Decorative sheet, decorative sheet assembly, and decorative moving body
A decorative sheet with structured irregular regions and controlled tensile stress minimizes shock lines and maintains glossiness, addressing the issues of partial peeling and surface appearance on moving bodies.
Patent Information
- Application Number
- PCT/JP2025/027630
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-08-02
- Filing Date
- 2025-08-04
- Publication Date
- 2026-02-05
AI Technical Summary
Decorative sheets used on moving bodies like automobiles often develop shock lines due to partial peeling, which reduces surface glossiness, and existing solutions to minimize these lines also diminish the glossiness.
A decorative sheet with a structured surface featuring regularly arranged irregular regions, including linear depressions and protrusions, is designed to minimize shock lines while maintaining surface glossiness, with specific tensile stress and peel strength properties.
The solution effectively suppresses shock lines and maintains glossiness by ensuring adequate adhesion and structural integrity, enhancing the aesthetic appeal of the decorative sheet.
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Figure JP2025027630_05022026_PF_FP_ABST
Abstract
Description
Decorative sheet, decorative sheet combination, and decorative mobile body
[0001] The present disclosure relates to a decorative sheet, a decorative sheet combination, and a decorative mobile body.
[0002] For example, as disclosed in JP2021-160220A, a decorative sheet is known that is used as an adherend for an exterior component of a moving body such as an automobile. The decorative sheet improves the design of the moving body.
[0003] A decorative sheet attached to an adherend is partially reattached due to various factors such as misalignment with the adherend. In a partially reattached decorative sheet, a linear depression occurs at the boundary between the peeled portion that has been peeled off from the adherend and the non-peeled portion that has not been peeled off from the adherend. When the linear depression is conspicuous, a defect in appearance called a shock line occurs in the decorative sheet.
[0004] To prevent the occurrence of shock lines, the surface of the decorative sheet is provided with an uneven surface. Even if the decorative sheet is partially reattached, the linear depressions at the boundary portions can be made less noticeable. However, the uneven surface reduces the glossiness of the surface of the decorative sheet.
[0005] An object of the present disclosure is to provide a decorative sheet that suppresses the occurrence of shock lines and the reduction in glossiness on the surface.
[0006] A decorative sheet according to an embodiment of the present disclosure has a first surface and a second surface opposite to the first surface, and is attached to an adherend from the second surface, and comprises, in this order from the first surface toward the second surface, a base layer and a bonding layer, the base layer containing a resin as a main component, a 3% strain tensile stress of 31 N / 10 mm or less, an initial peel strength from the adherend of 8 N / 25 mm or more and 28 N / 25 mm or less, the first surface having a plurality of regularly arranged irregular regions, each irregular region including a plurality of regularly arranged linear depressions and a plurality of linear protrusions, in each irregular region, a difference in height between adjacent linear depressions and linear protrusions of 5 μm or more, an area ratio of inclined portions on the first surface being 10.0% or more, a developed area ratio of the first surface being 0.06 or more, and an area of each irregular region being 1.5 mm. 2 Over 9.0 mm 2 or less, and the ratio of the height difference to the interval between two adjacent linear convex portions is 0.09 or more.
[0007] According to the present disclosure, the occurrence of shock lines and a decrease in glossiness on the surface of a decorative sheet can be suppressed.
[0008] FIG. 1 is a perspective view showing a decorative mobile body for explaining one embodiment. FIG. 2 is a cross-sectional view showing a rear edge portion of the roof of the decorative mobile body of FIG. 1. FIG. 3 is a plan view of a first surface of a decorative sheet included in the decorative mobile body of FIG. 1. FIG. 4 is a perspective view of a portion of the decorative sheet of FIG. 3. FIG. 5 is a perspective view of a portion of the decorative sheet of FIG. 3 different from the portion shown in FIG. 4. FIG. 6 is a cross-sectional view of the decorative sheet of FIG. 5. FIG. 7 is an enlarged grayscale image of the first surface of the decorative sheet of FIGS. 5 and 6. FIG. 8 is an image obtained by binarizing the enlarged image of FIG. 7 using Otsu's method. FIG. 9 is a diagram for explaining binarization using Otsu's method. FIG. 10 is a diagram for explaining a presumed mechanism of defect occurrence. FIG. 11 is a cross-sectional view showing a modified decorative sheet. FIG. 12 is a plan view of another modified decorative sheet.
[0009] An embodiment of the present disclosure relates to the following [1] to
[13] .
[0010] [1] A laminated sheet has a first surface and a second surface opposite to the first surface, and is attached to an adherend from the second surface, and includes a base layer and a bonding layer in this order from the first surface toward the second surface, the base layer contains a resin as a main component, the 3% strain tensile stress is 31 N / 10 mm or less, the initial peel force from the adherend is 8 N / 25 mm or more and 28 N / 25 mm or less, the first surface has a plurality of regularly arranged uneven regions, each uneven region includes a plurality of regularly arranged linear concave portions and a plurality of linear convex portions, in each uneven region, the difference in height between adjacent linear concave portions and linear convex portions is 5 μm or more, the area ratio of the inclined surfaces on the first surface is 10.0% or more, the developed area ratio of the first surface is 0.06 or more, and the area of each uneven region is 1.5 mm 2 Over 9.0 mm 2 or less, and the ratio of the height difference to the interval between two adjacent linear convex portions is 0.09 or more.
[0011] [2] The decorative sheet according to [1], wherein in at least one concave-convex region, the plurality of linear convex portions extend linearly.
[0012] [3] The decorative sheet according to [1] or [2], wherein in at least one concave-convex region, the plurality of linear convex portions extend radially within an angle range of 135° or less.
[0013] [4] The decorative sheet according to any one of [1] to [3], wherein in at least one concave-convex region, the plurality of linear convex portions extend circumferentially.
[0014] [5] The decorative sheet according to any one of [1] to [4], further comprising a transparent resin layer superimposed on the base material layer, the base material layer being positioned between the transparent resin layer and the bonding layer.
[0015] [6] The decorative sheet according to any one of [1] to [5], further comprising a decorative layer superimposed on the base layer, the base layer being positioned between the decorative layer and the bonding layer.
[0016] [7] The decorative sheet according to any one of [1] to [6], further comprising a protective layer that is overlaid on the base material layer and that constitutes the first surface.
[0017] [8] A decorative sheet according to any one of [1] to [7], which is attached to an exterior member of an automobile.
[0018] [9] A decorative sheet combination comprising: a decorative sheet according to any one of [1] to [8]; and a separator superimposed on the second surface side of the decorative sheet.
[0019]
[10] A decorated mobile body comprising: a mobile body; and a decorative sheet according to any one of [1] to [8] superimposed on the mobile body.
[0020]
[11] The decorated mobile body according to
[10] , wherein the mobile body includes an exterior member that forms an outer surface, and the decorative sheet is attached to the exterior member.
[0021]
[12] The decorated mobile body according to
[10] or
[11] , wherein the exterior member has a curved surface, and the decorative sheet is attached along the curved surface.
[0022]
[13] The decorated mobile body according to any one of
[10] to
[12] , wherein a first portion of the decorative sheet attached to the end portion of the exterior member is bent relative to a portion other than the first portion.
[0023] An embodiment of the present disclosure will now be described with reference to the drawings. In the drawings accompanying this specification, the scale and aspect ratios have been appropriately changed and exaggerated from those of the actual objects for the sake of ease of illustration and understanding.
[0024] In this specification, terms that specify shapes, geometric conditions, and their degrees, such as "parallel," "orthogonal," and "identical," as well as values of lengths and angles, are not limited to their strict meanings, but are interpreted to include a range within which similar functions can be expected.
[0025] In this specification, terms such as "sheet," "film," and "plate" are not distinguished from one another solely on the basis of differences in name. For example, a "decorative sheet" cannot be distinguished from a member called a decorative film or a decorative plate solely on the basis of differences in name.
[0026] In the present specification, when multiple upper limit candidates and multiple lower limit candidate values are listed for a certain parameter, the numerical range of the parameter may be constructed by combining any one upper limit candidate with any one lower limit candidate. As an example, consider the following statement: "Parameter B may be A1 or more, A2 or more, or A3 or more. Parameter B may be A4 or less, A5 or less, or A6 or less." In this example, the numerical range of parameter B may be A1 or more and A4 or less, A1 or more and A5 or less, A1 or more and A6 or less, A2 or more and A4 or less, A2 or more and A5 or less, A2 or more and A6 or less, A3 or more and A4 or less, A3 or more and A5 or less, or A3 or more and A6 or less.
[0027] To clarify the relationship between directions between the drawings, common directions are indicated in several drawings by arrows with common symbols. In each direction, the tip of the arrow is the first side. In each direction, the side opposite to the tip of the arrow is the second side. An arrow pointing into the paper in a direction perpendicular to the paper surface of the drawing is indicated by a symbol with an X in a circle, as shown in FIG. 6, for example. An arrow pointing toward the front of the paper in a direction perpendicular to the paper surface of the drawing is indicated by a symbol with a dot in a circle, as shown in FIG. 3, for example.
[0028] 1 to 6 are diagrams illustrating one embodiment. FIG. 1 is a perspective view showing a decorated mobile body 110. The decorated mobile body 110 includes a mobile body 100 and a decorative sheet 10 attached to the mobile body 100. The decorative sheet 10 is attached to an adherend AB included in the mobile body 100. The adherend AB includes an adherend surface ABM to which the decorative sheet 10 is attached. A decorative member 60 may be formed by the decorative sheet 10 and the adherend AB.
[0029] The adherend AB may be made of a metal such as iron, steel, or aluminum. The adherend AB may contain a resin such as an acrylonitrile-butadiene-styrene copolymer synthetic resin (ABS resin), an acrylonitrile-ethylene-propylene-diene-styrene copolymer synthetic resin (AES resin), or a polyolefin resin. The polyolefin resin may contain one or more of polypropylene and polyethylene.
[0030] The adherend surface ABM of the adherend AB may be painted. The adherend surface ABM of the painted adherend AB may contain a thermoplastic resin such as acrylic. The adherend surface ABM of the painted adherend AB may contain a cured resin. The cured resin may be a cured product of a thermosetting resin composition. The thermosetting resin may contain a water-affinity polyol such as an acrylic polyol, a polyester polyol, a polyether polyol, or an epoxy polyol. The thermosetting resin compound may contain a polyisocyanate compound. The polyisocyanate compound may have an isocyanurate bond or a urethane bond.
[0031] As shown in Fig. 6, the decorative sheet 10 includes a first surface 10a and a second surface 10b opposite the first surface 10a. The first surface 10a may constitute the outer surface of the decorative sheet 10. The decorative sheet 10 can be observed from the first surface 10a. The decorative sheet 10 can be attached to an adherend AB from the second surface 10b. The decorative sheet 10 includes, from the first surface 10a to the second surface 10b, a base layer 11 and a bonding layer 12. The bonding layer 12 constitutes the second surface 10b.
[0032] The mobile body 100 is a mobile device or equipment. Examples of the mobile body 100 include automobiles, motorcycles, bicycles, tricycles, trains, airplanes, ships, snowmobiles, industrial robots, drones, etc. Below, one embodiment will be described using an example in which the decorative sheet 10 is applied to an automobile 1, particularly a passenger car. In addition to passenger cars, examples of the automobile 1 include trucks, buses, taxis, ambulances, fire engines, police vehicles, construction vehicles, etc.
[0033] In the example shown in FIG. 1 , the automobile 1 includes a plurality of exterior members 50. The exterior members 50 form the outer surface of the automobile 1. The exterior members 50 can serve as adherends AB. The automobile 1 may also include a plurality of decorative members 60. In the example shown in the figure, the automobile 1 includes, as the exterior members 50, a roof 51, a hood 52, fenders 53, bumpers 54, mirrors 55, doors 56, pillars 57, sills 58, and a trunk lid 59. In the example shown in FIG. 1 , the decorative sheet 10 is attached to the roof 51 of the exterior members 50 of the automobile 1. The roof 51 serves as an adherend AB for the decorative sheet 10. The decorative sheet 10 may also be attached to an exterior member 50 other than the roof 51.
[0034] The decorative sheet 10 displays the design of the object to which the decorative sheet 10 is applied. The decorative sheet 10 improves the design of the moving body 100. The decorative sheet 10 may display a design such as a color or a geometric pattern. The decorative sheet 10 may display a metallic or leather-like texture. The decorative sheet 10 may have a matte texture.
[0035] The exterior member 50 may include a portion having a flat shape. The exterior member 50 may include a portion having a curved shape. In the example shown in FIG. 1 , the roof 51 has a flat shape in the central portion in the front-to-rear direction. The roof 51 has a curved shape in the leading edge portion. The leading edge portion of the roof 51 is curved downward more than the central portion of the roof 51. The decorative sheet 10 is attached to this curved shape of the roof 51. The decorative sheet 10 extends flat in the first portion 10X attached to the central portion of the roof 51. The decorative sheet 10 is curved downward more than the first portion 10X in the second portion 10Y attached to the leading edge portion of the roof 51.
[0036] The terms "front," "rear," "up," "down," and "front-rear direction" of the automobile 1 refer to the "front," "rear," "up," "down," and "front-rear direction" relative to a person sitting in the driver's seat of the automobile 1. In Fig. 1, the front-rear direction is the direction connecting the bottom left and top right of the page.
[0037] The decorative sheet 10 may be folded in a portion that is attached to an end portion of the exterior member 50. In the example shown in Figs. 1 and 2, the decorative sheet 10 is folded downward at a third portion 10Z that is attached to the rear edge portion of the roof 51. The third portion 10Z is located between the roof 51 and the trunk lid 59 in the front-to-rear direction. According to this specific example, the entire portion that constitutes the outer surface of the exterior member 50 can be covered with the decorative sheet 10.
[0038] Note that, when a certain portion of the decorative sheet 10 is "folded," it means that the certain portion is folded at an angle θ greater than 45° relative to a portion of the decorative sheet 10 connected to the certain portion. The certain portion may be folded at an angle θ greater than or equal to 90° relative to the portion of the decorative sheet 10 connected to the certain portion. In the example shown in FIG. 2 , the third portion 10Z of the decorative sheet 10 is folded from the state shown by the dashed line in the figure so as to form an angle θ of 90° relative to the first portion 10X connected to the third portion 10Z. The decorative sheet 10 may be folded multiple times at the portion that is attached to the edge of the adherend AB.
[0039] 3 and 4 includes a base material layer 11 and a bonding layer 12 that overlap in a stacking direction LD. In other words, the stacking direction LD is the direction in which the base material layer 11 and the bonding layer 12 overlap. The decorative sheet 10 shown in Fig. 3 is a sheet that extends in a plane perpendicular to the stacking direction LD.
[0040] The decorative sheet 10 shown in Fig. 4 includes a first surface 10a and a second surface 10b opposite the first surface 10a. The illustrated first surface 10a and second surface 10b are spaced apart from each other in the stacking direction LD. The decorative sheet 10 includes, in this order from the first surface 10a to the second surface 10b, a base layer 11 and a bonding layer 12. The bonding layer 12 forms the second surface 10b of the decorative sheet 10.
[0041] 4, the decorative sheet 10 may include layers other than the base layer 11 and the bonding layer 12. The illustrated decorative sheet 10 includes, from the first surface 10a to the second surface 10b, a protective layer 14, a transparent resin layer 13, a decorative layer 15, the base layer 11, and the bonding layer 12, in this order. The first surface 10a of the illustrated decorative sheet 10 is formed by the protective layer 14. The second surface 10b of the decorative sheet 10 is formed by the bonding layer 12.
[0042] <Base Material Layer> The base material layer 11 may contain a resin as a main component. The main component refers to the component with the largest content. The content of the main component may be 50% by mass or more, 60% by mass or more, 70% by mass or more, 80% by mass or more, or 90% by mass or more.
[0043] Examples of resins contained in the base layer 11 include vinyl chloride resins such as polyvinyl chloride (PVC), pentachlorinated polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, vinyl chloride-ethylene copolymer, vinyl chloride-propylene copolymer, vinyl chloride-styrene copolymer, vinyl chloride-isobutylene copolymer, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-styrene-maleic anhydride terpolymer, vinyl chloride-alkyl, cycloalkyl or aryl maleimide copolymer, vinyl chloride-styrene-acrylonitrile copolymer, vinyl chloride-butadiene copolymer, vinyl chloride-isoprene copolymer, vinyl chloride-chlorinated propylene copolymer, vinyl chloride-vinylidene chloride-vinyl acetate terpolymer, vinyl chloride-acrylic acid ester copolymer, vinyl chloride-maleic acid ester copolymer, vinyl chloride-methacrylic acid ester copolymer, vinyl chloride-acrylonitrile copolymer, and vinyl chloride-urethane copolymer. As the material for the base layer 11, one type of resin may be used alone from the multiple resins described above, or two or more types of resins may be used. When two or more types of resins selected from the above-described resins are used as the material for the base layer 11, the base layer 11 may be configured as a single layer containing a mixture of the two or more types of resins, or may be configured as multiple layers. The base layer 11 configured as multiple layers may be produced by, for example, co-extrusion.
[0044] The base layer 11 may further contain a plasticizer in addition to the resin. The plasticizer imparts flexibility to the resin contained in the base layer 11. The 3% strain tensile stress of the decorative sheet 10 may be adjusted depending on the content of the plasticizer contained in the base layer 11. Examples of plasticizers include ester-based plasticizers, polyester-based plasticizers, epoxy-based plasticizers, and phosphate ester-based plasticizers. The plasticizer may be contained in an amount of 31 parts by mass or more, 35 parts by mass or more, or 39 parts by mass or more per 100 parts by mass of the resin. The plasticizer in the base layer 11 may be contained in an amount of 55 parts by mass or less, 50 parts by mass or less, or 45 parts by mass or less per 100 parts by mass of the resin.
[0045] The base layer 11 may contain a coloring material. The base layer 11 is colored by using the coloring material. Such a decorative sheet 10 has design properties in the colored base layer 11. The coloring material may contain one or more of a pigment and a dye.
[0046] In the base layer 11, the colorant may be a dye, a pigment, or a combination of a dye and a pigment. Considering weather resistance and the like, the colorant is preferably a pigment. The pigment may be a colored pigment or a fluorescent pigment. The colored pigment may be, for example, an organic pigment such as a quinacridone pigment (e.g., quinacridone red), an azo pigment (e.g., pigment red), a phthalocyanine pigment (e.g., phthalocyanine blue, phthalocyanine green), or a perylene pigment (e.g., perylene red), or an inorganic pigment such as titanium oxide or carbon black. The color of the colorant may be a chromatic color or an achromatic color. The luster material reflects light. The luster material may be, for example, aluminum flake, mica, or a pearl pigment.
[0047] <Bonding Layer> In the example shown in Fig. 4, the bonding layer 12 is superimposed on the base material layer 11 from the second side in the stacking direction LD. The bonding layer 12 constitutes the second surface 10b of the decorative sheet 10. In the example shown in Fig. 4, the bonding layer 12 is sheet-shaped. The thickness of the sheet-shaped bonding layer 12 may be 20 µm or more, or 30 µm or more. The thickness of the sheet-shaped bonding layer 12 may be 120 µm or less, or 100 µm or less. The thickness of the sheet-shaped bonding layer 12 may be 20 µm or more and 120 µm or less, 30 µm or more and 120 µm or less, 20 µm or more and 100 µm or less, or 30 µm or more and 100 µm or less.
[0048] The bonding layer 12 comes into contact with the adherend AB when the decorative sheet 10 is attached to the adherend AB from the second surface 10b. The bonding layer 12 maintains the decorative sheet 10 attached to the adherend AB.
[0049] The bonding layer 12 shown in FIG. 4 exhibits adhesive properties and is bonded to other components by applying pressure. The bonding layer 12 exhibits appropriate adhesive properties and has a thickness that prevents the decorative sheet 10 from becoming too thick. The bonding layer 12 may be made from an adhesive composition. The adhesive composition contains an adhesive such as an acrylic resin, a urethane resin, a silicone resin, or rubber. The adhesive composition may also contain a curing agent to promote curing of the adhesive in addition to the adhesive. To prevent the decorative sheet 10 from unintentionally adhering to other components, the bonding layer 12 may be covered with a peelable separator (not shown) before bonding the decorative sheet 10 to the adherend AB.
[0050] 4, the transparent resin layer 13 is superposed on the base material layer 11 from the first side in the stacking direction LD. The transparent resin layer 13 is located between the protective layer 14 and the base material layer 11 in the stacking direction LD.
[0051] The transparent resin layer 13 has various functions. The transparent resin layer 13 may have a function of improving the chemical resistance of the decorative sheet 10. The transparent resin layer 13 may have a function of improving the weather resistance of the decorative sheet 10.
[0052] The transparent resin layer 13 is transparent. The base material layer 11 may be observable from the outside through the transparent resin layer 13. Note that "transparent" means that the visible light transmittance is 60% or more, and preferably 80% or more. The visible light transmittance is the average value of the transmittance at each wavelength when measured at an incident angle of 0° in 1 nm increments within a wavelength range of 380 nm to 780 nm using a spectrophotometer ("UV-3100PC" manufactured by Shimadzu Corporation).
[0053] The transparent resin layer 13 includes a resin. Resins are preferred because they are lightweight and easy to manufacture. The resin used for the transparent resin layer 13 may be an olefin-based resin such as polyethylene (low density, medium density, or high density), polypropylene (PP), polymethylpentene, or polybutene. The resin used for the transparent resin layer 13 may be a resin containing a polyolefin such as an ethylene-vinyl acetate copolymer or an ethylene-acrylic acid copolymer. The resin used for the transparent resin layer 13 may be a vinyl-based resin such as polyvinyl chloride (PVC), polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymer, or ethylene-vinyl alcohol copolymer. The resin used for the transparent resin layer 13 may be a thermoplastic resin such as polyester, acrylonitrile-butadiene-styrene copolymer (ABS), or polyvinyl chloride (PVC). The resin used for the transparent resin layer 13 may be an ester-based resin such as polyethylene terephthalate (PET), polyethylene naphthalate, or polybutylene terephthalate (PBT). The resin used for the transparent resin layer 13 may be a urethane-based resin. The resin used for the transparent resin layer 13 may be an acrylic resin such as polymethyl(meth)acrylate or polyethyl(meth)acrylate. The resin used for the transparent resin layer 13 may be a styrene resin such as polystyrene, a polyamide resin such as nylon 6 or nylon 66, or a cellulose resin such as triacetyl cellulose. Further examples of the resin used for the transparent resin layer 13 include resins such as polycarbonate, polyimide resins, and cycloolefin resins obtained from cycloolefins such as norbornene and dicyclopentadiene.
[0054] The resin used for the transparent resin layer 13 may be a polyethylene-based resin. The polyethylene-based resin used for the transparent resin layer 13 may be a homopolymer of ethylene, i.e., polyethylene, or may be a copolymer of ethylene and another comonomer copolymerizable with ethylene (for example, an α-olefin such as propylene, 1-butene, 1-hexene, or 1-octene, vinyl acetate, or vinyl alcohol). Examples of polyethylene include high-density polyethylene (HDPE), medium-density polyethylene (MDPE), and low-density polyethylene (LDPE), as well as linear low-density polyethylene (LLDPE), very low-density polyethylene (VLDPE), ultra-high molecular weight polyethylene (UHMWPE), and cross-linked polyethylene (PEX).
[0055] The resin used in the transparent resin layer 13 may be a polypropylene resin. The polypropylene-based resin used in the transparent resin layer 13 may be a homopolymer of propylene, i.e., polypropylene, or a copolymer of propylene and another comonomer copolymerizable with propylene (for example, an α-olefin such as ethylene, 1-butene, 1-hexene, or 1-octene; vinyl acetate, vinyl alcohol, or the like).
[0056] The transparent resin layer 13 may contain only one of the above-mentioned resins, or may contain two or more of the above-mentioned resins.
[0057] The transparent resin layer 13 may be composed of multiple layers. The transparent resin layer 13 composed of multiple layers may include a layer containing an acrylic resin such as polymethyl(meth)acrylate (PMMA) or polyethyl(meth)acrylate (PEMA), and a layer containing a fluororesin such as polyvinylidene fluoride (PVDF). In the transparent resin layer 13 composed of multiple layers, the layer containing the acrylic resin may be superimposed on the base material layer 11. The transparent resin layer 13 composed of multiple layers may be produced by co-extrusion.
[0058] The transparent resin layer 13 may contain a colorant. By containing a colorant, the transparent resin layer 13 is colored to a desired color. The colored transparent resin layer 13 can improve the design displayed by the decorative sheet 10. The colorant may contain one or more of a pigment and a dye.
[0059] 4, the protective layer 14 is superposed on the transparent resin layer 13 from the first side in the stacking direction LD. The protective layer 14 constitutes the first surface 10a of the decorative sheet 10. The protective layer 14 protects the other layers of the decorative sheet 10. The protective layer 14 may improve the scratch resistance of the first surface 10a of the decorative sheet 10.
[0060] 4 to 6 is a thin film. The thickness of the protective layer 14 may be, for example, 0.1 μm or more, 0.5 μm or more, 20 μm or less, or 10 μm or less. The thickness of the protective layer 14 may be 0.1 μm or more and 20 μm or less, 0.5 μm or more and 20 μm or less, 0.1 μm or more and 10 μm or less, or 0.5 μm or more and 10 μm or less.
[0061] The illustrated protective layer 14 is transparent. The protective layer 14 may include a cured resin. The cured resin is a cured product of a curable resin composition. The curable resin composition may be a thermosetting resin composition. The curable resin composition may be an ionizing radiation curable resin composition. The curable resin composition may be an ultraviolet curable resin composition. The protective layer 14 may include a cured product of a thermosetting resin composition and a cured product of an ionizing radiation curable resin composition. The cured product of the curable resin composition can improve the scratch resistance of the first surface 10a of the decorative sheet 10. The ionizing radiation curable resin composition is particularly useful from the viewpoint of improving scratch resistance.
[0062] The thermosetting resin composition contains a thermosetting resin. A thermosetting resin is a resin that hardens when heated. The thermosetting resin is not particularly limited. Examples of thermosetting resins include phenolic resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, unsaturated polyester resins, polyurethane resins, epoxy resins, aminoalkyd resins, melamine-urea co-condensation resins, and silicone resins. The thermosetting resin composition may contain one or more of these thermosetting resins.
[0063] The ionizing radiation-curable resin composition contains a compound having an ionizing radiation-curable functional group. Hereinafter, the compound having an ionizing radiation-curable functional group is also referred to as an "ionizing radiation-curable resin." Examples of the ionizing radiation-curable functional group include ethylenically unsaturated bond groups such as (meth)acryloyl groups, vinyl groups, and allyl groups, as well as epoxy groups and oxetanyl groups.
[0064] The material forming the protective layer 14 may be the material for the surface protective layer described in Japanese Patent No. 5476903. The ionizing radiation curable resin forming the protective layer 14 may be, for example, a mixture of polycarbonate (meth)acrylate and a polyfunctional (meth)acrylate. In this case, from the viewpoint of improving scratch resistance and moldability, the mass ratio of the polycarbonate (meth)acrylate to the polyfunctional (meth)acrylate is preferably 95:5 to 80:20.
[0065] Ionizing radiation refers to electromagnetic waves or charged particle beams having energy quanta capable of polymerizing or crosslinking molecules. Electromagnetic waves may be X-rays or gamma rays. Charged particle beams may be alpha rays or ion beams. Ionizing radiation may be ultraviolet (UV) rays or electron beams (EB).
[0066] When an ultraviolet-curable resin composition is used as the ionizing radiation-curable resin composition, it is desirable to add about 0.1 to 5 parts by mass of a photopolymerization initiator per 100 parts by mass of the ultraviolet-curable resin. The photopolymerization initiator is not particularly limited, and known initiators can be used. The photopolymerization initiator may be, for example, the photopolymerization initiator described in Japanese Patent No. 5,476,903. Furthermore, the photosensitizer may be, for example, the photosensitizer described in Japanese Patent No. 5,476,903.
[0067] <Decorative Layer> In the example shown in FIG. 4 , the decorative layer 15 is located between the transparent resin layer 13 and the base layer 11 in the stacking direction LD. The decorative layer 15 forms a design displayed by the decorative sheet 10. The design formed by the decorative layer 15 may be monochromatic. The material of the decorative layer 15 is not particularly limited. The decorative layer 15 may include, for example, a binder resin and at least one of a colorant and a luster material. In this case, the decorative layer 15 forms the design using the colorant and / or the luster material. The thickness of the decorative layer 15 may be, for example, 0.1 μm or more and 50 μm or less, or 0.1 μm or more and 20 μm or less.
[0068] The binder resin may contain a colorant and a luster material. The binder resin may be, for example, a urethane resin, an acrylic polyol resin, an acrylic resin, an ester resin, an amide resin, a butyral resin, a styrene resin, a urethane-acrylic copolymer, a vinyl chloride-vinyl acetate copolymer resin, a vinyl chloride-vinyl acetate-acrylic copolymer resin, a chlorinated propylene resin, a nitrocellulose resin, or a cellulose acetate resin.
[0069] In the decorative layer 15, the colorant may be a dye, a pigment, or a combination of a dye and a pigment. Considering weather resistance, etc., the colorant is preferably a pigment. The pigment may be a colored pigment or a fluorescent pigment. The colored pigment may be, for example, an organic pigment such as a quinacridone pigment (e.g., quinacridone red), an azo pigment (e.g., pigment red), a phthalocyanine pigment (e.g., phthalocyanine blue, phthalocyanine green), or a perylene pigment (e.g., perylene red), or an inorganic pigment such as titanium oxide or carbon black. The color of the colorant may be a chromatic color or an achromatic color. The luster material reflects light. The luster material may be, for example, aluminum flake, mica, or a pearl pigment.
[0070] The decorative layer 15 may be a pattern layer that displays a pattern. The decorative layer 15 may be a metal layer that contains metal. The metal layer may be a metallic layer. The decorative layer 15 may include both a pattern layer and a metal layer.
[0071] The picture layer may display figures, patterns, designs, colors, pictures, photographs, characters, marks, pictograms, letters, numbers, etc. The picture layer may also display a design that displays a background.
[0072] The metal layer may contain one or more metal elements such as gold, silver, copper, tin, iron, nickel, chromium, cobalt, and indium. The metal layer may contain an alloy such as brass, bronze, or stainless steel. The thickness of the metal layer may be 0.03 μm or more and 1 μm or less.
[0073] The decorative sheet 10 has a certain degree of flexibility so that it can stably adhere to substrates AB having various shapes. From this perspective, an upper limit may be set for the 3% strain tensile stress of the decorative sheet 10. The 3% strain tensile stress of the decorative sheet 10 may be 31 N / 10 mm or less, 30 N / 10 mm or less, or 27 N / 10 mm or less. The "3% strain tensile stress" of the decorative sheet refers to the stress when the strain of the decorative sheet reaches 3%. Therefore, the lower the 3% strain tensile stress, the higher the flexibility of the decorative sheet 10. From the perspective of ensuring strength, a lower limit may be set for the 3% strain tensile stress of the decorative sheet 10. The 3% strain tensile stress of the decorative sheet 10 may be 20 N / 10 mm or more. The 3% strain tensile stress of the decorative sheet 10 may be 20 N / 10 mm or more and 31 N / 10 mm or less, 20 N / 10 mm or more and 30 N / 10 mm or less, or 20 N / 10 mm or more and 27 N / 10 mm or less.
[0074] The "3% strain tensile stress" of the decorative sheet 10 is measured as follows using a decorative sheet sample having a length of 120 mm in one direction and a length of 10 mm in a direction perpendicular to the one direction. First, both ends of the sample in the longitudinal direction are clamped between chucks so that the chuck distance is 100 mm. Next, the clamped sample is pulled at a pulling rate of 200 mm / min at 25°C, and the stress is measured when the sample strain reaches 3%. This stress is measured for five samples to obtain five measured values. The 3% strain tensile stress of the decorative sheet 10 is determined as the average of three measured values excluding the largest and smallest measured values among the five measured values. The 3% strain tensile stress of the decorative sheet 10 is measured in accordance with JIS K 7161:1994 under conditions other than those described above.
[0075] A lower limit may be set for the initial peel strength of the decorative sheet 10 from the adherend AB. The initial peel strength of the decorative sheet 10 from the adherend AB may be 8 N / 25 mm or more, 17 N / 25 mm or more, 20 N / 25 mm or more, or 23 N / 25 mm or more. By setting a lower limit for the initial peel strength of the decorative sheet 10 from the adherend AB, sufficient adhesion can be ensured between the decorative sheet 10 and the adherend AB. By ensuring sufficient adhesion between the decorative sheet 10 and the adherend AB, unintentional peeling of the decorative sheet 10 from the adherend AB can be suppressed.
[0076] An upper limit may be set for the initial peel strength of the decorative sheet 10 from the adherend AB. The initial peel strength of the decorative sheet 10 from the adherend AB may be 28 N / 25 mm or less, or may be 26 N / 25 mm or less. By setting an upper limit for the initial peel strength of the decorative sheet 10 from the adherend AB, the occurrence of shock lines, which will be described later, can be suppressed.
[0077] Therefore, the initial peel strength of the decorative sheet 10 from the adherend AB may be 8 N / 25 mm or more and 28 N / 25 mm or less, 17 N / 25 mm or more and 28 N / 25 mm or less, or 20 N / 25 mm or more and 28 N / 25 mm or less. The initial peel strength of the decorative sheet 10 from the adherend AB may be 8 N / 25 mm or more and 26 N / 25 mm or less, 17 N / 25 mm or more and 26 N / 25 mm or less, or 20 N / 25 mm or more and 26 N / 25 mm or less.
[0078] The "initial peeling force" of the decorative sheet 10 from the adherend AB means the strength of the force required to peel the decorative sheet 10 immediately after it has been attached to the adherend AB.
[0079] The initial peel force of the decorative sheet 10 from the adherend A and B is measured as follows. First, a sample of the decorative sheet (first sample) and a sample of the adherend (second sample) are prepared. The first sample has a length of 100 mm in one direction (X direction) and a length of 25 mm in a direction perpendicular to the first direction (Y direction). The second sample has a length of 100 mm or more in one direction (Z direction) and a length of 25 mm or more in a direction perpendicular to the first direction (W direction).
[0080] Next, the first sample is attached from the second side to the attachment surface ABM of the second sample. The first sample is attached to the second sample so that the X direction and the Z direction are approximately parallel. The first sample is attached to a portion of the second sample other than the portion that is clamped by a chuck, which will be described later. The portion of the first sample attached to the second sample has a length of 40 mm in the X direction. The portion of the first sample attached to the second sample includes one end in the X direction. When attaching the first sample to the second sample, the first sample is pressed against the second sample with a load of 1 kilogram force (kgf) using a plate-shaped squeegee (XE1032 33-6045, manufactured by KLASS Co., Ltd.).
[0081] Next, within one minute after the first sample is attached to the second sample, a 180-degree peel strength test is performed as follows. The end of the second sample in the Z direction is clamped in one chuck. The portion of the first sample that is not attached to the second sample is folded back 180 degrees relative to the portion of the first sample that is attached to the second sample. A 24 mm wide cellophane tape (CT405AP-24, manufactured by Nichiban Co., Ltd.) is attached to the folded back portion of the first sample, and this cellophane tape is clamped in the other chuck. The first sample in this state is pulled at a pulling rate of 200 mm / min under a condition of 25°C, and the average stress is measured from 10 mm to 30 mm of the length of the first sample peeled from the second sample. This average stress is measured for five samples to obtain five measured values.
[0082] The initial peel strength of the decorative sheet 10 from the adherend A and B is determined as the average of three of the five measured values excluding the largest and smallest measured values. The initial peel strength of the decorative sheet 10 from the adherend A and B is measured in accordance with JIS Z 0237:2009 under conditions other than those mentioned above.
[0083] The decorative sheet 10 having the layer structure described above may include a repeating unit 20X on the first surface 10a, as shown in Fig. 3. The repeating unit 20X in Fig. 3 includes a plurality of regularly arranged concave-convex regions 20. The decorative sheet 10 may display a design such as a geometric pattern on the first surface 10a using the plurality of repeating units 20X, as shown in Fig. 3.
[0084] As shown in Fig. 3, multiple repeating units 20X may be arranged at intervals on the first surface 10a. As shown in Fig. 3, the first surface 10a may include intermediate convex portions between the multiple repeating units 20X. Alternatively, unlike Fig. 3, the first surface 10a may include intermediate concave portions between the multiple repeating units 20X.
[0085] 3 are arranged at intervals in a first arrangement direction DR1. Each of the concave-convex regions 20 is connected to another of the concave-convex regions 20 in a second arrangement direction DR2 that is perpendicular to the first arrangement direction DR1.
[0086] Each of the concave-convex regions 20 shown in Fig. 3 includes a plurality of linear recesses 21 and a plurality of linear protrusions 22 that are regularly arranged. In the concave-convex region 20, the plurality of linear recesses 21 are arranged without crossing each other. In the concave-convex region 20, the plurality of linear protrusions 22 are arranged without crossing each other. In the concave-convex region 20, the linear recesses 21 and the linear protrusions 22 are arranged alternately. Fig. 4 is a perspective view of a portion of the concave-convex region 20 in Fig. 3. One linear recess 21 and two linear protrusions 22 are shown in the portion of the concave-convex region 20 shown in Fig. 4.
[0087] The linear depressions 21 and linear protrusions 22 on the first surface 10a are identified by observing the first surface 10a using a laser microscope as follows. An image acquired by a laser microscope capable of acquiring information regarding height is used to observe the first surface 10a. The image of the first surface 10a has dimensions of 4 mm square. The image of the first surface 10a includes information regarding the height of the first surface 10a. The image of the first surface 10a is acquired as an image having different colors depending on the height. As an example, the color of the image changes in the following order as the height of the first surface 10a decreases: red, orange, yellow, green, blue, and indigo. The height of the reference plane is calculated by calculating the average height of all pixels constituting the image of the first surface 10a. The reference plane is a plane perpendicular to the stacking direction LD and having the acquired average height. The linear depressions 21 are identified as portions that extend linearly in the image of the first surface 10a and are lower than the reference plane. The linear convex portion 22 is identified as a portion that extends linearly in the image of the first surface 10a and is higher than the reference surface.
[0088] When each linear recess 21 is viewed in plan, i.e., when observed from the stacking direction LD, the longest dimension in a direction non-parallel to the stacking direction LD may be 3.0 times or more, 5.0 times or more, or 10 times or more of the shortest dimension in a direction non-parallel to the stacking direction LD. There is no particular upper limit on the ratio of the longest dimension of each linear recess 21 in plan view to the shortest dimension. When each linear recess 21 is viewed in plan, the longest dimension in a direction non-parallel to the stacking direction LD may be 1,000 times or less, or may be 500 times or less, of the shortest dimension in a direction non-parallel to the stacking direction LD.
[0089] When each linear protrusion 22 is viewed in plan, i.e., when observed from the stacking direction LD, the longest dimension in a direction non-parallel to the stacking direction LD may be 3.0 times or more, 5.0 times or more, or 10 times or more of the shortest dimension in a direction non-parallel to the stacking direction LD. There is no particular upper limit on the ratio of the longest dimension of the linear protrusion 22 in plan view to the shortest dimension. When each linear recess 21 is viewed in plan, the longest dimension in a direction non-parallel to the stacking direction LD may be 1000 times or less, or 500 times or less, of the shortest dimension in a direction non-parallel to the stacking direction LD. When each linear protrusion 22 is viewed in plan, the longest dimension in a direction non-parallel to the stacking direction LD may be 3.0 times or more and 1000 times or less, 5.0 times or more and 1000 times or less, of the shortest dimension in a direction non-parallel to the stacking direction LD. When each linear protrusion 22 is viewed in a plane, the longest dimension in a direction non-parallel to the stacking direction LD may be 3.0 times or more and 500 times or less, 5.0 times or more and 500 times or less, or 10 times or more and 500 times or less, of the shortest dimension in a direction non-parallel to the stacking direction LD.
[0090] 3 is a first uneven region 20A or a second uneven region 20B having different shapes. In the illustrated decorative sheet 10, the first uneven region 20A and the second uneven region 20B form a repeating unit 20X. A plurality of repeating units 20X are two-dimensionally arranged on the first surface 10a of the illustrated decorative sheet 10.
[0091] The phrase "two-dimensionally arranged" of the multiple repeating units 20X means that the multiple repeating units 20X are dispersed in two or more directions that are non-parallel to each other and perpendicular to the stacking direction LD of the decorative sheet 10. The multiple repeating units 20X shown in Fig. 3 are two-dimensionally arranged in a first arrangement direction DR1 and a second arrangement direction DR2.
[0092] The arrangement of the multiple linear recesses 21 and the arrangement of the multiple linear protrusions 22 shown in Figure 3 are symmetrical to each other between the first uneven region 20A and the second uneven region 20B, with a line parallel to the first arrangement direction DR1 as the boundary.
[0093] In the first concave-convex region 20A and the second concave-convex region 20B shown in FIG. 3, the regularly arranged linear convex portions 22 each extend linearly.
[0094] 3, the plurality of regularly arranged linear protrusions 22 extend radially without intersecting with each other. The distance between a certain linear protrusion 22 and another linear protrusion 22 adjacent to the certain linear protrusion 22 varies depending on the position of the certain linear protrusion 22 in the linear extension direction.
[0095] In each uneven region 20, the linear protrusions 22 may extend radially within an angular range of 10° or greater, or within an angular range of 20° or greater. The linear protrusions 22 may extend radially within an angular range of 30° or greater, or within an angular range of 45° or greater. Furthermore, as shown in FIG. 3 , the linear protrusions 22 may extend radially within an angular range greater than 90°. They may also extend radially within an angular range of 120° or greater. In the first uneven region 20A, the linear protrusions 22 extend radially within a first angular range AR1 between the A direction DA and the B direction DB perpendicular to the stacking direction LD. In the second uneven region 20B, the linear protrusions 22 extend radially within a second angular range AR2 between the A direction DA and the C direction DC perpendicular to the stacking direction LD.
[0096] An upper limit may be set for the angular range of the plurality of radially extending linear protrusions 22 in each uneven region 20. As shown in Fig. 3, in each uneven region 20, the plurality of linear protrusions 22 may extend radially within an angular range of 135° or less.
[0097] The first surface 10a shown in FIG. 4 includes an inclined portion 31. The inclined portion 31 is a surface inclined with respect to a reference plane perpendicular to the stacking direction LD. In FIG. 3, the inclined portion 31 is indicated by a black line. The inclined portion 31 shown in FIG. 4 constitutes a part of the linear recess 21. The inclined portion 31 constitutes a part of the linear protrusion 22. The inclined portion 31 is a portion whose inclination angle with respect to the reference plane is equal to or greater than a predetermined threshold. The inclination angle is the angle between the normal direction of the reference plane and the normal direction of the inclined portion 31 of the first surface 10a. The inclination angle is an angle greater than 0° and less than 90°. The threshold is determined by binarization processing of an image of the first surface 10a, as described below.
[0098] After extensive research, the present inventors have found that the configuration of the uneven region 20 and the configuration of the linear recesses 21 and linear protrusions 22 in the uneven region 20 affect not only the design expressed by the decorative sheet 10 but also the shock lines and glossiness described below. According to the results of the research by the present inventors, as demonstrated in the examples described below, the developed area ratio of the first surface 10a, the height difference between adjacent linear recesses 21 and linear protrusions 22, the area ratio of the inclined portions 31, and the area of the uneven region 20 affect the shock lines. Furthermore, according to the results of the research by the present inventors, as demonstrated in the examples described below, the area of the uneven region 20 and the ratio of the height difference to the spacing between adjacent linear protrusions 22 affect the glossiness of the first surface 10a.
[0099] In order to suppress the occurrence of shock lines and the decrease in glossiness, the developed area ratio of the first surface 10a, the height difference between adjacent linear depressions 21 and linear protrusions 22, the area ratio of the inclined portion 31, the area of the uneven region 20, and the ratio of the height difference to the distance between adjacent linear protrusions 22 may be adjusted as described below.
[0100] Below, mainly referring to Figures 5 and 6, the developed area ratio of the first surface 10a, the height difference between adjacent linear depressions 21 and linear protrusions 22, the ratio of the height difference to the spacing between adjacent linear protrusions 22, the area of the uneven region 20, and the area ratio of the inclined portion 31 will be explained.
[0101] 5 and 6 show perspective views of the decorative sheet 10 in a position different from that shown in FIG. 4. The illustrated linear recesses 21 and linear protrusions 22 are each arranged in a first direction D1. The linear recesses 21 and linear protrusions 22 each extend in a second direction D2 perpendicular to the first direction D1. In the illustrated decorative sheet 10, the stacking direction LD is parallel to a third direction D3. The third direction D3 is perpendicular to both the first direction D1 and the second direction D2.
[0102] 5 and 6, the first linear recesses 211 and the second linear recesses 212 are arranged in this order from the second side to the first side in the first direction D1. The first linear protrusions 221, the second linear protrusions 222, and the third linear protrusions 223 are arranged in this order from the second side to the first side in the first direction D1. The linear recesses 21 and the linear protrusions 22 are adjacent to each other in the first direction D1.
[0103] <Developed area ratio of first surface> The "developed area ratio" used for the first surface 10a of the decorative sheet 10 means the developed interface area ratio of the contoured curved surface as defined in JIS B 0681-2:2018. The developed interface area ratio of the contoured curved surface is the ratio of the difference between the area of the interface of the contoured curved surface and the area of the reference area to the area of a reference area. On the first surface 10a of the decorative sheet 10, the area of the reference area means the area of the first surface 10a projected onto a plane perpendicular to the stacking direction LD of the decorative sheet 10. On the first surface 10a of the decorative sheet 10, the area of the interface of the contoured curved surface means the surface area of the first surface 10a.
[0104] The developed area ratio of the first surface 10a is determined by measuring a 4 mm square measurement area of the first surface 10a using a laser microscope (Keyence Corporation, VK-X150) with a 20x objective lens. The developed area ratio of the first surface 10a is determined from five measured values of the developed area ratio obtained by measuring five different measurement areas. The developed area ratio of the first surface 10a is determined as the average value of three of the five measured values, excluding the largest and smallest measured values.
[0105] Setting a lower limit for the developed area ratio of the first surface 10a can prevent flattening of the first surface 10a and suppress the occurrence of shock lines. The developed area ratio of the first surface 10a may be 0.06 or more, 0.20 or more, 0.30 or more, 0.40 or more, 0.55 or more, 0.70 or more, or 1.0 or more. No upper limit for the developed area ratio of the first surface 10a is particularly set from the viewpoint of suppressing the occurrence of shock lines. The developed area ratio of the first surface 10a may be 1.5 or less. The developed area ratio of the first surface 10a may be 0.06 or more and 1.5 or less, 0.20 or more and 1.5 or less, 0.30 or more and 1.5 or less, 0.40 or more and 1.5 or less, 0.55 or more and 1.5 or less, 0.70 or more and 1.5 or less, or 1.0 or more and 1.5 or less.
[0106] 5 and 6 , adjacent linear recesses 21 and linear protrusions 22 have a height difference H. Fig. 6 shows the height difference HA between the first linear recess 211 and the first linear protrusion 221 adjacent to each other in the first direction D1, the height difference HB between the first linear recess 211 and the second linear protrusion 222 adjacent to each other in the first direction D1, the height difference HC between the second linear protrusion 222 and the second linear recess 212 adjacent to each other in the first direction D1, and the height difference HD between the second linear recess 212 and the third linear protrusion 223 adjacent to each other in the first direction D1.
[0107] When the "difference in height between adjacent linear recesses 21 and linear protrusions 22" on the first surface 10a is large, the occurrence of shock lines can be suppressed. From the viewpoint of suppressing the occurrence of shock lines, a lower limit of the "difference in height between adjacent linear recesses 21 and linear protrusions 22" on the first surface 10a may be set. The difference in height H between the linear recesses 21 and linear protrusions 22 may be 5 μm or more, 7 μm or more, 18 μm or more, or 30 μm or more. The upper limit of the "difference in height between adjacent linear recesses 21 and linear protrusions 22" on the first surface 10a is not particularly set from the viewpoint of shock lines and glossiness. The difference in height H between adjacent linear recesses 21 and linear protrusions 22 may be 60 μm or less. The height difference H between adjacent linear recesses 21 and linear protrusions 22 may be 5 μm or more and 60 μm or less, 7 μm or more and 60 μm or less, 18 μm or more and 60 μm or less, or 30 μm or more and 60 μm or less.
[0108] The "height difference between adjacent linear depressions 21 and linear protrusions 22" on the first surface 10a of the decorative sheet 10 is measured as follows. The laser microscope used to identify the linear depressions 21 and linear protrusions 22 is used for the measurement. The first surface 10a is observed in plan view at 10x magnification using this laser microscope, and a 4 mm square measurement area on the first surface 10a is obtained. In one measurement area, a linear protrusion 22 including a point with the maximum height is identified. The maximum height difference between the linear protrusion 22 and the linear depression 21 adjacent to the linear protrusion 22 is measured. The above laser microscope is also used to identify the linear protrusion 22 including the point with the maximum height and to measure the maximum height difference.
[0109] The "height difference between adjacent linear depressions 21 and linear protrusions 22" on the first surface 10a of the decorative sheet 10 is determined from five measurement values relating to the above-mentioned maximum height difference measured in each of five different measurement regions. When the linear depressions 21 and linear protrusions 22 constitute a plurality of repeating units 20X arranged two-dimensionally, at least one of the above-mentioned five measurement regions allows observation of one entire repeating unit 20X on the first surface 10a. The "height difference between adjacent linear depressions 21 and linear protrusions 22" on the first surface 10a of the decorative sheet 10 is determined as the average of three measurement values excluding the largest and smallest measurement values among the five measurement values.
[0110] <Spacing Between Adjacent Linear Convexities> The laser microscope used to identify the linear depression 21 and the linear convexity 22 is used to measure the spacing between two adjacent linear convexities 22. The first surface 10a is observed in plan view at 10x magnification using this laser microscope, and a 4 mm square measurement area on the first surface 10a is obtained. In one measurement area, a linear convexity 22 (reference linear convexity) including the point of maximum height is identified. Next, a cross-sectional curve (primary profile) of the first surface 10a is obtained, including the reference linear convexity and other linear convexities 22 adjacent to the reference linear convexity. The linear depression 21 is a valley recessed from the reference surface on the cross-sectional curve. The linear convexity 22 is a peak protruding from the reference surface on the cross-sectional curve. When the reference linear protrusion is adjacent to multiple other linear protrusions 22, the cross-sectional curve of the first surface 10a includes all of the other linear protrusions 22. On the cross-sectional curve of the first surface 10a, the distance (separation distance) between the highest point of the reference linear protrusion and the highest point of the linear protrusion 22 adjacent to the reference linear protrusion is measured. Multiple separation distances are measured from the multiple cross-sectional curves. The multiple cross-sectional curves are selected so that the separation distances are small. The smallest value of the multiple separation distances is taken as the measured value of the distance between two adjacent linear protrusions 22. The distance between two adjacent linear protrusions 22 is determined from the above-mentioned five measurement values measured in each of five different measurement regions. The distance between two adjacent linear protrusions 22 is determined as the average value of three measurement values excluding the largest and smallest measurement values among the five measurement values.
[0111] 1 to 6, a lower limit is set for the ratio of the height difference between adjacent linear recesses 21 and linear protrusions 22 to the spacing between two adjacent linear protrusions 22. Hereinafter, the "ratio of the height difference between adjacent linear recesses 21 and linear protrusions 22 to the spacing between two adjacent linear protrusions 22" is also referred to as the aspect ratio of the linear recesses 21. From the viewpoint of suppressing a decrease in gloss on the first surface 10a of the decorative sheet 10, the aspect ratio of the linear recesses 21 is set to 0.09 or more. The aspect ratio of the linear recesses 21 may be 0.12 or more, 0.17 or more, 0.29 or more, or 0.40 or less. Therefore, the aspect ratio of the linear recess 21 may be 0.09 or more and 0.40 or less, 0.12 or more and 0.40 or less, 0.17 or more and 0.40 or less, or 0.29 or more and 0.40 or less.
[0112] <Area of the Concave and Convex Regions 20> A numerical range is set for the area of each concave and convex region 20 when the first surface 10a of the illustrated decorative sheet 10 is observed from the stacking direction LD. By setting an upper limit value for the area of each concave and convex region 20, it is possible to suppress the occurrence of shock lines, as will be described later. The area of each concave and convex region 20 is 9.0 mm 2 It may be less than 6.0 mm 2 It may be less than 5.0 mm 2 By setting a lower limit for the area of each of the concave-convex regions 20, it is possible to suppress a decrease in glossiness on the first surface 10a, as will be described later. 2 It may be 2.0 mm or more. 2 It may be 3.0 mm or more. 2 It may be 5.0 mm or more. 2 Therefore, the area of each concave and convex region 20 is 1.5 mm 2 Over 9.0 mm 2 It may be less than 2.0 mm 2 Over 9.0 mm 2 It may be less than 3.0 mm 2 Over 9.0 mm 2 It may be less than 5.0 mm 2 Over 9.0 mm 2 The area of each concave and convex region 20 may be 1.5 mm2 Over 6.0 mm 2 It may be less than 2.0 mm 2 Over 6.0 mm 2 It may be less than 3.0 mm 2 Over 6.0 mm 2 It may be less than 5.0 mm 2 Over 6.0 mm 2 The area of each concave and convex region 20 may be 1.5 mm 2 Over 5.0 mm 2 It may be less than 2.0 mm 2 Over 5.0 mm 2 It may be less than 3.0 mm 2 Over 5.0 mm 2 The following is also acceptable.
[0113] The area of the uneven region 20 is specified using an image of the first surface 10a and a laser microscope, which are used to specify the linear depressions 21 and linear protrusions 22. The image of the first surface 10a includes at least one uneven region 20. The area of each of the linear depressions 21 and linear protrusions 22 is calculated from the image of the first surface 10a using a laser microscope. The area of the uneven region 20 is specified as the sum of the calculated areas of the linear depressions 21 and linear protrusions 22. When each uneven region 20 of the decorative sheet 10 is equal to or less than the above-mentioned upper limit, it means that the maximum area of the five different uneven regions 20 of the decorative sheet 10 is equal to or less than the above-mentioned upper limit. When each uneven region 20 of the decorative sheet 10 is equal to or greater than the above-mentioned lower limit, it means that the minimum area of the five different uneven regions 20 of the decorative sheet 10 is equal to or greater than the above-mentioned lower limit.
[0114] <Area Proportion of Inclined Portion 31> The area proportion of the inclined portion 31 on the first surface 10a is an index relating to the proportion of the area of the inclined portion 31 to the area of the first surface 10a. More precisely, it is the proportion of the area of the inclined portion 31 projected onto a plane perpendicular to the direction in which the first surface 10a and the second surface 10b face each other to the area of the projection of the first surface 10a onto the plane. The inclined portion 31 is a portion that is significantly inclined with respect to the first surface 10a. More specifically, the inclined portion 31 is a portion whose inclination angle exceeds a predetermined threshold. The inclination angle is the angle between the direction in which the first surface 10a and the second surface 10b face each other and the normal direction of the target portion. The inclination angle is greater than 0° and less than 90°. As described below, the threshold is determined based on a binarization process performed on an image captured of the first surface 10a.
[0115] As the area ratio of the inclined portions 31 on the first surface 10a increases, the region in which the inclined portions 31 are dispersed becomes wider. As the area ratio of the inclined portions 31 on the first surface 10a increases, the occurrence of shock lines can be suppressed. From the viewpoint of suppressing the occurrence of shock lines, a lower limit of the area ratio of the inclined portions 31 on the first surface 10a may be set. The area ratio of the inclined portions 31 on the first surface 10a may be 10.0% or more, 13.0% or more, 25.0% or more, 30.0% or more, 39.0% or more, 50.0% or more, or 58.0% or more. From the viewpoint of suppressing the occurrence of shock lines, no upper limit is particularly set for the area ratio of the inclined portions 31 on the first surface 10a. The area ratio of the inclined portions 31 on the first surface 10a may be 90.0% or less, 80.0% or less, 70.0% or less, or 60.0% or less. The area ratio of the inclined portion 31 on the first surface 10a may be 10.0% to 90.0%, 13.0% to 90.0%, 25.0% to 90.0%, 30.0% to 90.0%, 39.0% to 90.0%, 50.0% to 90.0%, or 58.0% to 90.0%. The area ratio of the inclined portion 31 on the first surface 10a may be 10.0% to 80.0%, 13.0% to 80.0%, 25.0% to 80.0%, 30.0% to 80.0%, 39.0% to 80.0%, 50.0% to 80.0%, or 58.0% to 80.0%. The area ratio of the inclined portion 31 on the first surface 10a may be 10.0% to 70.0% or less, 13.0% to 70.0% or less, 25.0% to 70.0% or less, 30.0% to 70.0% or less, 39.0% to 70.0% or less, 50.0% to 70.0% or less, or 58.0% to 70.0%. The area ratio of the inclined portion 31 on the first surface 10a may be 10.0% to 90.0% or less, 13.0% to 60.0% or less, 25.0% to 60.0% or less, 30.0% to 60.0% or less, 39.0% to 60.0% or less, 50.0% to 60.0% or less, or 58.0% to 60.0%.
[0116] The area ratio of the inclined portion 31 on the first surface 10a is determined as follows. First, a laser microscope (VK-X150, manufactured by Keyence Corporation) is used to obtain an image of a 4 mm square measurement area on the first surface 10a to be measured. The measurement area on the first surface 10a to be measured is imaged from the direction in which the first surface 10a and the second surface 10b face each other, that is, from the third direction D3 in the illustrated example. The image is enlarged by 400 times.
[0117] Next, the image acquired by the laser microscope is converted into a grayscale image with 256 gradations using image processing software "Image J." Fig. 7 shows an example of a grayscale image with 256 gradations. Fig. 7 is an image of the decorative sheet 10 shown in Figs. 5 and 6. In the image shown, the gradation value is smallest for black and largest for white.
[0118] The intensity of light reflected from each portion of the first surface 10a depends on the tilt angle of that portion. Therefore, as the tilt angle increases or decreases, the gradation value in the grayscale image displaying that portion also increases or decreases. When parallel or diffused light is incident on the first surface 10a primarily from the third direction D3 along which the first surface 10a and the second surface 10b face each other, the intensity of light reflected from portions of the first surface 10a with large tilt angles decreases, and the intensity of light reflected from portions of the first surface 10a with small tilt angles increases. Therefore, in the grayscale image shown in FIG. 7 , the gradation value decreases in portions of the first surface 10a with large tilt angles and increases in portions of the first surface 10a with small tilt angles. In the grayscale image of the first surface 10a, portions of the first surface 10a with large tilt angles appear darker than portions of the first surface 10a with large tilt angles.
[0119] Next, the grayscale image is binarized using the image processing software "ImageJ." The binarization using the image processing software "ImageJ" is performed using the Otsu method. FIG. 8 shows an example of an image obtained after the binarization of the grayscale image shown in FIG. 7. As will be described in detail later, a threshold value for the inclination angle of the first surface 10a is determined by the binarization. The planar region of the first surface 10a to be measured is divided into a region with a large inclination angle and a region with a small inclination angle based on the threshold value for the inclination angle of the first surface 10a. The inclination angle of the region with a large inclination angle is equal to or less than the threshold. The inclination angle of the region with a small inclination angle is greater than the threshold. Therefore, in the binarized image, the region with a large inclination angle of the first surface 10a is displayed in black, as shown in FIG. 8. The region with a small inclination angle of the first surface 10a is displayed in white, as shown in FIG. 8. The inclined portion 31 is identified as a portion displayed in black in the binarized image.
[0120] Next, the image processing software "Image J" is used to calculate the proportion of the inclined portion 31 in the region to be measured. The area proportion of the inclined portion 31 is determined from five calculated values related to the proportion of the inclined portion 31 calculated in each of five different measurement regions. When the linear recesses 21 and linear protrusions 22 constitute a plurality of repeating units 20X arranged two-dimensionally, the center of gravity of any one repeating unit 20X on the first surface 10a is located in the center of at least one of the five measurement regions. The area proportion of the inclined portion 31 is determined as the average of three calculated values excluding the largest and smallest calculated values out of the five calculated values.
[0121] Here, the threshold value for the tilt angle is specified as the tilt angle corresponding to the threshold value t for the gradation value in the binarization process of a grayscale image using Otsu's method. The threshold value t for the gradation value is specified as follows using a histogram of the gradation values of a grayscale image, as disclosed in, for example, JP2011-22945A. FIG. 9 shows an example of this histogram. In FIG. 9, the horizontal axis represents the gradation value. The gradation value is smallest for black and largest for white. In the illustrated histogram, the maximum gradation value is 255. The vertical axis represents the frequency, i.e., the number of pixels having the gradation value shown on the horizontal axis.
[0122] Consider the case where the histogram shown in Fig. 9 is divided into two classes using a certain gradation value as a threshold. In the example shown, the histogram is divided into a first class and a second class. The mean value m 2 is the mean value m in the first class 1 In the histogram divided into two classes, the number of pixels included in each class is n 1 , n 2 , the total number of pixels contained in the entire histogram is n, and the variance of each class is S 1 2 , S 2 2 As the within-class variance S w 2 is calculated by the following formula (i). In addition, the mean value of the entire histogram is m, and the inter-class variance S b 2 is calculated by the following formula (ii).
[0123] In the binarization of grayscale images by Otsu's method, the inter-class variance S calculated by Equation (ii) is b 2 The within-class variance S calculated by equation (i) for w 2The gradation value at which the ratio is minimum is defined as the threshold value t. In the histogram shown in Figure 9, pixels having gradation values below the threshold t are binarized to black. Pixels having gradation values equal to or greater than the threshold t are binarized to white.
[0124] 5 , a sheet-like separator 45 is superimposed on the second surface 10b side of the decorative sheet 10. The separator 45 covers the bonding layer 12 from the second side in the third direction D3. The bonding layer 12 is located between the base material layer 11 and the separator 45 in the third direction D3. The decorative sheet 10 and the separator 45 may form a decorative sheet combination 40.
[0125] The separator 45 prevents the decorative sheet 10 from being unintentionally attached. The separator 45 is peeled off from the decorative sheet combination 40 when the decorative sheet 10 is attached to the adherend AB.
[0126] Paper such as fine paper or kraft paper may be used as the material of the separator 45. Resin may be used as the material of the separator 45. Examples of resins that can be used for the separator 45 include at least one selected from various resins, such as polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), olefin resins such as polyethylene (PE) and polypropylene (PP), vinyl resins such as acrylonitrile-butadiene-styrene copolymer (ABS), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyvinyl alcohol (PVA), ethylene-vinyl acetate copolymer (EVA), and ethylene-vinyl alcohol copolymer (EVOH), acrylic resins such as polymethyl (meth)acrylate (PMMA) and polyethyl (meth)acrylate (PEMA), fluororesins such as polyvinylidene fluoride (PVDF), amide resins such as nylon 6 and nylon 66, and modified resins of these resins. Examples of modified resins include fluorine-modified acrylic resins such as fluorine-containing polymethyl(meth)acrylate and fluorine-containing polyethyl(meth)acrylate. Separator 45 may contain one type of resin alone or two or more types of resins selected from these resins.
[0127] An example of a method for manufacturing the illustrated decorative sheet 10 will now be described.
[0128] A sheet constituting the base layer 11 is prepared. The thickness of the sheet constituting the base layer 11 may be 100 μm or more and 200 μm or less. An ink constituting the decorative layer 15 is applied to one side of this sheet. The decorative layer 15 is formed by drying the ink. Next, a sheet constituting the transparent resin layer 13 is laminated on the decorative layer 15. The thickness of the sheet constituting the transparent resin layer 13 may be 30 μm or more, or 40 μm or more. The thickness of the sheet constituting the transparent resin layer 13 may be 100 μm or less, or 90 μm or less. The sheet constituting the transparent resin layer 13 may be laminated on the sheet constituting the base layer 11 by thermal lamination. In this way, a laminate including the transparent resin layer 13, the decorative layer 15, and the base layer 11 in this order is produced.
[0129] Next, a concave-convex shape is formed on the surface of the produced laminate constituted by the transparent resin layer 13. In the step of forming the concave-convex shape, the laminate of the transparent resin layer 13, the decorative layer 15, and the base material layer 11 may be heated. The concave-convex shape may be formed by embossing. In the embossing, the concave-convex shape may be formed by pressing a plate. The plate may be a roll.
[0130] Next, a curable resin composition that forms the protective layer 14 is applied onto the transparent resin layer 13. The protective layer 14 is formed by curing the curable resin composition. The curable resin composition may be the ionizing radiation curable resin composition described above, or the thermosetting resin composition described above. The ionizing radiation curable resin composition is cured by irradiation with ionizing radiation. The thermosetting resin composition is cured by heating.
[0131] Next, the bonding layer 12 is laid on the base layer 11. When producing the illustrated decorative sheet 10, the bonding layer 12 is laid on the surface of the base layer 11 opposite to the surface on which the decorative layer 15 is laid.
[0132] In this manner, a decorative sheet 10 is obtained, which includes, from the first surface 10a to the second surface 10b, the protective layer 14, the transparent resin layer 13, the decorative layer 15, the base layer 11, and the bonding layer 12.
[0133] The function of the illustrated decorative sheet 10 will now be described.
[0134] The decorative sheet 10 is attached to the adherend AB from the second surface 10b. When the decorative sheet 10 is attached to the adherend AB, the separator 45 may be peeled off from the decorative sheet combination 40.
[0135] One method for attaching a decorative sheet to an adherend is manual attachment. In manual attachment, the decorative sheet is attached to the adherend by hand. In manual attachment, the decorative sheet is partially reattached due to various factors. In partial reattachment of the decorative sheet, at least a portion of the decorative sheet is peeled off within a short period of time after being attached to the adherend and then reattached. Factors that cause partial reattachment of the decorative sheet include wrinkles during attachment, misalignment of the decorative sheet with respect to the exterior member, and foreign matter getting caught between the decorative sheet and the exterior member. A partially reattached decorative sheet will include a peeled portion that has been peeled off from the adherend and a non-peeled portion that has not been peeled off from the adherend.
[0136] In a conventional decorative sheet that had been partially reapplied, a poor appearance known as a shock line occurred. Linear depressions were observed on the surface of the decorative sheet where the shock line occurred. The inventors of the present invention confirmed that the linear depressions occurred at the boundary between the peeled and non-peeled parts of the decorative sheet. When the linear depressions are visible from the outside, the decorative sheet on which the shock line occurred and the design of the object to which this decorative sheet is applied may be degraded.
[0137] The causes of the linear depressions in the partially reattached decorative sheet are presumed to be as follows, judging from their locations and appearances: However, the present disclosure is not bound by the presumptions below.
[0138] FIG. 10 illustrates a decorative sheet 70 and a substrate AB to which the decorative sheet 70 is attached to explain the estimated mechanism of shock line generation. The decorative sheet 70, attached to the substrate AB, expands in a first direction D1 and a second direction D2 perpendicular to the first direction D1 at the non-peeling portion SS. When the decorative sheet 70 is peeled from the substrate AB, as shown in FIG. 10 , a difference in the amount of elongation due to an external force occurs between the second surface 70b and the first surface 70a of the decorative sheet 70 at the boundary portion CS located between the peeling portion PS and the non-peeling portion SS. The amount of elongation due to an external force may also be referred to as the amount of deformation due to an external force. In FIG. 10 , the difference in the amount of elongation in the decorative sheet 70 is indicated by the difference between the length of the arrow FA along the first surface 70a and the length of the arrow FB along the second surface 70b. As shown in FIG. 10 , the amount of elongation at the boundary portion CS of the decorative sheet 70 increases as it approaches the second surface 70b. The difference in elongation occurs when the peeled portion PS of the adherend AB is tilted significantly relative to the non-peeled portion SS, for example, tilted by more than 45°, or even tilted by 90° as shown in Figure 10. The boundary portion CS, unlike the positions of the peeled portion PS, is maintained in this state for a short period of time. The difference in elongation at the boundary portion CS of the decorative sheet 70 causes a linear depression along the boundary portion CS. The noticeable depression is presumably the result of the shock line.
[0139] The present inventors have studied shock lines and found that the linear depressions and protrusions provided on the first surface can make the linear depressions less noticeable. They have also found that the occurrence of shock lines can be suppressed. Based on this finding, as demonstrated in the examples described below, when the decorative sheet satisfies the following three conditions (A), (B), (C), and (D) regarding the first surface, the linear depressions are made less noticeable, thereby suppressing the occurrence of shock lines. (A) The height difference between adjacent linear depressions 21 and linear protrusions 22 is 5 μm or more. (B) The area ratio of the inclined portions 31 on the first surface 10a is 10.0% or more. (C) The developed area ratio of the first surface 10a is 0.06 or more. (D) The area of each uneven region 20 is 9.0 mm or more.2 The following applies.
[0140] Condition (A) is a regulation regarding the size of each unevenness provided on the first surface 10a. When condition (A) is satisfied, the first surface 10a includes unevenness with a certain level or more. Condition (B) is a regulation regarding the area ratio of the inclined portions 31 located on the first surface 10a. When condition (B) is satisfied, the unevenness of the inclined portions 31 is prevented from becoming biased. Condition (C) can be said to be a regulation regarding the total amount of unevenness on the first surface 10a. When condition (C) is satisfied, the total amount of unevenness can be made to be a certain level or more. When condition (D) is satisfied, the possibility of effectively concealing an area where a linear depression occurs by multiple uneven areas 20 increases. Therefore, conditions (A), (B), (C), and (D) regarding the first surface 10a are useful for making the above-mentioned linear depression less noticeable in a decorative sheet that has been partially reattached.
[0141] On the other hand, in a decorative sheet that does not satisfy condition (A), the difference in elevation between the concave and convex portions on the first surface may be small relative to the depth of the linear depression that may occur. In a decorative sheet that does not satisfy condition (B), there is an increased risk that the area where the linear depression occurs will not have an inclined portion to hide the depression. In a decorative sheet that does not satisfy condition (C), the total amount of depressions and protrusions may be small relative to the length and depth of the linear depression. In a decorative sheet that does not satisfy condition (D), there is an increased risk that multiple concave and convex areas will not be arranged in the area where the linear depression occurs. In other words, the combination of conditions (A), (B), (C), and (D) can contribute to effectively suppressing the occurrence of shock lines.
[0142] Considering the presumed mechanism by which the linear dents described above occur, it is useful to set an upper limit on the adhesiveness of the decorative sheet in order to prevent the occurrence of linear dents. As described above, the initial peel force of the decorative sheet 10 from the adherend A / B may be 28 N / 25 mm or less. By setting the initial peel force from the adherend A / B to 28 N / 25 mm or less, the external force required to peel the decorative sheet 10 is reduced, thereby preventing the occurrence of linear dents. Therefore, in addition to conditions (A)-(D), setting the upper limit on the adhesiveness of the decorative sheet as described above can effectively prevent the occurrence of shock lines. The initial peel force of the decorative sheet 10 from the adherend A / B may be 25 N / 25 mm or less, 24 N / 25 mm or less, 23 N / 25 mm or less, 21 N / 25 mm or less, 20 N / 25 mm or less, or 17 N / 25 mm or less.
[0143] On the other hand, if the initial peel strength from the adherend AB is too low, the decorative sheet cannot maintain its adherence to the adherend. In this case, the decorative sheet may unintentionally peel off from the adherend. For this reason, the initial peel strength of the decorative sheet 10 from the adherend AB is set to 8 N / 25 mm or more.
[0144] Furthermore, considering the estimated mechanism by which the linear indentations described above occur, increasing the 3% strain tensile stress of the decorative sheet is effective in reducing the visibility of the linear indentations. The greater the 3% strain tensile stress of the decorative sheet, the less the decorative sheet elongates during peeling, making the linear indentations less noticeable. On the other hand, if the 3% strain tensile stress of the decorative sheet is too high, the ease of application when bonding the decorative sheet to an adherend deteriorates. For example, when the adherend has a curved surface, it becomes difficult for the decorative sheet to conform to the shape of the adherend. For this reason, an upper limit is set for the 3% strain tensile stress of the decorative sheet 10. Specifically, the 3% strain tensile stress of the decorative sheet 10 is set to 31 N / 10 mm or less. As described above, the occurrence of shock lines can be suppressed by satisfying the combination of conditions (A)-(D) and setting the initial peel force from the adherend A and B to 28 N / 25 mm or less. That is, the linear depressions described above can be prevented from being conspicuously observed without unnecessarily increasing the rigidity of the decorative sheet 10. In addition, the occurrence of shock lines can be prevented without unnecessarily reducing the initial peel strength of the decorative sheet 10. Therefore, according to this example, the design of the re-attached decorative sheet 10 can be improved while preventing a decrease in the commercial value of the decorative sheet 10.
[0145] However, from the viewpoint of suppressing the occurrence of shock lines, the 3% strain tensile stress [N / 10 mm] of the decorative sheet 10 may be greater than the initial peel strength [N / 25 mm] of the decorative sheet 10. According to this specific example, the decorative sheet 10 is endowed with sufficient rigidity against the initial peel strength applied to the decorative sheet from the adherend AB. This makes it possible to more effectively make the above-mentioned linear depressions less noticeable, and suppresses a decrease in the commercial value of the decorative sheet 10.
[0146] However, as the range of applications of decorative sheets expands, there is a demand for providing the decorative sheets with a glossy finish, which may further improve the design of the object to which the decorative sheet is applied.
[0147] As shown in Fig. 1, when a decorative sheet is applied to an automobile, the automobile may include a portion whose design is formed by paint and a portion whose design is formed by the decorative sheet. When paint is applied to the exterior members of the automobile, a glossy finish can be imparted to the automobile design by applying wax, coating agent, abrasive, etc. to the exterior members. By imparting a glossy finish to the decorative sheet as well, a harmony between the design formed by the decorative sheet and the design formed by the paint can be achieved.
[0148] However, the decorative sheet described above, which can suppress the occurrence of shock lines, has a problem in that the surface glossiness is reduced depending on the unevenness provided on the surface. In a mobile body in which such a decorative sheet is partially attached to an exterior member, the design formed by the decorative sheet may be difficult to harmonize with the design formed by the paint. As a result, even if the decorative sheet can suppress the occurrence of shock lines, the reduced glossiness on the surface may prevent the decorative sheet from being used in a wider range of applications.
[0149] Therefore, the present inventors have found that in a decorative sheet having an uneven surface, the reduction in glossiness on the first surface can be improved by further satisfying the following conditions (E) and (F) regarding the first surface. That is, the present inventors have found that it is possible to simultaneously suppress the occurrence of shock lines by the above-mentioned conditions (A), (B), (C), and (D), and to suppress the reduction in glossiness on the first surface by the conditions (E) and (F). (E) The area of each uneven region 20 is 1.5 mm 2 (F) The ratio of the difference in height between adjacent linear recesses 21 and linear protrusions 22 to the distance between two adjacent linear protrusions 22 is set to 0.09 or more.
[0150] When condition (E) is satisfied, it is possible to ensure that, in the decorative sheet 10 when light is irradiated onto the first surface 10a, an area in which the light irradiated onto the first surface 10a is reflected and observed as bright can be secured. When condition (F) is satisfied, the linear depressions 21 are likely to be cast in the shadow of the linear protrusions 22 when light is irradiated onto the first surface 10a, and can be observed as darker than the linear protrusions 22. When the combination of condition (E) and condition (F) is satisfied, when the first surface 10a is irradiated with light, the linear contrast along the linear depressions 21 and the linear protrusions 22 is observed as gloss. Therefore, conditions (E) and (F) regarding the first surface 10a contribute to suppressing a decrease in glossiness on the first surface 10a.
[0151] Next, consider a decorative sheet 10 that satisfies the above-mentioned conditions (A), (E), and (F). When this decorative sheet 10 is attached to an adherend AB with a foreign object such as a pebble sandwiched between it and the adherend AB, the plurality of uneven regions 20 can make the step caused by the foreign object less noticeable, as will be described in the examples below.
[0152] In the embodiment described above, the decorative sheet 10 has a first surface 10a and a second surface 10b opposite the first surface 10a. The decorative sheet 10 is attached to an adherend AB from the second surface 10b. The decorative sheet 10 includes a base layer 11 and a bonding layer 12, in this order, from the first surface 10a to the second surface 10b. The 3% strain tensile stress of the decorative sheet 10 is 31 N / 10 mm or less. The initial peel strength of the decorative sheet 10 from the adherend AB is 8.0 N / 25 mm or more and 28 N / 25 mm or less. The first surface 10a has a plurality of regularly arranged uneven regions 20. Each uneven region 20 includes a plurality of regularly arranged linear recesses 21 and a plurality of linear protrusions 22. In each uneven region 20, the difference in height between adjacent linear recesses 21 and linear protrusions 22 is 5 μm or more. The area ratio of the inclined portions 31 on the first surface 10a is 10% or more. The developed area ratio of the first surface 10a is 0.06 or more. The area of each uneven region 20 is 1.5 mm 2 Over 9.0 mm 2 The ratio of the height difference to the distance between two adjacent linear protrusions 22 is 0.09 or more.
[0153] According to this embodiment, it is possible to suppress the occurrence of shock lines when the decorative sheet 10 is reattached, thereby improving the design of the reattached decorative sheet. Furthermore, according to this embodiment, even if the first surface 10a has a plurality of uneven regions 20, it is possible to suppress a decrease in glossiness on the first surface 10a.
[0154] Although one embodiment has been described with reference to specific examples, the above-described specific examples do not limit the present invention. The above-described embodiment can be implemented with various other specific examples, and various omissions, substitutions, changes, additions, etc. can be made without departing from the spirit of the present invention.
[0155] In the above-described specific example of the decorative sheet 10, the linear recesses 21 and the linear protrusions 22 are each formed of a plurality of flat surfaces. However, the present invention is not limited to this, and the linear recesses 21 and the linear protrusions 22 may include curved surfaces as shown in FIG.
[0156] 12 is a view of a modified decorative sheet 10 as viewed from the first surface 10a. The decorative sheet 10 shown in FIG. 12 is a different modified example from the modified example shown in FIG.
[0157] 12 includes a third uneven region 20C, a fourth uneven region 20D, a fifth uneven region 20E, and a sixth uneven region 20F as a plurality of regularly arranged uneven regions 20. In the illustrated first surface 10a, the third uneven region 20C, the fourth uneven region 20D, the fifth uneven region 20E, and the sixth uneven region 20F constitute a repeating unit 20X. In the illustrated first surface 10a, a plurality of repeating units 20X are two-dimensionally arranged in a first arrangement direction DR1 and a second arrangement direction DR2.
[0158] In the first surface 10a of the decorative sheet 10 shown in Fig. 3, the plurality of linear protrusions 22 extend radially without intersecting with each other in each of the concave-convex regions 20. The configuration of the linear protrusions 22 in the concave-convex region 20 is not limited to that shown in Fig. 3. The concave-convex region 20 does not have to include the plurality of linear protrusions 22 extending radially from each other. In at least one of the plurality of concave-convex regions 20, the plurality of linear protrusions 22 may extend radially without intersecting with each other.
[0159] As shown in FIG. 12 , in at least one uneven region 20, the multiple linear recesses 21 may extend linearly. Among the multiple uneven regions 20 shown in FIG. 12 , in a fourth uneven region 20D, the multiple linear recesses 21 and the multiple linear protrusions 22 extend in the first longitudinal direction DM1. In the fourth uneven region 20D, the multiple linear recesses 21 are spaced apart from each other in a direction non-parallel to the first longitudinal direction DM1. In the fourth uneven region 20D, the multiple linear protrusions 22 are spaced apart from each other in a direction non-parallel to the first longitudinal direction DM1. Among the multiple uneven regions 20 shown, in a sixth uneven region 20F, the multiple linear recesses 21 and the multiple linear protrusions 22 extend in the second longitudinal direction DM2. The second longitudinal direction DM2 is a direction non-parallel to the first longitudinal direction DM1. In the sixth uneven region 20F, the linear recesses 21 are spaced apart from one another in a direction non-parallel to the second longitudinal direction DM2. In the sixth uneven region 20F, the linear protrusions 22 are spaced apart from one another in a direction non-parallel to the second longitudinal direction DM2.
[0160] 12, the linear protrusions 22 may have different widths. In the sixth uneven region 20F shown in the figure, the linear protrusions 22 have different widths, i.e., different dimensions in the direction perpendicular to the second longitudinal direction DM2.
[0161] As shown in Fig. 12, the plurality of linear convex portions 22 may extend circumferentially in at least one of the concave-convex regions 20. Of the plurality of concave-convex regions 20 shown in Fig. 12, the third concave-convex region 20C and the fifth concave-convex region 20E each include a plurality of linear convex portions 22 extending circumferentially.
[0162] Hereinafter, one embodiment of the present disclosure will be described in more detail using examples, but the present disclosure is not limited to these examples.
[0163] Decorative sheets according to Examples 1 to 12 and decorative sheets according to Comparative Examples 1 to 9 were produced. The produced decorative sheets had a first surface and a second surface opposite to the first surface. The produced decorative sheets had, from the first surface to the second surface, a transparent resin layer, a base layer, and a bonding layer. The first surface of the produced decorative sheets was constituted by a transparent resin layer. The second surface of the produced decorative sheets was constituted by a bonding layer. In the produced decorative sheets, the base layer was located between the transparent resin layer and the bonding layer. The produced decorative sheets had recesses and protrusions on the first surface. A separator was superimposed on the second surface of the produced decorative sheets. The decorative sheets according to Examples 1 to 12 and the decorative sheets according to Comparative Examples 1 to 9 had the above configuration in common.
[0164] Example 1: A sheet forming a substrate layer and a sheet forming a transparent resin layer were laminated at 160°C. The sheet forming the substrate layer had a thickness of 150 μm. The sheet forming the substrate layer contained polyvinyl chloride manufactured by Riken Technos Corporation. The sheet forming the substrate layer contained a polyester-based plasticizer. The plasticizer content in the sheet forming the substrate layer was 39 parts by mass per 100 parts by mass of polyvinyl chloride. The sheet forming the transparent resin layer was FBS007 manufactured by Mitsubishi Chemical Corporation, which was a laminate of a layer containing polymethyl(meth)acrylate (PMMA) and a layer containing polyvinylidene fluoride (PVDF) by coextrusion. The sheet forming the transparent resin layer had a thickness of 50 μm. In the sheet forming the transparent resin layer, the layer containing polymethyl(meth)acrylate (PMMA) had a thickness of 46 μm. In the sheet forming the transparent resin layer, the layer containing polyvinylidene fluoride (PVDF) had a thickness of 7 μm.
[0165] The produced laminate was heated to 180°C, and a plate was pressed against the surface formed by the transparent resin layer with a load of 2 tons, thereby forming multiple uneven regions 20. In the decorative sheet according to Example 1, multiple uneven regions 20 were formed on the first surface so as to display a first geometric pattern on the first surface.
[0166] The adhesive composition forming the bonding layer was applied to a separator (Rikeishi N, manufactured by Riken Technos Corporation). In the decorative sheet according to Example 1, the adhesive composition contained a base material available from Daido Chemical Industry Co., Ltd. under the product name "Dicalac® 5021" and a curing agent available from Tosoh Corporation under the product name "Coronate HX." The curing agent was included in an amount of 0.08 parts by mass per 100 parts by mass of the base material. The adhesive composition applied to the separator was dried at 80°C for 5 minutes to obtain a sheet-like bonding layer. The bonding layer had a thickness of 50 μm after drying.
[0167] The resulting bonding layer was placed on the base layer, and then left for 3 days at 40° C. In this manner, the decorative sheet according to Example 1 was obtained.
[0168] Example 2 The decorative sheet according to Example 2 had the same configuration as the decorative sheet according to Example 1, except for the configuration of the concave-convex regions formed on the first surface. In the decorative sheet according to Example 2, a plurality of concave-convex regions were formed on the first surface so as to display a second geometric pattern on the first surface.
[0169] Example 3 The decorative sheet according to Example 3 had the same configuration as the decorative sheet according to Example 2, except for the configuration of the concave-convex regions formed on the first surface. In the decorative sheet according to Example 3, a plurality of concave-convex regions were formed on the first surface so as to display a third geometric pattern.
[0170] Example 4 The decorative sheet according to Example 4 had the same configuration as the decorative sheet according to Example 1, except for the configuration of the concave-convex regions formed on the first surface. In the decorative sheet according to Example 4, a plurality of concave-convex regions were formed on the first surface so as to display a fourth geometric pattern on the first surface.
[0171] Example 5 The decorative sheet according to Example 5 had the same configuration as the decorative sheet according to Example 1, except for the thickness of the bonding layer after drying. In the decorative sheet according to Example 5, the thickness of the bonding layer after drying was 30 μm.
[0172] Example 6 The decorative sheet according to Example 6 had the same configuration as the decorative sheet according to Example 1, except for the thickness of the bonding layer after drying. In the decorative sheet according to Example 6, the thickness of the bonding layer after drying was 70 μm.
[0173] Example 7 The decorative sheet according to Example 7 had the same configuration as the decorative sheet according to Example 1, except for the content of plasticizer in the sheet forming the base layer. In the decorative sheet according to Example 7, the content of plasticizer in the sheet forming the base layer was 31 parts by mass with respect to 100 parts by mass of polyvinyl chloride.
[0174] Example 8 The decorative sheet according to Example 8 had the same configuration as the decorative sheet according to Example 1, except for the material of the bonding layer. In the decorative sheet according to Example 8, the thermosetting resin composition forming the bonding layer contained an acrylic resin available from Daido Chemical Industry Co., Ltd. under the product name "Dicalac (registered trademark) 5018" and a curing agent available from Tosoh Corporation under the product name "Coronate HX." The curing agent was contained in an amount of 0.04 parts by mass per 100 parts by mass of the main resin.
[0175] Example 9 The decorative sheet according to Example 9 had the same configuration as the decorative sheet according to Example 1, except for the content of the curing agent in the thermosetting resin composition forming the bonding layer. In the decorative sheet according to Example 9, the thermosetting resin composition forming the bonding layer contained 0.03 parts by mass of the curing agent relative to 100 parts by mass of the main agent.
[0176] Example 10 The decorative sheet according to Example 10 had the same configuration as the decorative sheet according to Example 1, except for the material of the bonding layer and the method of overlaying the bonding layer on the base layer. In the decorative sheet according to Example 10, a sheet available from Nichiei Shinka Co., Ltd. under the product name "Mold Fit 50" was used as the bonding layer. "Mold Fit 50" contained a pressure-sensitive adhesive composition available from Nichiei Shinka Co., Ltd. under the product name "S-925." The "S-925" was sandwiched between two separators. For the decorative sheet according to Example 10, a "-" in the "Curing agent mass parts [mass parts]" column in Table 3 described below indicates that the thermosetting resin composition forming the bonding layer had already cured. The above-described process of drying the thermosetting resin composition was not performed to obtain the bonding layer of the decorative sheet according to Example 10. The adhesive layer was exposed by peeling off one of the two separators and then laminated to the substrate layer.
[0177] Example 11 The decorative sheet according to Example 11 had the same configuration as the decorative sheet according to Example 1. The initial peel strength of the decorative sheet according to Example 11 was measured in a state where it was attached to an adherend different from that of Example 1, as will be described later.
[0178] Example 12 The decorative sheet according to Example 12 had the same configuration as the decorative sheets according to Examples 1 and 11. The initial peel strength of the decorative sheet according to Example 12 was measured in a state where it was attached to an adherend different from those of Examples 1 and 11, as will be described later.
[0179] <Comparative Example 1> The decorative sheet according to Comparative Example 1 had the same configuration as the decorative sheet according to Example 1, except for the uneven shape formed on the first surface. In the decorative sheet according to Comparative Example 1, the uneven shape was formed on the first surface so as to present a leather-like texture on the first surface.
[0180] <Comparative Example 2> The decorative sheet according to Comparative Example 2 had the same configuration as the decorative sheet according to Example 1, except for the uneven shape formed on the first surface. The first surface of the decorative sheet according to Comparative Example 2 was formed with fine unevenness. These unevennesses were randomly distributed, so that the first surface was formed as a matte surface.
[0181] <Comparative Example 3> The decorative sheet according to Comparative Example 3 had the same configuration as the decorative sheet according to Example 1, except for the uneven shape formed on the first surface. The first surface of the decorative sheet according to Comparative Example 3 was configured with fine unevenness. These unevennesses were randomly dispersed, resulting in the first surface being configured as a matte surface. The matte surface configured on the first surface of the decorative sheet according to Comparative Example 3 was different from the matte surface configured on the first surface of the decorative sheet according to Comparative Example 2.
[0182] <Comparative Example 4> The decorative sheet according to Comparative Example 4 had the same configuration as the decorative sheet according to Example 1, except for the configuration of the concave-convex regions formed on the first surface. In the decorative sheet according to Comparative Example 4, a plurality of concave-convex regions were formed on the first surface so as to display a fifth geometric pattern on the first surface.
[0183] <Comparative Example 5> The decorative sheet according to Comparative Example 5 had the same configuration as the decorative sheet according to Example 1, except for the configuration of the concave-convex regions formed on the first surface. In the decorative sheet according to Comparative Example 5, a plurality of concave-convex regions were formed on the first surface so as to display a sixth geometric pattern on the first surface.
[0184] <Comparative Example 6> The decorative sheet according to Comparative Example 6 had the same configuration as the decorative sheet according to Comparative Example 4, except for the content of plasticizer in the sheet forming the base layer. In the decorative sheet according to Comparative Example 6, the content of plasticizer in the sheet forming the base layer was 25 parts by mass with respect to 100 parts by mass of polyvinyl chloride.
[0185] <Comparative Example 7> The decorative sheet according to Comparative Example 7 had the same configuration as the decorative sheet according to Comparative Example 4, except for the material of the bonding layer. In the decorative sheet according to Comparative Example 7, the thermosetting resin composition forming the bonding layer contained an acrylic resin available from Daido Chemical Industry Co., Ltd. under the product name "Dicalac (registered trademark) 5018" and a curing agent available from Tosoh Corporation under the product name "Coronate HX". The curing agent was contained in an amount of 0.03 parts by mass per 100 parts by mass of the main resin.
[0186] <Comparative Example 8> The decorative sheet according to Comparative Example 8 had the same configuration as the decorative sheet according to Example 10. The initial peel strength of the decorative sheet according to Comparative Example 8 was measured in a state where it was attached to an adherend different from that of Example 10, as described below.
[0187] <Comparative Example 9> The decorative sheet according to Comparative Example 9 had the same configuration as the decorative sheet according to Example 10. The initial peel strength of the decorative sheet according to Comparative Example 9 was measured in a state where it was attached to an adherend different from that of Example 10, as will be described later.
[0188] <Adherend> The adherend for each decorative sheet was in the form of a plate. The adherend for the decorative sheets in Examples 1 to 9 and Comparative Examples 1 to 8 was a painted steel plate. A paint (KINO1210TW Clear, manufactured by Kansai Paint Co., Ltd.) was applied to the painted steel plate on the surface that would come into contact with the second surface of the decorative sheet. The adherend for the decorative sheets in Examples 10 and 11 was plate-shaped aluminum (A5052). The adherend for the decorative sheets in Example 12 and Comparative Example 9 was an ABS resin (Supersheet HA-ABS, manufactured by Resonac Corporation). The adherend at the time of measurement is shown in the "Adherend" column of each table described below.
[0189] The following items were measured for the decorative sheets of Examples 1 to 12 and Comparative Examples 1 to 9. Table 1 shows the measurement results for the decorative sheets of Examples 1 to 6. Table 2 shows the measurement results for the decorative sheets of Examples 7 to 12. Table 3 shows the measurement results for the decorative sheets of Comparative Examples 1 to 4. Table 4 shows the measurement results for the decorative sheets of Comparative Examples 5 to 9. (1) Aspect ratio of linear recesses (2) Area of uneven region (3) Height difference of uneven shape on the first surface (4) Area ratio of sloped surface on the first surface (5) Developed area ratio of the first surface (6) 3% strain tensile stress (7) Initial peel force
[0190] (1) Aspect ratio of linear depressions The aspect ratio of linear depressions was measured by the method described above for the decorative sheets according to Examples 1 to 12 and the decorative sheets according to Comparative Examples 4 to 8. The measurement results are shown in the "Aspect ratio of linear depressions [-]" column in each table. Note that in the decorative sheets according to Comparative Examples 1 to 3, where the "Aspect ratio of linear depressions [-]" column is marked with "-", no uneven regions were observed.
[0191] (2) Area of the Concave and Convex Regions The area of the concave and convex regions was measured by the above-mentioned method for the decorative sheets according to Examples 1 to 12 and the decorative sheets according to Comparative Examples 4 to 8. For each decorative sheet, the maximum value of the areas of five different concave and convex regions was used as the area of the concave and convex region. The measurement results are shown in the table as "Concave and Convex Region Area [mm 2 ]" column. 2 In the decorative sheets according to Comparative Examples 1 to 3, where the column "Number of convexo-concave regions" is marked with "-", no concave-convex regions were observed. In addition, the minimum area of the five different concave-convex regions measured in the examples and comparative examples other than Comparative Examples 1 to 3 was 1.5 mm 2 That was all.
[0192] (3) Height difference of the uneven shape on the first surface The height difference between adjacent linear concave and convex portions was measured by the above-mentioned method for the decorative sheets according to Examples 1 to 12 and the decorative sheets according to Comparative Examples 4 to 8. The measurement results are shown in the column "Height difference [μm]" in each table.
[0193] Note that no linear depressions or linear protrusions were observed in the decorative sheets according to Comparative Examples 1 to 3. For the decorative sheets according to Comparative Examples 1 to 3, the height difference between adjacent depressions and protrusions in the uneven shape was measured using the following method. A laser microscope (Keyence Corporation, VK-X150) was used for the measurement. The first surface was observed in plan view at 10x magnification using this laser microscope, and a 4 mm square measurement area on the first surface was obtained. In one measurement area, a protrusion including the point with the maximum height was identified. The maximum height difference between the protrusion and the depression adjacent to the protrusion was measured. The above laser microscope was also used to identify the protrusion including the point with the maximum height and to measure the maximum height difference. The measurement results are shown in the "Height difference [μm]" column in Table 3.
[0194] (4) Area ratio of the inclined surface on the first surface For each decorative sheet, the area ratio of the inclined surface on the first surface was measured by the method described above. The measurement results are shown in the column "Area ratio of inclined surface [%]" in each table.
[0195] (5) Developed Area Ratio of First Side For each decorative sheet, the developed area ratio of the first side was measured by the method described above. The measurement results are shown in the "Developed Area Ratio [-]" column in each table.
[0196] (6) 3% strain tensile stress The 3% strain tensile stress of each decorative sheet was measured using the method described above. The 3% strain tensile stress was measured with the separator peeled off. A tensile tester (Instron (registered trademark) 5565, manufactured by Instron Japan Co., Ltd.) conforming to JIS B 7721:2009 was used to measure the 3% strain tensile stress. The measurement results are shown in the column "3% strain tensile stress [N / 10 mm]" in each table.
[0197] (7) Initial Peel Strength The initial peel strength of each decorative sheet from the adherend was measured using the method described above. The initial peel strength was measured when the separator was peeled off. A tensile tester (Instron (registered trademark) 5565, manufactured by Instron Japan Co., Ltd.) conforming to JIS B 7721:2009 was used to measure the initial peel strength. The measurement results are shown in the "Initial Peel Strength [N / 25 mm]" column in each table.
[0198] <Evaluation 1> For the decorative sheets according to Examples 1 to 12 and the decorative sheets according to Comparative Examples 1 to 9, the first surfaces were observed within a range where the inclination angle with respect to the stacking direction was 60° or less, and the presence or absence of gloss was confirmed. The observation results for the decorative sheets according to Examples 1 to 6 are shown in the "Evaluation 1" column in Table 1. The observation results for the decorative sheets according to Examples 7 to 12 are shown in the "Evaluation 1" column in Table 2. The observation results for the decorative sheets according to Comparative Examples 1 to 4 are shown in the "Evaluation 1" column in Table 3. The observation results for the decorative sheets according to Comparative Examples 5 to 9 are shown in the "Evaluation 1" column in Table 4. Gloss was confirmed for the decorative sheets marked "OK." No gloss was confirmed for the decorative sheets marked "NG."
[0199] <Evaluation 2> First, the decorative sheets according to Examples 1 to 12 and Comparative Examples 1 to 9 were each attached to a 25 mm-wide adherend from the second side. When attaching each decorative sheet to the adherend, a plate-shaped squeegee was used to press each decorative sheet against the adherend with a load of 1 kilogram force (kgf). Next, each decorative sheet was partially peeled off so that the angle between the peeled and non-peeled portions of each decorative sheet was 180°. The peeled portions of each decorative sheet were then reattached to a steel plate. Next, light was applied to the first side from the direction in which the decorative sheet and the adherend were superimposed, and the boundary between the peeled and non-peeled portions was observed by 10 observers. The observation results of the decorative sheets according to Examples 1 to 6 are shown in the "Evaluation 2" column in Table 1. The observation results of the decorative sheets according to Examples 7 to 12 are shown in the "Evaluation 2" column in Table 2. The observation results of the decorative sheets according to Comparative Examples 1 to 4 are shown in the "Evaluation 2" column in Table 3. The observation results of the decorative sheets according to Comparative Examples 5 to 9 are shown in the "Evaluation 2" column in Table 4. For the decorative sheets marked "AAA," the occurrence of shock lines was not confirmed by any observer. For the decorative sheets marked "AA," the occurrence of shock lines was confirmed by less than three observers. For the decorative sheets marked "A," the occurrence of shock lines was confirmed by at least three observers but less than six observers. For the decorative sheets marked "B," the occurrence of shock lines was confirmed by at least six observers but less than ten observers. For the decorative sheets marked "C," the occurrence of shock lines was confirmed by all observers.
[0200] <Evaluation 3> A 10 mm wide aluminum foil ("My Foil" manufactured by UACJ Corporation) was placed on a 25 mm wide adherend. The aluminum foil had a thickness of 12 μm. The decorative sheets according to Examples 1 to 12 and Comparative Examples 1 to 9 were attached from the second side so that each decorative sheet covered one piece of aluminum foil. When attaching the decorative sheets to the adherend, each decorative sheet was pressed with a plate-shaped squeegee at a load of 1 kilogram force (kgf). Ten observers observed the boundaries between the overlapping and non-overlapping portions of the aluminum foil. The observation results for the decorative sheets according to Examples 1 to 6 are shown in the "Evaluation 3" column in Table 1. The observation results for the decorative sheets according to Examples 7 to 12 are shown in the "Evaluation 3" column in Table 2. The observation results for the decorative sheets according to Comparative Examples 1 to 4 are shown in the "Evaluation 3" column in Table 3. The observation results for the decorative sheets according to Comparative Examples 5 to 9 are shown in the "Evaluation 3" column in Table 4. For the decorative sheet marked "AAA", no step was found by any observer. For the decorative sheet marked "AA", less than three observers found a step. For the decorative sheet marked "A", three or more but less than six observers found a step. For the decorative sheet marked "B", six or more but less than ten observers found a step. For the decorative sheet marked "C", all observers found a step.
[0201] <Evaluation 4> The decorative sheets according to Examples 1 to 12 and Comparative Examples 1 to 9 were attached to the top of a helmet (SC-MB RA) manufactured by Midori Anzen Co., Ltd. at 25°C. Each decorative sheet measured 60 mm square. Each decorative sheet was attached to the helmet by pressing a plate-shaped squeegee from the center of the decorative sheet toward the edge. Each attached decorative sheet was observed for the presence or absence of at least one of wrinkles and partial peeling. The observation results for the decorative sheets according to Examples 1 to 6 are shown in the "Evaluation 4" column in Table 1. The observation results for the decorative sheets according to Examples 7 to 12 are shown in the "Evaluation 4" column in Table 2. The observation results for the decorative sheets according to Comparative Examples 1 to 4 are shown in the "Evaluation 4" column in Table 3. The observation results for the decorative sheets according to Comparative Examples 5 to 9 are shown in the "Evaluation 4" column in Table 4. For the decorative sheets marked "OK," no wrinkles or partial peeling were observed. Wrinkles and partial peeling were observed in the decorative sheets marked "NG."
[0202] <Evaluation 5> The decorative sheets according to Examples 1 to 12 and Comparative Examples 1 to 9 were attached to one side of an adherend having a length of 70 mm from the second side at 25°C. Each decorative sheet was attached so as to protrude 2 mm from the edge of the adherend. The protruding portion of each decorative sheet was folded and attached to the other side of the adherend. Each decorative sheet attached in this manner was left at 25°C for 24 hours, and then the portion attached to the other side of the adherend was observed. The observation results of the decorative sheets according to Examples 1 to 6 are shown in the "Evaluation 5" column in Table 1. The observation results of the decorative sheets according to Examples 7 to 12 are shown in the "Evaluation 5" column in Table 2. The observation results of the decorative sheets according to Comparative Examples 1 to 4 are shown in the "Evaluation 5" column in Table 3. The observation results of the decorative sheets according to Comparative Examples 5 to 9 are shown in the "Evaluation 5" column in Table 4. For the decorative sheets marked "OK," the part attached to the other side of the decorative sheet had not changed since it was left for 24 hours. For the decorative sheets marked "NG," lifting and partial peeling were observed. The part attached to the other side of the decorative sheet had peeled off.
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Claims
1. A laminate having a first surface and a second surface opposite to the first surface, and attached to an adherend from the second surface, comprising a base layer and a bonding layer in this order from the first surface toward the second surface, the base layer containing a resin as a main component, a 3% strain tensile stress of 31 N / 10 mm or less, an initial peel strength from the adherend of 8 N / 25 mm or more and 28 N / 25 mm or less, the first surface having a plurality of regularly arranged irregular regions, each irregular region including a plurality of regularly arranged linear concave portions and a plurality of linear convex portions, in each irregular region, the difference in height between adjacent linear concave portions and linear convex portions is 5 μm or more, the area ratio of the inclined surfaces on the first surface is 10.0% or more, the developed area ratio of the first surface is 0.06 or more, and the area of each irregular region is 1.5 mm. 2 Over 9.0 mm 2 or less, and the ratio of the height difference to the interval between two adjacent linear convex portions is 0.09 or more.
2. The decorative sheet according to claim 1, wherein in at least one concave-convex region, the plurality of linear convex portions extend linearly.
3. The decorative sheet according to claim 1, wherein in at least one uneven region, the plurality of linear protrusions extend radially within an angular range of 135° or less.
4. The decorative sheet according to claim 1, wherein in at least one uneven region, the plurality of linear protrusions extend circumferentially.
5. The decorative sheet according to claim 1, further comprising a transparent resin layer superimposed on the base material layer, the base material layer being positioned between the transparent resin layer and the bonding layer.
6. The decorative sheet according to claim 1, further comprising a decorative layer superimposed on the base layer, the base layer being positioned between the decorative layer and the bonding layer.
7. The decorative sheet according to claim 1, further comprising a protective layer overlaid on the base layer and constituting the first surface.
8. The decorative sheet according to any one of claims 1 to 7, which is attached to an exterior member of an automobile.
9. A decorative sheet combination comprising the decorative sheet according to any one of claims 1 to 7 and a separator superimposed on the second surface side of the decorative sheet.
10. A decorated mobile body comprising: a mobile body; and a decorative sheet according to any one of claims 1 to 7 superimposed on the mobile body.
11. The decorated mobile body according to claim 10, wherein the mobile body includes an exterior member that forms an outer surface, and the decorative sheet is attached to the exterior member.
12. The decorated mobile body according to claim 11, wherein the exterior member has a curved surface, and the decorative sheet is attached along the curved surface.
13. A decorated mobile body according to claim 11, wherein a first portion of the decorative sheet attached to the end of the exterior member is bent relative to portions other than the first portion.
Citation Information
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