrinkage rate of a release film in the MD direction is usually greater than the heat shrinkage rate in the TD direction.

[0038] The heat shrinkage rate is a value measured by the following method in accordance with JIS K7133:1999. First, the release film peeled from the transfer sheet is cut to prepare a test piece of 150 mm length (MD direction) x 150 mm width (TD direction). A straight line of 100 mm is formed in each of the longitudinal and transverse directions passing through the center of the sheet. This release film is heated at 200°C for 5 minutes, then rapidly cooled to room temperature (25°C), and the length of the straight line in the longitudinal direction (MD direction) and transverse direction (TD direction) is measured. The change in the length of the straight line in the longitudinal and transverse directions is calculated, and the percentage of the straight line length (100 mm) before heating is taken as the heat shrinkage rate.

[0039] Methods for controlling the thermal shrinkage rate of the release film include, for example, a method of selecting the type of resin contained in the release film, a method of adjusting the crystallinity of the resin, and a method of adjusting the molding method or molding conditions when molding into a film.

[0040] (b) Loop Stiffness The release film in the present disclosure has a loop stiffness within a specific range. The degree of stiffness of the release film is determined by the loop stiffness. FIG. 3 is an explanatory diagram outlining the method for measuring loop stiffness in the present disclosure. As shown in FIG. 3, the release film 1 peeled from the transfer sheet is cut to prepare a rectangular sample, and the ends of the release film 1 are overlapped to deform the release film 1 into a loop shape. The overlapped ends are then fixed with a fixing jig 31 of a loop stiffness tester. A pressure jig 32 of the loop stiffness tester is pressed vertically against the loop-shaped release film 1 fixed with the fixing jig 31, and the stress during compression is measured. In the present disclosure, the release film peeled from the transfer sheet is cut into a rectangular shape with a width of 15 mm and a length of 150 mm to prepare a sample. The sample is then fixed to a loop stiffness tester so that the loop length is 60 mm, and a pressure tool is pressed against the sample from the vertical direction to measure the stress during compression, and the maximum value of the stress is determined as the loop stiffness. The measurement environment is a temperature of 25°C and a humidity of 60% RH.

[0041] The loop stiffness of the release film is usually 35.0 mN / 15 mm or less, and may be 30.0 mN / 15 mm or less. If the loop stiffness of the release film is too high, the transfer sheet is likely to lift at the corners. On the other hand, the loop stiffness of the release film is, for example, 5 mN / 15 mm or more, and may be 10 mN / 15 mm or more.

[0042] The loop stiffness of the release film can be controlled, for example, by adjusting the thickness of the release film. The thicker the release film, the greater the loop stiffness.

[0043] (c) Material The release film preferably includes a resin film. The resin contained in the resin film may be any resin having the above-described heat shrinkage rate, and examples thereof include ester-based resins, amide-based resins, and imide-based resins.

[0044] The release film preferably contains an ester-based resin. Examples of ester-based resins include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polyethylene terephthalate-isophthalate copolymer. Among these, PET or PBT are preferred, and PET is more preferred, from the viewpoint of being less susceptible to thermal shrinkage.

[0045] The melting point of the resin contained in the release film is preferably 180°C or higher, more preferably 200°C or higher. If the melting point of the resin is within the above range, significant shrinkage or melting during processing can be suppressed. On the other hand, the melting point of the resin contained in the release film may be, for example, 270°C or lower, or 250°C or lower. The melting point of the resin contained in the release film is the melting peak temperature measured by differential scanning calorimetry (DSC) in accordance with the method for measuring the transition temperature of plastics (JIS K 7121:2012).

[0046] The release film may be a stretched film or an unstretched film. The stretching ratio in the machine direction (MD) of the stretched film is, for example, 5 to 30 times. The stretching ratio in the width direction (TD) of the stretched film is, for example, 5 to 30 times.

[0047] (d) Others The thickness of the release film is, for example, 100 μm or less, or may be 45 μm or less, or may be 40 μm or less. When the thickness of the release film is within the above range, the loop stiffness tends to fall within a predetermined range, although this depends on the type of resin. On the other hand, the thickness of the release film is, for example, 10 μm or more, or may be 15 μm or more, or may be 20 μm or more. When the thickness of the release film is within the above range, it is possible to prevent the transfer sheet from being caught in the corners of the metal member during the adhesion process.

[0048] The release film in the present disclosure may be a mirror film or a low-gloss film, depending on the desired surface shape of the first protective layer.

[0049] The 60° gloss value of the surface of the release film located on the transfer layer side (hereinafter also referred to as the first surface of the release film) is, for example, 40 or less, or may be 35 or less, or may be 30 or less. If the 60° gloss value of the first surface of the release film is the above value or less, the transfer layer after the release film is peeled off will exhibit a low gloss feeling. On the other hand, the 60° gloss value of the first surface of the release film is, for example, 3.0 or more, or may be 5.0 or more, or may be 10 or more. If the 60° gloss value is low, the resin of the first protective layer may penetrate into the fine matte shape, making peeling difficult. In addition, it may be impossible to form the desired shape.

[0050] The 60° gloss value of the first surface of the release film is a value measured by the following method: The release film peeled from the transfer sheet is placed on a non-glossy black backing with the first surface facing up, and the 60° specular gloss is measured using a gloss meter ("Micro Trigloss (model name)" manufactured by BYK Gardner) in accordance with Method 3 of JIS Z 8741:1997.

[0051] The arithmetic mean height Sa of the first surface of the release film is, for example, 0.1 μm or more, and may be 0.2 μm or more. If the arithmetic mean height Sa of the first surface is low, the transfer layer is less likely to exhibit a low gloss after the release film is peeled off. On the other hand, the arithmetic mean height Sa of the first surface may be, for example, 6.0 μm or less, and may be 5.0 μm or less. The arithmetic mean height Sa of the first surface of the release film is measured in accordance with ISO 25178-2 2012 using a shape analysis laser microscope. As the shape analysis laser microscope, a 3D shape measuring instrument VK-X1000 manufactured by Keyence Corporation can be used. Note that, in this specification, the arithmetic mean height Sa of the first surface of the release film is the average value of measurements taken at any 10 locations.

[0052] The above-mentioned 60° gloss value and arithmetic mean height Sa of the release film can be adjusted by selecting the type of particles, adjusting the average particle diameter and content, etc., as described below.

[0053] The release film in the present disclosure is not particularly limited, and may be a single layer or may have a multi-layer structure.

[0054] The release film may contain a matting agent kneaded therein. A portion of the kneaded matting agent is usually exposed from the release film. By adding a matting agent to the release film, the peel strength of the release film and the transfer layer can be adjusted. Examples of matting agents include inorganic particles and organic particles. Examples of inorganic particles include silica, alumina, calcium carbonate, magnesium carbonate, calcium sulfate, barium sulfate, and kaolin. Examples of organic particles include acrylic beads, urethane beads, nylon beads, silicone beads, silicone rubber beads, polycarbonate beads, and polyolefin wax (e.g., polypropylene wax, polyethylene wax). The average particle size of the matting agent is, for example, 1.0 μm or more and 10 μm or less, and may be 2.0 μm or more and 8.0 μm or less. The average particle size of the matting agent is determined by the D of particle size distribution measurement (volume basis) by laser light diffraction method. ５０ This refers to

[0055] The release film may have a film layer and a matte layer containing a matting agent. The film layer is the same as the resin film described above. The matte agent used in the matte layer is the same as the matte agent described above. The matte layer may also contain a cured product (crosslinked structure) of a curable resin composition as a resin component. Examples of curable resin compositions used in the matte layer include ionizing radiation curable resin compositions and thermosetting resin compositions. Details of the ionizing radiation curable resin composition and the thermosetting resin composition are the same as those described above. The matte layer may also contain a thermoplastic resin as a resin component. The matte layer may contain additives such as a release agent, an ultraviolet absorber, an infrared absorber, a light stabilizer, a polymerization inhibitor, a crosslinking agent, an antistatic agent, an antioxidant, a leveling agent, a coupling agent, a plasticizer, an antifoaming agent, a filler, a thermal radical generator, and an aluminum chelating agent, as necessary. The thickness of the matte layer is not particularly limited, but is, for example, 0.1 μm or more and 10 μm or less.

[0056] A release film having a matte layer containing a cured product of a curable resin composition tends to have strong stiffness. Therefore, when the release film of the present disclosure is a low-gloss film, a release film having a matte agent kneaded therein is preferred over a release film containing a matte layer on the transfer layer side. This is because the loop stiffness is more likely to fall within the specified range.

[0057] (2) Transfer Layer The transfer layer in the present disclosure is a layer transferred from a transfer sheet. As shown in FIG. 2( a), the transfer layer X is formed by transferring the first protective layer 2 and the adhesive layer 3 from the release film 1 side in the thickness direction D. Ｔ As shown in FIG. 2( b ), the transfer layer X may have a second protective layer 4 between the first protective layer 2 and the adhesive layer 3. As shown in FIG. 2( c ), the transfer layer X may have a design layer 5 between the first protective layer 2 and the adhesive layer 3. As shown in FIG. 2( d ), the transfer layer X has the first protective layer 2, the second protective layer 4, the design layer 5, and the adhesive layer 3 arranged in the thickness direction D from the release film 1 side. Ｔ may be included in this order.

[0058] (a) Adhesive Layer The adhesive layer may constitute the outermost surface of the transfer layer opposite the release film. In the present disclosure, the thickness of the adhesive layer is 1.5 μm or more, may be 2.0 μm or more, or may be 2.4 μm or more. When the thickness of the adhesive layer is within the above range, the adhesion between the transfer layer and the metal member is good. On the other hand, the thickness of the adhesive layer is, for example, 30 μm or less, may be 20 μm or less, or may be 10 μm or less. If the thickness of the adhesive layer is too thick, scratch resistance may be deteriorated.

[0059] The thickness of the adhesive layer is preferably greater than the maximum height Sz of the transfer surface of the metal member, since this further improves the adhesion between the transfer layer and the metal member.

[0060] The adhesive layer preferably has heat-sealing properties. When the adhesive layer has heat-sealing properties, i.e., when it is a heat-sealing layer, the adhesive layer contains a thermoplastic resin that can be melted by heating. The thermoplastic resin is not particularly limited, and examples thereof include acrylic resin, vinyl chloride-vinyl acetate copolymer, polyamide resin, polyester resin, chlorinated polypropylene, chlorinated rubber, urethane resin, epoxy resin, and styrene resin. The above resins may be used alone or in combination of two or more.

[0061] The proportion of the thermoplastic resin in the adhesive layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0062] The adhesive layer preferably contains both an acrylic resin and a vinyl chloride-vinyl acetate copolymer as thermoplastic resins. By mixing an acrylic resin with a relatively high glass transition temperature Tg with a vinyl chloride-vinyl acetate copolymer with a relatively low glass transition temperature Tg, the glass transition temperature Tg can be shifted to a lower temperature. By using such a mixture in the adhesive layer (heat seal layer), it becomes easier to conform to the shape of the metal member.

[0063] Examples of acrylic resins include homopolymers of acrylic esters, copolymers of two or more different acrylic ester monomers, and copolymers of acrylic esters with other monomers. Specifically, acrylic resins made of homopolymers or copolymers containing acrylic esters such as polymethyl acrylate, polyethyl acrylate, polypropyl acrylate, polybutyl acrylate, methyl acrylate-butyl acrylate copolymer, ethyl acrylate-butyl acrylate copolymer, ethylene-methyl acrylate copolymer, and styrene-methyl acrylate copolymer are preferably used. The glass transition temperature of the acrylic resin is, for example, 80°C or higher, preferably 90°C or higher, and more preferably 100°C or higher.

[0064] Examples of vinyl chloride-vinyl acetate copolymers include Solvin C, Solvin CL, Solvin CH, Solvin CN, Solvin C5, Solvin M, Solvin MF, Solvin A, Solvin AL, Solvin TA5R, Solvin TAO, Solvin MK6, and Solvin TA2 (all trade names, manufactured by Nissin Chemical Industry Co., Ltd.). The glass transition temperature Tg of vinyl chloride-vinyl acetate copolymers is generally lower than the glass transition temperature Tg of acrylic resins. The glass transition temperature Tg of vinyl chloride-vinyl acetate copolymers is not particularly limited, but is preferably less than 80°C, more preferably 75°C or lower. By having the glass transition temperature Tg of the vinyl chloride-vinyl acetate copolymer within the above range, the glass transition temperature Tg of the entire resin constituting the adhesive layer can be lowered.

[0065] The glass transition temperatures Tg of the acrylic resin and the vinyl chloride-vinyl acetate copolymer can be measured using a dynamic mechanical analyzer (DMA).

[0066] The proportion of the total mass of the acrylic resin and the vinyl chloride-vinyl acetate copolymer relative to all resin components constituting the adhesive layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 80% by mass or more, and particularly preferably 90% by mass or more.

[0067] When the total amount of the acrylic resin and vinyl chloride-vinyl acetate copolymer contained in the adhesive layer is 100 parts by mass, the content of the acrylic resin is, for example, 20 parts by mass or more, or may be 30 parts by mass or more, while the content of the acrylic resin is, for example, 50 parts by mass or less, or may be 40 parts by mass or less.

[0068] When the total amount of the acrylic resin and the vinyl chloride-vinyl acetate copolymer contained in the adhesive layer is 100 parts by mass, the content of the vinyl chloride-vinyl acetate copolymer is, for example, 50 parts by mass or more, and may be 60 parts by mass or more, while the content of the vinyl chloride-vinyl acetate copolymer is, for example, 80 parts by mass or less, and may be 70 parts by mass or less.

[0069] The adhesive layer and the first protective layer may be disposed so as to be in direct contact with each other, or may be disposed via another layer (for example, a design layer or a second protective layer).

[0070] (b) First Protective Layer The transfer layer in the present disclosure has a first protective layer. The first protective layer contributes to improving the surface properties of the article (e.g., weather resistance, solvent resistance, and scratch resistance). The first protective layer and the release film may be arranged so as to be in direct contact with each other, or may be arranged via another layer.

[0071] The first protective layer preferably contains a cured product (crosslinked structure) of a curable resin composition as a resin component, and the proportion of the cured product of the curable resin composition relative to the total resin components constituting the first protective layer is, for example, 70% by mass or more, or may be 90% by mass or more, or may be 95% by mass or more, or may be 100% by mass.

[0072] Examples of the curable resin composition used for the first protective layer include an ionizing radiation curable resin composition and a heat curable resin composition. Examples of the ionizing radiation curable resin composition include an electron beam curable resin composition and an ultraviolet ray curable resin composition. Among these, an electron beam curable resin composition is preferred because it does not require a polymerization initiator, has little odor, and is less likely to cause coloration.

[0073] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). The ionizing radiation-curable functional group is a group that crosslinks and cures upon irradiation with ionizing radiation, and examples thereof include functional groups having an ethylenic double bond, such as a (meth)acryloyl group, a vinyl group, and an allyl group. In the present disclosure, the (meth)acryloyl group refers to an acryloyl group or a methcroyl group.

[0074] Ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing or crosslinking molecules. Examples of ionizing radiation include electron beams (EB) and ultraviolet (UV) rays. Other examples of ionizing radiation include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

[0075] The ionizing radiation-curable resin composition preferably contains, as the ionizing radiation-curable compound, one or more compounds selected from, for example, urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, polycarbonate (meth)acrylate, and acrylic (meth)acrylate. Among these, the ionizing radiation-curable resin composition preferably contains at least a urethane (meth)acrylate as the ionizing radiation-curable compound. In the present disclosure, urethane (meth)acrylate refers to urethane acrylate or urethane methacrylate. The urethane (meth)acrylate is preferably a caprolactone-based urethane (meth)acrylate.

[0076] When the ionizing radiation curable resin composition contains a caprolactone-based urethane (meth)acrylate, the caprolactone-based urethane (meth)acrylate preferably has 2 or more and 4 or less functional groups, more preferably 2 or more and 3 or less functional groups.

[0077] The ionizing radiation curable resin composition may contain a caprolactone-based urethane (meth)acrylate and a non-caprolactone-modified urethane (meth)acrylate. In this case, the content of the caprolactone-based urethane (meth)acrylate in the first protective layer is set to MＣＬＵＡ The content of the urethane (meth)acrylate that is not modified with caprolactone is M ＵＡ Let's say. ＵＡ and M ＣＬＵＡ M for the sum of ＣＬＵＡ Mass ratio (M ＣＬＵＡ / (M ＵＡ +M ＣＬＵＡ )) is, for example, 40% by mass or more and 90% by mass or less, or may be 45% by mass or more and 80% by mass or less, or may be 50% by mass or more and 70% by mass or less.

[0078] Caprolactone-based urethane (meth)acrylates can usually be obtained by reacting caprolactone-based polyols, organic isocyanates, and hydroxy (meth)acrylates. Examples of synthesis methods include reacting polycaprolactone-based polyols with organic polyisocyanates to produce polyurethane prepolymers containing -NCO groups (isocyanate groups) at both ends, followed by reaction with hydroxy (meth)acrylates.

[0079] Commercially available caprolactone polyols can be used, preferably those having two hydroxyl groups and a number-average molecular weight of 500 to 3,000, more preferably 750 to 2,000. Non-caprolactone polyols, such as ethylene glycol, diethylene glycol, 1,4-butanediol, and 1,6-hexanediol, can also be used singly or in combination in any ratio. Preferred organic polyisocyanates are diisocyanates having two isocyanate groups. From the viewpoint of suppressing yellowing, preferred examples include isophorone diisocyanate, hexamethylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, and trimethylhexamethylene diisocyanate. Preferred hydroxy(meth)acrylates include 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, and caprolactone-modified 2-hydroxyethyl acrylate.

[0080] When the ionizing radiation-curable resin composition contains a caprolactone-based urethane (meth)acrylate, the caprolactone-based urethane (meth)acrylate is preferably a caprolactone diol-based urethane (meth)acrylate. The caprolactone diol-based urethane (meth)acrylate refers to a caprolactone-based urethane (meth)acrylate having a diethylene glycol terminal. The use of a caprolactone diol-based urethane (meth)acrylate can prevent cracking and whitening of the first protective layer.

[0081] The proportion of the caprolactone-based urethane (meth)acrylate in the ionizing radiation-curable resin composition is, for example, 10 parts by mass or more, or may be 20 parts by mass or more, based on 100 parts by mass of the entire ionizing radiation-curable resin composition, while the proportion of the caprolactone-based urethane (meth)acrylate is, for example, 50 parts by mass or less, or may be 40 parts by mass or less.

[0082] The ionizing radiation-curable resin composition may contain a polyfunctional (meth)acrylate monomer as the ionizing radiation-curable compound. Among the polyfunctional (meth)acrylate compounds, examples of the bifunctional (meth)acrylate monomer include ethylene glycol di(meth)acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate.

[0083] Examples of trifunctional or higher functional (meth)acrylate monomers include trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol tetra(meth)acrylate, and isocyanuric acid-modified tri(meth)acrylate.

[0084] The (meth)acrylate monomer may have a part of its molecular skeleton modified, for example, with ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl, cyclic alkyl, aromatic, bisphenol, or the like.

[0085] The proportion of the polyfunctional (meth)acrylate monomer in the ionizing radiation-curable resin composition is, for example, 50 parts by mass or more, or may be 60 parts by mass or more, based on 100 parts by mass of the entire ionizing radiation-curable resin composition, while the proportion of the caprolactone-based urethane (meth)acrylate is, for example, 90 parts by mass or less, or may be 80 parts by mass or less.

[0086] The ionizing radiation curable resin composition preferably contains, as the ionizing radiation curable compound, a caprolactone-based urethane (meth)acrylate and a polyfunctional (meth)acrylate-based monomer.

[0087] The number average molecular weight of the ionizing radiation-curable compound is, for example, from 200 to 10,000, or from 1,000 to 10,000, or from 2,000 to 10,000. The number average molecular weight is an average molecular weight measured by GPC analysis and converted into standard polystyrene.

[0088] For example, when the ionizing radiation-curable compound is an ultraviolet-curable compound, the ionizing radiation-curable resin composition preferably contains at least one of a photopolymerization initiator and a photopolymerization accelerator. Examples of photopolymerization initiators include acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, α-acyloxime ester, acylphosphine oxide, and thioxanthones. Examples of photopolymerization accelerators include p-dimethylaminobenzoic acid isoamyl ester and p-dimethylaminobenzoic acid ethyl ester.

[0089] The first protective layer preferably contains a weathering agent. Examples of weathering agents include an ultraviolet absorber and a light stabilizer. The first protective layer preferably contains at least one of an ultraviolet absorber and a light stabilizer. The first protective layer may contain one or more ultraviolet absorbers. Similarly, the first protective layer may contain one or more light stabilizers.

[0090] Examples of the ultraviolet absorber contained in the first protective layer include organic ultraviolet absorbers such as triazine-based ultraviolet absorbers, benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, oxybenzophenone-based ultraviolet absorbers, salicylic acid ester-based ultraviolet absorbers, and cyano(meth)acrylate-based ultraviolet absorbers, and inorganic ultraviolet absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based ultraviolet absorbers are more preferred.

[0091] Examples of triazine-based ultraviolet absorbers include hydroxyphenyltriazine-based ultraviolet absorbers, such as 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2,4-bis[2-hydroxy-4-butoxyphenyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine. azine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5[2-(2-ethylhexanoyloxy)ethoxy]phenol.

[0092] The content of the ultraviolet absorber in the first protective layer is, for example, 0.5 parts by mass to 10 parts by mass, or alternatively, 0.8 parts by mass to 8 parts by mass, or alternatively, 1 part by mass to 5 parts by mass, relative to 100 parts by mass of the ionizing radiation-curable compound. If the content of the ultraviolet absorber is too high, bleeding out of the ultraviolet absorber may occur, whereas if the content of the ultraviolet absorber is too low, sufficient ultraviolet absorption performance may not be obtained.

[0093] Examples of the light stabilizer contained in the first protective layer include hindered amine light stabilizers, such as 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, methyl(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidin-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine).

[0094] The content of the light stabilizer in the first protective layer is, for example, 1 part by mass to 10 parts by mass, or alternatively 1.5 parts by mass to 8 parts by mass, or alternatively 2 parts by mass to 5 parts by mass, relative to 100 parts by mass of the ionizing radiation-curable compound. If the content of the light stabilizer is too high, bleed-out of the light stabilizer may occur, whereas if the content of the light stabilizer is too low, sufficient light stability may not be obtained.

[0095] The first protective layer may contain additives such as a silicone compound, a polymerization inhibitor, a crosslinking agent, an antistatic agent, an adhesion improver, an antioxidant, a leveling agent, a thixotropy imparting agent, a coupling agent, a plasticizer, an antifouling agent, an antifoaming agent, and a filler. The thickness of the first protective layer is, for example, 2 μm to 20 μm, 3 μm to 15 μm, or 4 μm to 10 μm. If the first protective layer is too thin, sufficient surface properties (e.g., weather resistance, scratch resistance, and solvent resistance) may not be obtained. If the first protective layer is too thick, cracks may easily occur in the first protective layer, and good adhesion may not be obtained.

[0096] (c) Other Layers The transfer layer in the transfer sheet of the present disclosure may have layers other than the adhesive layer and the first protective layer described above. Examples of the other layers include a second protective layer and a design layer.

[0097] (i) Second Protective Layer The transfer layer in the present disclosure preferably has a second protective layer on the side of the first protective layer opposite the release film.

[0098] When a transfer sheet includes a second protective layer, the adhesion between the first protective layer and the second protective layer is likely to be insufficient. Here, in the case of a decorative sheet, a design layer is typically formed on a base layer, then a second protective layer is formed on the design layer, and then a first protective layer is formed on the second protective layer. The first protective layer is typically formed by curing a composition for forming the first protective layer formed on the second protective layer, resulting in good adhesion between the first protective layer and the second protective layer. In contrast, in the case of a transfer sheet, the first protective layer is typically formed on a release film, then a second protective layer is formed on the first protective layer, and then a design layer is formed on the second protective layer. The first protective layer is typically formed by curing a composition for forming the first protective layer on a release film. Since the second protective layer is formed on the cured first protective layer, the adhesion between the first protective layer and the second protective layer is likely to be insufficient. In the present disclosure, the second protective layer is preferably a layer with higher flexibility than the first protective layer. This allows for increased adhesion between the first protective layer and the second protective layer. The second protective layer and the first protective layer may be disposed so as to be in direct contact with each other, or may be disposed with another layer interposed therebetween.

[0099] The second protective layer preferably contains a cured product (crosslinked structure) of a curable resin composition as a resin component. The proportion of the cured product of the curable resin composition relative to the total resin components constituting the second protective layer is, for example, 70% by mass or more, or may be 90% by mass or more, or 95% by mass or more, or may be 100% by mass.

[0100] Examples of the curable resin composition used in the second protective layer include thermosetting resin compositions. The thermosetting resin composition is a composition containing at least a thermosetting resin and is a composition that cures when heated. Examples of the thermosetting resin include (meth)acrylic resins, phenolic resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. The thermosetting resin composition preferably contains a urethane (meth)acrylic resin as the thermosetting resin. The thermosetting resin composition may further contain a curing agent such as an isocyanate curing agent or an epoxy curing agent. The curable resin composition used in the second protective layer may also be an ionizing radiation curable resin composition.

[0101] Furthermore, when the curable resin composition contains a urethane(meth)acrylic resin, the urethane(meth)acrylic resin is preferably a urethane(meth)acrylic copolymer, more preferably a polycarbonate-based urethane(meth)acrylic copolymer. The polycarbonate-based urethane(meth)acrylic copolymer is a resin obtained by radical polymerization of a (meth)acrylic monomer with a polycarbonate-based polyurethane polymer obtained by reacting a polycarbonate diol with a (di)isocyanate.

[0102] Examples of the (di)isocyanate include aromatic isocyanates such as 4,4'-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 1,5-naphthalene diisocyanate, n-isocyanate phenylsulfonyl isocyanate, o-isocyanate phenylsulfonyl isocyanate, and p-isocyanate phenylsulfonyl isocyanate; aliphatic isocyanates such as 1,6-hexamethylene diisocyanate; and alicyclic isocyanates such as isophorone diisocyanate, hydrogenated xylylene diisocyanate, and hydrogenated diphenylmethane diisocyanate.

[0103] Examples of the (meth)acrylic monomer include (meth)acrylic acid, alkyl (meth)acrylate esters such as methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, and isobutyl (meth)acrylate.

[0104] In the polycarbonate-based urethane (meth)acrylic copolymer, the mass ratio of the urethane component to the total of the (meth)acrylic component and the urethane component ([urethane component] / ([(meth)acrylic component]+[urethane component]) is, for example, 70% by mass or more and 95% by mass or less, alternatively 75% by mass or more and 95% by mass or less, or alternatively 80% by mass or more and 90% by mass or less.

[0105] The second protective layer preferably contains a weathering agent. In the present disclosure, when the transfer layer has a second protective layer, both the first protective layer and the second protective layer preferably contain a weathering agent. This makes it possible to impart high weathering resistance while maintaining the properties required for the first protective layer (e.g., surface properties such as scratch resistance) and the properties required for the second protective layer (e.g., adhesion).

[0106] Examples of weather-resistant agents include ultraviolet absorbers and light stabilizers. The second protective layer preferably contains at least one of an ultraviolet absorber and a light stabilizer. Preferred types and modes of weather-resistant agents are the same as those described for the first protective layer, and therefore will not be described here. In particular, the second protective layer preferably contains a triazine-based ultraviolet absorber. Furthermore, the second protective layer preferably contains a hindered amine-based light stabilizer.

[0107] The content of the ultraviolet absorber in the second protective layer is, for example, 0.1 parts by mass or more and 50 parts by mass or less, or may be 3 parts by mass or more and 40 parts by mass or less, or may be 10 parts by mass or more and 35 parts by mass or less, relative to 100 parts by mass of the resin component. Furthermore, the content of the ultraviolet absorber in the second protective layer (content relative to 100 parts by mass of the resin component) may be greater than the content of the ultraviolet absorber in the first protective layer (content relative to 100 parts by mass of the resin component).

[0108] The content of the light stabilizer in the second protective layer is, for example, 0.1 to 15 parts by mass, or alternatively 1 to 15 parts by mass, or alternatively 3 to 10 parts by mass, relative to 100 parts by mass of the resin component. The content of the light stabilizer in the second protective layer (per 100 parts by mass of the resin component) may be greater than the content of the light stabilizer in the first protective layer (per 100 parts by mass of the resin component).

[0109] The second protective layer may contain additives such as silicone compounds, polymerization inhibitors, crosslinking agents, antistatic agents, adhesion improvers, antioxidants, leveling agents, thixotropy-imparting agents, coupling agents, plasticizers, antifouling agents, antifoaming agents, and fillers. The thickness of the second protective layer is, for example, 2 μm to 10 μm, or 3 μm to 8 μm, or 3 μm to 5 μm. If the second protective layer is thin, adhesion (particularly initial adhesion) with the relatively hard first protective layer may be reduced. On the other hand, if the second protective layer is thick, the second protective layer may move more due to heat, making the first protective layer more susceptible to cracking.

[0110] (ii) Design Layer The transfer layer in the present disclosure may or may not have a design layer on the side of the first protective layer opposite the release film. By providing a design layer, the design of the article is improved. The design layer and the first protective layer may be arranged so as to be in direct contact with each other, or may be arranged via another layer (e.g., a second protective layer).

[0111] Examples of the design layer include a solid layer (a layer coated with ink) and a picture layer (a layer printed with ink). The transfer sheet may have, as the design layer, a picture layer and a solid layer in this order from the release film side. Examples of the picture (pattern) in the picture layer include wood grain patterns, stone grain patterns, sand grain patterns, tile patterns, brickwork patterns, fabric patterns, leather-striped patterns, geometric shapes, letters, symbols, abstract patterns, and floral patterns.

[0112] The design layer usually contains a colorant and a binder resin. Examples of the colorant include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments (including dyes) such as quinacridone red, isoindolinone yellow, nickel azo complex, phthalocyanine blue, and azomethine azo black; metal pigments such as aluminum and brass; and pearl pigments such as titanium dioxide-coated mica and basic lead carbonate.

[0113] Examples of binder resins include urethane-based resins, acrylic polyol-based resins, (meth)acrylic resins, ester-based resins, amide-based resins, butyral-based resins, styrene-based resins, urethane-acrylic copolymers, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-acrylic copolymers, chlorinated propylene-based resins, nitrocellulose-based resins, and cellulose acetate-based resins.

[0114] The design layer may contain additives such as ultraviolet absorbers, light stabilizers, curing agents, plasticizers, catalysts, etc. The thickness of the design layer is, for example, 0.5 μm to 20 μm, or may be 1 μm to 10 μm, or may be 2 μm to 5 μm.

[0115] (d) Transfer Layer The thickness of the transfer layer is, for example, 8 μm or more, or may be 10 μm or more, 12 μm or more, or 14 μm or more, while the thickness of the transfer layer is, for example, 50 μm or less, or may be 40 μm or less, or may be 30 μm or less.

[0116] (3) Transfer Sheet The method for producing the transfer sheet in the present disclosure is not particularly limited. For example, when producing the transfer sheet shown in FIG. 2( a), it is preferable to form a first protective layer 2 on one side of a release film 1, and then form an adhesive layer 3 on the side of the first protective layer 2 opposite the release film 1. When producing the transfer sheet shown in FIG. 2( b), it is preferable to form a first protective layer 2 on one side of a release film 1, then form a second protective layer 4 on the side of the first protective layer 2 opposite the release film 1, and then form an adhesive layer 3 on the side of the second protective layer 4 opposite the first protective layer 2. When producing the transfer sheet shown in FIG. 2( c), it is preferable to form a first protective layer 2 on one side of a release film 1, then form a design layer 5 on the side of the first protective layer 2 opposite the release film 1, and then form an adhesive layer 3 on the side of the design layer 5 opposite the first protective layer 2. Furthermore, when producing the transfer sheet shown in Figure 2 (d), it is preferable to form a first protective layer 2 on one side of a release film 1, then form a second protective layer 4 on the side of the first protective layer 2 opposite the release film 1, then form a design layer 5 on the side of the second protective layer 4 opposite the first protective layer 2, and then form an adhesive layer 3 on the side of the design layer 5 opposite the second protective layer 4.

[0117] The first protective layer can be formed, for example, by applying a composition for forming the first protective layer to the surface of a release film and then curing the composition. Examples of the composition application method include gravure printing, bar coating, roll coating, reverse roll coating, and comma coating. Examples of the curing method include irradiation with ionizing radiation such as electron beams and ultraviolet rays.

[0118] The second protective layer may be formed, for example, by applying a composition for forming the second protective layer to the surface of the first protective layer opposite the release film, and then curing the composition as needed. Examples of the composition application method include gravure printing, bar coating, roll coating, reverse roll coating, and comma coating. Examples of the curing method include heat.

[0119] The design layer may be formed, for example, by applying an ink containing a colorant, a binder resin, and a solvent to the surface of the second protective layer opposite to the first protective layer.

[0120] The adhesive layer may be formed, for example, by applying an adhesive composition or by laminating an adhesive film by dry lamination.

[0121] The transfer sheet in the present disclosure has a release film (first release film) and a transfer layer. The transfer sheet may have a second release film on the side of the transfer layer opposite the release film. For example, when the transfer sheet is produced by winding it into a roll, the occurrence of blocking can be suppressed. Details of the second release film are the same as those described above for the first release film, so description here is omitted.

[0122] 3. Adhesion Step This step is a step in which the adhesive layer side of the transfer sheet is placed opposite the surface of the metal member to which the transfer is to be made, and the two are brought into close contact under a reduced pressure atmosphere to obtain a laminate.

[0123] The adhesion process preferably includes a first process of wrapping the metal member in a cylindrical transfer sheet, or further wrapping the package in which the metal member is covered with the transfer sheet in a cylindrical bag, and a second process of evacuating the internal space of the cylindrical transfer sheet or cylindrical bag to create a reduced pressure atmosphere, thereby obtaining a laminate in which the metal member and the transfer sheet are adhered to each other.

[0124] (1) First Treatment Figures 4(a) and (b) are schematic diagrams illustrating the first treatment in the adhesion step. In the first treatment, for example, as shown in Figure 4(a), a cylindrical transfer sheet 10 is wrapped around a metal member 20. At this time, the surface of the transfer sheet 10 on the adhesive layer 3 side faces the surface to be transferred of the metal member 20. In other words, the transfer sheet 10 is cylindrically shaped so that the transfer layer 3 side of the transfer sheet 10 faces inward.

[0125] 4(b), in the first process, the package obtained by covering the metal member 20 with the transfer sheet 10 may be further wrapped in a tubular bag 40. One method for covering the metal member 20 with the transfer sheet 10 is to wrap the transfer sheet 10 around the metal member 20. In this case, the adhesive layer 3 side of the transfer sheet 10 faces the surface of the metal member 20 to be transferred. That is, the transfer layer side of the transfer sheet faces inward. The tubular bag 40 preferably contains an ester-based resin. This is because it has excellent heat resistance and can be easily peeled off after the heating process, described below, even after being exposed to a high-temperature environment for a long period of time. Examples of ester-based resins include polyethylene terephthalate (PET) and polyethylene naphthalate (PEN).

[0126] (2) Second Treatment In the second treatment, the internal space of the cylindrical transfer sheet or cylindrical bag is degassed to create a reduced pressure atmosphere, thereby obtaining a laminate in which the metal member and the transfer sheet are tightly adhered to each other. This allows the transfer sheet and the metal member to be tightly adhered to each other without any gaps, and the transfer sheet can be made to conform to the shape of the metal member. Degassing can be performed, for example, by vacuum suction or by manually removing the air. By sealing the cylindrical transfer sheet or bag after degassing, the internal space of the cylindrical transfer sheet or cylindrical bag can be made to be in a reduced pressure state. A reduced pressure state can be any state in which the pressure is lower than atmospheric pressure.

[0127] The first and second treatments are preferably carried out consecutively.

[0128] 4. Heating Step This step is a step of heating the laminate to bond the transfer sheet and the metal member. When the adhesive layer is a heat seal layer, the heat seal layer melts due to heat and exhibits adhesiveness.

[0129] The heating temperature is, for example, 150° C. or higher, and may be 180° C. or higher. On the other hand, the heating temperature is, for example, 200° C. or lower. The heating time is, for example, 30 seconds or longer and 30 minutes or shorter.

[0130] The adhesion step and the heating step are preferably carried out using a sublimation transfer device, which includes, for example, at least one of a pressure reducing device and a heating device.

[0131] 5. Peeling Step The method for manufacturing an article according to the present disclosure may include a peeling step of peeling the release film from the transfer layer after the heating step. On the other hand, the method for manufacturing an article according to the present disclosure does not necessarily include a peeling step. In this case, after the transfer sheet is adhered to the metal member, the release film functions as a protective film that protects the metal member and the transfer layer from external impact.

[0132] 5(a) and (b) are schematic cross-sectional views illustrating an example of an article manufactured by the method for manufacturing an article according to the present disclosure. As shown in FIG. 5(a), the article 100 has a metal member 20 and a transfer layer X. The transfer layer X is formed by transferring an adhesive layer 3 and a first protective layer 2 from the metal member 20 side in a thickness direction D. Ｔ The transfer layer X and the metal member 20 are in close contact with each other via the adhesive layer 3 of the transfer layer X. As shown in FIG. 5( b ), the article 100 of the present disclosure may also have a release film 1 on the side of the transfer layer X opposite to the metal member 20. In this case, the article 100 has the release film 1, the transfer layer X, and the metal member 20 arranged in the thickness direction D Ｔ In this order,

[0133] In the article of the present disclosure, the thickness of the adhesive layer of the transfer sheet falls within a predetermined range, thereby achieving good adhesion between the metal member and the transfer layer. In particular, the article exhibits good adhesion to the transfer surface of a metal member on which a crystalline coating has been formed by chemical conversion treatment. In the present disclosure, the loop stiffness of the release film in the transfer sheet falls within a predetermined range, thereby obtaining an article in which lifting of the transfer sheet at corners is suppressed. Furthermore, in the article of the present disclosure, the transfer layer includes a first protective layer, thereby achieving desired surface properties (e.g., weather resistance, solvent resistance, and scratch resistance).

[0134] The article in the present disclosure is used, for example, as a building material. The building material is used, for example, in buildings such as houses, offices, stores, hospitals, and clinics. The article may be an exterior product (an article for outdoor use) or an interior product (an article for indoor use). Specific examples of the article include exterior walls, roofs, soffits, louvers, door pockets, window frames, doors, door frames, handrails, fences, and clothes drying racks.

[0135] B. Transfer Sheet The present disclosure provides a transfer sheet for use in the above-described method for manufacturing an article, the transfer sheet having a release film and a transfer layer disposed on one side of the release film, the transfer layer having a first protective layer and an adhesive layer in this order in the thickness direction from the release film side. Figures 2(a) to 2(d) are schematic cross-sectional views illustrating examples of transfer sheets in the present disclosure. Figure 2 has been described in detail above in "A. Method for manufacturing an article," so its description is omitted here. The transfer sheet in the present disclosure is a sheet used in the manufacturing method described above in "A. Method for manufacturing an article."

[0136] According to the present disclosure, by carrying out the above manufacturing method using the above transfer sheet, an article can be obtained in which the metal member and the transfer layer have high adhesion, lifting of the transfer sheet at the corners is suppressed, and wrinkles are less likely to occur in the transfer sheet.

[0137] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and anything that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits similar effects is included within the technical scope of the present disclosure.

[0138] [Example 1] (Preparation of Transfer Sheet) A 25 μm thick polyethylene terephthalate film (Release film 1: Diafoil E130-26 (manufactured by Mitsubishi Chemical)) having a matting agent kneaded into it was prepared as a release film. The 60° gloss value of the surface (first surface) of release film 1 on which the transfer layer was to be disposed was 27%. The arithmetic mean height Sa of the first surface of release film 1 was 0.3 μm. The following composition for forming a first protective layer was coated on the first surface of release film 1 and dried. Thereafter, the composition was irradiated with 50 kGy of electron beams at an acceleration voltage of 165 kV, cured, and a 5 μm thick first protective layer was formed. <Composition for forming first protective layer (EB1)> Ionizing radiation curable resin composition: 100 parts by mass Caprolactone-based urethane acrylate (molecular weight: approximately 8,000): 30 parts by mass Isocyanuric acid EO-modified triacrylate (molecular weight: approximately 369): 70 parts by mass Triazine-based ultraviolet absorber: 3.5 parts by mass Light stabilizer: 3 parts by mass

[0139] Next, the following composition for forming a second protective layer was applied to the corona-irradiated surface of the first protective layer and dried to form a second protective layer with a thickness of 4 μm. <Composition for forming second protective layer> Polycarbonate-based urethane acrylic copolymer (urethane component / acrylic component=90 / 10 (mass ratio)): 100 parts by mass Hexamethylene diisocyanate-based curing agent: 6 parts by mass Triazine-based ultraviolet absorber: 35 parts by mass Light stabilizer: 3 parts by mass

[0140] Next, an ink for forming a pattern layer containing an acrylic polyol resin, a urethane resin, and an organic pigment was applied to the surface of the obtained second protective layer by gravure coating and dried to form a pattern layer. Next, an ink for forming a solid layer containing an acrylic polyol resin, a urethane resin, and an inorganic pigment was applied and dried to form a solid layer (undercoat hiding layer). This resulted in a design layer including the pattern layer and the solid layer.

[0141] Next, the following adhesive layer-forming composition was applied to the surface of the solid layer by gravure coating and dried to form an adhesive layer (heat seal layer) with a thickness of 2.4 μm. <Adhesive layer-forming composition> Mixture of vinyl chloride-vinyl acetate copolymer (Tg: about 65° C.) / acrylic resin (Tg: about 100° C.): 100 parts by mass (vinyl chloride-vinyl acetate copolymer / acrylic resin (mass ratio) = 60 / 40)

[0142] This resulted in a transfer sheet having a release film, a first protective layer, a second protective layer, a design layer (a picture layer and a solid layer), and an adhesive layer in this order in the thickness direction.

[0143] (Production of Articles) Aluminum bars were subjected to a Parkerizing treatment (chemical conversion treatment) as a surface treatment. Next, the transfer sheet was formed into a cylindrical shape with the transfer layer side of the transfer sheet facing inward, and the aluminum bars after the chemical conversion treatment were wrapped in the cylindrical transfer sheet (first adhesion step). Next, the space between the aluminum bars and the transfer sheet was evacuated to create a reduced pressure atmosphere, thereby tightly adhering the aluminum bars and the transfer sheet to obtain a laminate (second adhesion step). Next, the obtained laminate was heated under the conditions shown in Table 1 to bond the transfer sheet and the metal member (heating step). The adhesion step and heating step were performed using a sublimation transfer device. Next, the release film was peeled off from the transfer layer to obtain an article (peeling step).

[0144] [Example 2] (Preparation of transfer sheet) A polyethylene terephthalate film (release film 2) having a thickness shown in Table 1 and having a matting agent kneaded therein was prepared as a release film. A transfer sheet was prepared in the same manner as in Example 1, except for using this release film 2. (Production of article) An article was produced in the same manner as in Example 1, except for using the obtained transfer sheet.

[0145] [Example 3] (Preparation of transfer sheet) A transfer sheet was prepared in the same manner as in Example 2, except that the thickness of the adhesive layer (heat seal layer) was set to the thickness shown in Table 1. (Preparation of article) An article was prepared in the same manner as in Example 1, except that the obtained transfer sheet was used.

[0146] [Example 4] (Preparation of Transfer Sheet) A transfer sheet was prepared in the same manner as in Example 1. (Production of Article) An aluminum block was subjected to surface treatments, sequentially including anodizing and sanding. Next, the transfer sheet was formed into a cylindrical shape with the transfer layer side of the transfer sheet facing inward, and the aluminum block after sanding was wrapped in the cylindrical transfer sheet (first adhesion step). Next, the space between the aluminum block and the transfer sheet was evacuated to create a reduced pressure atmosphere, thereby tightly adhering the aluminum block and the transfer sheet to obtain a laminate (second adhesion step). Next, the obtained laminate was heated under the conditions shown in Table 1 to bond the transfer sheet and the metal member (heating step). The adhesion step and heating step were performed using a sublimation transfer device. Next, the release film was peeled off from the transfer layer to obtain an article (peeling step).

[0147] [Comparative Example 1] (Preparation of transfer sheet) A transfer sheet was prepared in the same manner as in Example 2, except that the thickness of the adhesive layer (heat seal layer) was set to the thickness shown in Table 1. (Production of article) An article was produced in the same manner as in Example 1, except that the obtained transfer sheet was used.

[0148] [Comparative Example 2] (Production of Transfer Sheet) A release film 3 (total thickness 46 μm) having a polyethylene terephthalate film (thickness 38 μm) and a matte layer (thickness 8 μm) was prepared as a release film. A transfer sheet was produced in the same manner as in Example 1, except that a first protective layer was formed on the surface of the matte layer side using release film 3. (Production of Article) An article was produced in the same manner as in Example 1, except that the obtained transfer sheet was used.

[0149] [Comparative Example 3] (Production of transfer sheet) A transfer sheet was produced in the same manner as in Example 1, except that a heat-resistant biaxially oriented polypropylene film (OPP film, release film 4) with a mirror surface and a thickness of 30 μm was used as the release film. (Production of article) An article was produced in the same manner as in Example 1, except that the obtained transfer sheet was used.

[0150] Comparative Example 4 (Sublimation Transfer Film) A sublimation transfer film having a 19 μm-thick polyethylene terephthalate film (matte PET film) and a colorant layer was prepared. (Production of an Article) An aluminum block was subjected to a Parkerizing treatment (chemical conversion treatment) as a surface treatment. A thermosetting polyester resin was sprayed onto the chemically converted aluminum block and baked at 180°C for 20 minutes to form a 60 μm-thick underlayer. The above-mentioned sublimation transfer film was formed into a cylindrical shape with the colorant layer facing inward, and the aluminum block was wrapped around it. Next, the space between the aluminum block and the sublimation transfer film was degassed and a reduced pressure was created to tightly adhere the aluminum block and the sublimation transfer film to obtain a laminate. The resulting laminate was then heated under the conditions shown in Table 1 to perform sublimation transfer. The PET film was then peeled off to obtain an article.

[0151] [Evaluation] (Maximum height Sz and arithmetic mean height Sa of aluminum bar surface) The maximum height Sz and arithmetic mean height Sa of the transferred surface of the surface-treated aluminum bar were measured in accordance with ISO25178-2 2012 using a shape analysis laser microscope "Keyence 3D shape measuring machine VK-X1000" under the following conditions, with 10 arbitrary locations on the transferred surface of the aluminum bar as the measurement area. The average value of each measurement value was calculated. [Measurement conditions] Brightness adjustment: Auto Magnification: 50x Field of view: 100 μm x 100 μm Focus: Auto Cutoff: λc = 0.8 Analysis software: VK-X1000 series multi-file analysis application (Keyence)

[0152] (Measurement of Thermal Shrinkage Ratio) The thermal shrinkage ratio of the release film in the transfer sheet used in each Example and Comparative Example was measured in accordance with JIS K7133:1999. First, the transfer layer was peeled off from the transfer sheet, leaving only the release film. The release film was cut to prepare a test piece measuring 150 mm in length (MD direction) x 150 mm in width (TD direction). A 100 mm straight line was formed in each of the longitudinal and transverse directions passing through the center of the sheet. This release film was heated at 200°C for 5 minutes, then rapidly cooled to room temperature (25°C), and the length of the straight line in the longitudinal direction (MD direction) and transverse direction (TD direction) was measured. The change in the length of the straight line in the longitudinal and transverse directions was calculated, and the percentage of the straight line length (100 mm) before heating was taken as the thermal shrinkage ratio. The results are shown in Table 1.

[0153] (Measurement of Loop Stiffness) The loop stiffness of the release film in the transfer sheet used in each Example and Comparative Example was measured. First, the transfer layer was peeled off from the transfer sheet, leaving only the release film. Next, the release film was cut into a strip shape with a width of 15 mm and a length of 150 mm to prepare a sample. Next, the sample was fixed to a "Loop Stiffness Tester (Model: DR)" manufactured by Toyo Seiki Seisaku-sho so that the loop length was 60 mm, and a pressure jig was pressed against it from the vertical direction to measure the stress during compression, and the maximum value of the stress was determined as the loop stiffness (RS).

[0154] (Flat Surface Adhesion) The adhesion between the transfer layer and the aluminum block on the flat surface of the articles obtained in each Example and Comparative Example was evaluated according to the cross-cut method specified in JIS K 5600-5-6:1999. The samples prepared in the Examples and Comparative Examples were stored for 24 hours at 23°C and 50% relative humidity. The flat surface was then cross-cut into a grid of 10 squares (10 vertical x 10 horizontal) = 100 squares (number of cuts: 11 in each direction of the grid pattern, cut interval: 1 mm) with the blade tip reaching from the transfer layer to the aluminum block. An adhesive tape (manufactured by Nichiban Co., Ltd., product name "Cellotape (registered trademark)") was applied to the cross-cut surface of the cross-cut sample, and a peel test was performed according to the cross-cut method specified in JIS K 5600-5-6:1999. Based on the results of the peel test, adhesion was evaluated according to the following evaluation criteria. Evaluation criteria AA: Classification 0 according to the cross-cut method of JIS K5600-5-6 (1999) A: Classification 1 according to the cross-cut method of JIS K5600-5-6 (1999) B: Classification 2 or 3 according to the cross-cut method of JIS K5600-5-6 (1999) C: Classification 4 or 5 according to the cross-cut method of JIS K5600-5-6 (1999)

[0155] (Corner lifting and wrinkles) The articles obtained in each example and comparative example were visually evaluated for corner lifting (lifting of the transfer sheet at the corners) and wrinkles according to the following evaluation criteria. - Evaluation criteria for corner lifting A: The transfer sheet completely conformed to the corners. B: The transfer sheet significantly lifted from the corners. - Evaluation criteria for wrinkles A: No wrinkles were visible on either the flat surface or the corners. B: Wrinkles were visible on either the flat surface or the corners.

[0156] (Weather resistance) Evaluation members obtained from the articles produced in Examples 1 to 4 and Comparative Example 4 were subjected to an accelerated weather resistance test using a metal halide lamp (MWOM) for 1000 hours (a test in which one cycle consisted of irradiating with ultraviolet light for 20 hours under the irradiation conditions below, followed by condensation for 4 hours under the condensation conditions below, and the cycle was repeated). After the accelerated weather resistance test, the appearance of the evaluation members was visually inspected and evaluated according to the following evaluation criteria. <Conditions for accelerated weather resistance test> Testing equipment: Daipla Wintes, product name "Daipla Metal Weather" Irradiation conditions: Illuminance: 65 mW / cm ２ Black panel temperature: 63°C, chamber humidity: 50% RH, time: 20 hours Condensation conditions Illuminance: 0 mW / cm ２ Humidity in the chamber: 98% RH, Time: 4 hours Evaluation criteria A: No change in either color or gloss B: Significant change in color or gloss

[0157] (Scratch Resistance) For the evaluation members obtained from the articles produced in Examples 1 to 4 and Comparative Example 4, a test was carried out on the transfer layer side using a pencil with a hardness of 2H in accordance with JIS K5600-5-4:1999, and the evaluation was carried out according to the following evaluation criteria: A: Neither dents nor exposed aluminum bars were visually observed. B: Neither dents nor exposed aluminum bars were visually observed.

[0158] (Solvent Resistance) The evaluation members obtained from the articles produced in Examples 1 to 4 and Comparative Example 4 were subjected to a solvent resistance test according to the following procedure. Absorbent cotton soaked in methyl ethyl ketone (MEK) was placed on a weight with a load of 1.5 kg (the installation area was 6.15 cm). ２ The transfer layer side was reciprocated 20 times at 400 mm / s, and the change in appearance before and after the test was observed. <Evaluation criteria> A: No change in appearance such as wrinkles, swelling, peeling, discoloration, or gloss. B: Change in appearance such as wrinkles, swelling, peeling, discoloration, or gloss.

[0159]

[0160] As shown in Table 1, the articles obtained in Examples 1 to 4 were all good in the evaluation results for flat surface adhesion, corner lifting, and wrinkles. Among them, the articles of Examples 1 to 3, in which the adhesive layer thickness was greater than the maximum height Sz of the transfer surface of the metal member, had particularly excellent flat surface adhesion. In contrast, the articles obtained in Comparative Examples 1 to 4 were insufficient in the evaluation results for flat surface adhesion, corner lifting, and wrinkles. In Comparative Example 1, the adhesive layer was too thin, resulting in poor flat surface adhesion. In Comparative Example 2, the loop stiffness of the release film was too high, resulting in corner lifting. In Comparative Example 3, the heat shrinkage rate of the release film was too high, resulting in wrinkles. In Comparative Example 4, the surface properties of the article were reduced because the article did not have a protective layer. Furthermore, scratch resistance was good due to the powder coating.

[0161] Thus, the present disclosure provides, for example, the following inventions.

[0162] [1] A method for manufacturing an article having a metal member, comprising: a metal member preparation step of preparing the metal member that has been surface-treated; a transfer sheet preparation step of preparing a transfer sheet having a release film and a transfer layer disposed on one side of the release film, the transfer layer having, from the release film side, a first protective layer and an adhesive layer in that order in the thickness direction; a bonding step of placing the adhesive layer side of the transfer sheet opposite a transfer surface of the metal member and closely adhering them together under a reduced pressure atmosphere to obtain a laminate; and a heating step of heating the laminate to bond the transfer sheet and the metal member, wherein the transfer sheet has a thickness of the adhesive layer of 1.5 μm or more, a heat shrinkage rate of the release film of 3.4% or less, and a loop stiffness of the release film of 35.0 mN / 15 mm or less. [2] The method for manufacturing an article according to [1], wherein the thickness of the adhesive layer is greater than a maximum height Sz of the transfer surface of the metal member. [3] The method for manufacturing an article according to [1] or [2], wherein the adhering step includes a first step of wrapping the metal member in the cylindrical transfer sheet, or further wrapping a package in which the metal member is covered with the transfer sheet, in a cylindrical bag, and a second step of evacuating the internal space of the cylindrical transfer sheet or the cylindrical bag to create a reduced pressure atmosphere and obtaining the laminate in which the metal member and the transfer sheet are adhered together, wherein in the first step, the surface of the transfer sheet on the adhesive layer side faces the surface to be transferred of the metal member. [4] The method for manufacturing an article according to any of [1] to [3], wherein the surface treatment is at least one of degreasing, cleaning, chemical conversion, anodizing, plating, and painting. [5] The method for manufacturing an article according to any of [1] to [4], wherein the method includes a peeling step of peeling the release film from the transfer layer after the heating step. [6] The method for manufacturing an article according to any of [1] to [5], wherein the adhering step and the heating step are performed using a sublimation transfer apparatus. [7] The method for manufacturing an article according to any one of [1] to [6], wherein the transfer sheet has a second protective layer between the first protective layer and the adhesive layer.[8] The method for manufacturing an article according to any one of [1] to [7], wherein the transfer sheet has a design layer between the first protective layer and the adhesive layer. [9] The method for manufacturing an article according to any one of [1] to [8], wherein the first protective layer in the transfer sheet comprises a cured product of an ionizing radiation curable resin composition.

[10] The method for manufacturing an article according to [7], wherein the second protective layer in the transfer sheet comprises a cured product of a thermosetting resin composition.

[11] The method for manufacturing an article according to any one of [1] to

[10] , wherein the first protective layer in the transfer sheet contains at least one of an ultraviolet absorber and a light stabilizer.

[12] The method for manufacturing an article according to [7] or

[10] , wherein the second protective layer in the transfer sheet contains at least one of an ultraviolet absorber and a light stabilizer.

[13] The method for manufacturing an article according to any one of [1] to

[12] , wherein the transfer sheet is used in the manufacture of an exterior product.

[14] A transfer sheet used in the method for manufacturing an article according to any one of [1] to

[13] , comprising a release film and a transfer layer disposed on one surface of the release film, the transfer layer having a first protective layer and an adhesive layer in this order in the thickness direction from the release film side.

[0163] DESCRIPTION OF SYMBOLS 1: Release film 2: First protective layer 3: Adhesive layer 10: Transfer sheet 20: Metal member 50: Laminate 100: Article

Claims

1. A method for manufacturing an article having a metal member, comprising: a metal member preparation step of preparing the metal member that has been surface-treated; a transfer sheet preparation step of preparing a transfer sheet having a release film and a transfer layer disposed on one side of the release film, the transfer layer having a first protective layer and an adhesive layer in that order in the thickness direction from the release film side; a bonding step of aligning the adhesive layer side of the transfer sheet against the surface of the metal member to be transferred and bringing them into close contact under a reduced pressure atmosphere to obtain a laminate; and a heating step of heating the laminate to bond the transfer sheet and the metal member, wherein the transfer sheet has an adhesive layer thickness of 1.5 μm or more, the release film has a thermal shrinkage rate of 3.4% or less, and the release film has a loop stiffness of 35.0 mN / 15 mm or less.

2. The method for manufacturing an article according to claim 1, wherein the thickness of the adhesive layer is greater than the maximum height Sz of the transfer surface of the metal member.

3. The method for manufacturing an article according to claim 1, wherein the adhesion step comprises a first step of wrapping the metal member in the cylindrical transfer sheet, or further wrapping the package in which the metal member is covered with the transfer sheet in a cylindrical bag, and a second step of evacuating the internal space of the cylindrical transfer sheet or the cylindrical bag to create a reduced pressure atmosphere and obtaining the laminate in which the metal member and the transfer sheet are adhered together, wherein in the first step, the surface of the transfer sheet on the adhesive layer side is placed opposite the surface to be transferred of the metal member.

4. The method for manufacturing an article according to claim 1, wherein the surface treatment is at least one of degreasing, cleaning, chemical conversion coating, anodizing, plating, and painting.

5. The method for producing an article according to claim 1, further comprising a peeling step of peeling the release film from the transfer layer after the heating step.

6. The method for manufacturing an article according to claim 1, wherein the adhesion step and the heating step are carried out using a sublimation transfer device.

7. The method for manufacturing an article according to claim 1, wherein the transfer sheet has a second protective layer between the first protective layer and the adhesive layer.

8. The method for manufacturing an article according to claim 1, wherein the transfer sheet has a design layer between the first protective layer and the adhesive layer.

9. The method for producing an article according to claim 1, wherein the first protective layer in the transfer sheet comprises a cured product of an ionizing radiation curable resin composition.

10. The method for manufacturing an article according to claim 7, wherein the second protective layer in the transfer sheet comprises a cured product of a thermosetting resin composition.

11. The method for manufacturing an article according to claim 1, wherein the first protective layer in the transfer sheet contains at least one of an ultraviolet absorber and a light stabilizer.

12. The method for manufacturing an article according to claim 7, wherein the second protective layer in the transfer sheet contains at least one of an ultraviolet absorber and a light stabilizer.

13. The method for manufacturing an article according to claim 1, wherein the transfer sheet is used in the manufacture of an exterior product.

14. A transfer sheet having a release film and a transfer layer arranged on one side of the release film, the transfer layer having a first protective layer and an adhesive layer in this order in the thickness direction from the release film side, and used in a method for manufacturing an article according to any one of claims 1 to 13.

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