JP2018024110A - Transfer sheet, method for manufacturing transfer sheet and method for manufacturing decorative molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transfer sheet allowing transferring a transfer layer to a correct position of an object to be transferred.SOLUTION: A transfer sheet has a transfer layer on a mold release sheet. The mold release sheet has: a substrate layer having a first region and a second region on a surface in a side of the transfer layer; a projection in the second region of the substrate layer; and a pigmented layer on the projection.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a transfer sheet, a transfer sheet manufacturing method, and a decorative molded product manufacturing method.

In the fields of household appliances, automobile interior parts, general goods, etc., the surface of an article may be decorated by a transfer method.
In the transfer method, a transfer sheet having a release layer, a design layer, an adhesive layer, or the like formed on a base material is adhered to an article to be transferred, and then the base material is peeled off. In this method, only the transfer layer is transferred to the surface of the transfer product to decorate.

In the transfer method, by adjusting the configuration of the transfer layer, it is possible to give a glossy feeling to an article to be transferred, or conversely, to reduce the glossiness and give a matte feeling.
For example, Patent Document 1 discloses a release layer containing a matting agent entirely on a base sheet, a mask layer partially containing an active energy ray-curable resin, a release layer and a design layer as a transfer layer. A partial mat transfer sheet characterized in that is formed is disclosed.

Japanese Patent No. 5095598

When the transfer layer is transferred onto the surface of the article to be transferred, alignment is extremely important as described in paragraph 0034 of Patent Document 1.
2. Description of the Related Art Conventionally, in the printing field or the like, alignment is performed by printing a registration pattern called a registration mark and reading the pattern with a sensor. Also in the transfer method, it is conceivable to perform alignment by printing a pattern for alignment in this way.

  However, there is a problem that it is difficult to print an alignment pattern at an accurate location on the transfer sheet, and it is difficult to transfer the transfer layer to an accurate position on the transfer object. In the first place, when the pattern for alignment is printed after the transfer sheet is completed, there is a problem that the number of processes is increased and it is complicated.

  The present invention has been made in view of such circumstances, a transfer sheet capable of transferring a transfer layer to an accurate position of a transfer object, a method for producing the transfer sheet, and decorative molding using the transfer sheet It aims at providing the manufacturing method of goods.

That is, the present invention provides the following [1] to [3].
[1] A transfer sheet having a transfer layer on a release sheet, wherein the release sheet has a base material layer having a first region and a second region on a surface on the transfer layer side, and the base material The transfer sheet which has a protrusion part in the 2nd field of a layer, and has a colored layer on the protrusion part further.
[2] The method for producing a transfer sheet according to the above [1], wherein the release sheet is produced by the following steps (A1) to (A3), and then a transfer layer is formed on at least a part of the release sheet.
(A1) The process of apply | coating the ink for resin layer formation containing an ionizing radiation curable resin composition on a support body, and forming an uncured resin layer.
(A2) Using a plate having a shape complementary to the first region and the second region, the uncured resin layer is shaped, and simultaneously irradiated with ionizing radiation to cure the shaped resin layer and support The process of obtaining the base material layer in which the resin layer was formed on the body.
(A3) The process of forming a colored layer on the protrusion part in the 2nd area | region of a base material layer.
[3] A method for producing a decorative molded product, comprising: a step of transferring the transfer layer of the transfer sheet according to the above [1] to a transfer target; and a step of peeling the release sheet of the transfer sheet.

  ADVANTAGE OF THE INVENTION According to this invention, the transfer sheet which can transfer a transfer layer to the exact position of a to-be-transferred object, the manufacturing method of this transfer sheet, and the manufacturing method of a decorative molded product using this transfer sheet can be provided.

It is sectional drawing which shows one Embodiment of the transfer sheet of this invention. It is sectional drawing which shows one Embodiment of the transfer sheet of this invention. It is sectional drawing which shows one Embodiment of the transfer sheet of this invention. It is sectional drawing which shows one Embodiment of the transfer sheet of this invention. It is a top view which shows one Embodiment of the transfer sheet of this invention. It is a top view which shows one Embodiment of the transfer sheet of this invention. It is a top view which shows the state by which the transfer sheet of this invention was multifaceted. It is sectional drawing which shows one Embodiment of the decorative molded product obtained using the transfer sheet of this invention. It is a perspective view explaining one Embodiment of the manufacturing process of the plate used for manufacture of the transfer sheet of this invention.

Embodiments of the present invention will be described below.
[Transfer sheet]
The transfer sheet of the present invention is a transfer sheet having a transfer layer on a release sheet, and the release sheet has a base material layer having a first region and a second region on the transfer layer side surface. , Having a protruding portion in the second region of the base material layer, and further having a colored layer on the protruding portion.

1 to 4 are sectional views showing embodiments of the transfer sheet of the present invention.
1 to 4, the transfer sheet 100 has a transfer layer 20 on the release sheet 10. 1 to 4, the release sheet 10 has a base material layer 11 having a first region R ₁ and a second region R ₂ on the surface on the transfer layer 20 side, and the second of the base material layer 11. The protrusion 3 is provided in the region R ₂ , and the colored layer 12 is further provided on the protrusion 3.
Describing more specifically with respect to FIG. 1 which is a representative view, the release sheet 10 is composed of a support 1, a base material layer 11 including a resin layer 2 and a protruding portion 3, a colored layer 12 and a release layer 13. Yes. The transfer layer 20 includes a protective layer 21, an adhesive layer 22, and a print layer 23.
1 to 4 show an embodiment of the transfer sheet of the present invention, and the transfer sheet of the present invention is not limited to the configuration of FIGS.

<Release sheet>
The release sheet has a base material layer having a first region and a second region on the surface on the transfer layer side, a protrusion in the second region of the base material layer, and a colored layer on the protrusion It is what has. The release sheet is peeled off after the transfer layer is transferred to a transfer object such as a resin molded body.

(Base material layer)
Base layer 11, as shown in FIGS. 1 to 4, having a first region _{R 1} and the second region _{R 2} on the surface of the transfer layer 20 side. Moreover, as shown in FIGS. 3 to 4, the base material layer 11 may further have other regions R _n on the surface on the transfer layer 20 side.

  The base material layer 11 is formed from the support body 1 and the resin layer 12, for example, as shown in FIGS. Of course, the base material layer may be a single layer of a support or a resin layer, or may have a configuration of three or more layers having layers other than the support and the resin layer.

As the support constituting the base material layer, polyolefin resins such as polyethylene and polypropylene, vinyl chloride such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer, etc. Resins, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, acrylic resins such as poly (meth) methyl acrylate and poly (meth) ethyl acrylate, styrene resins such as polystyrene, nylon 6 or nylon Examples thereof include a plastic film made of a resin such as polyamide resin represented by No. 66 and the like.
Among these plastic films, a biaxially stretched polyester film having excellent heat resistance and dimensional stability and excellent alignment suitability is preferable.

The thickness of the support is preferably 12 to 150 μm, more preferably 25 to 100 μm, from the viewpoints of moldability, shape followability, and handling.
Further, in order to enhance the adhesion to the resin layer or the like, the surface of the support may be subjected in advance to a physical treatment such as corona discharge treatment or oxidation treatment, or application of a paint called an anchor agent or a primer. .

(Resin layer)
The resin layer is preferably composed mainly of resin components such as a thermoplastic resin, a cured product of a thermosetting resin composition, and a cured product of an ionizing radiation curable resin composition. Among the resin components, a cured product of an ionizing radiation curable resin composition that is excellent in strength and capable of giving an accurate and precise shape because it is instantly cured is preferable.

  The resin layer may be formed by coating, but is preferably formed by printing using a plate having a shape complementary to the first region and the second region from the viewpoint of forming an accurate and precise shape. . When the resin layer has other regions, it is preferable that the plate further has a shape complementary to the other regions. Details of the method for forming a resin layer using a plate will be described later.

Examples of the thermoplastic resin include acrylic resins, cellulose resins, urethane resins, vinyl chloride resins, polyester resins, polyolefin resins, polycarbonate, nylon, polystyrene, and ABS resins.
The thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that is cured by heating. Examples of the thermosetting resin include acrylic resin, urethane resin, phenol resin, urea melamine resin, epoxy resin, unsaturated polyester resin, and silicone resin. In the thermosetting resin composition, a curing agent is added to these curable resins as necessary.

The ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter also referred to as “ionizing radiation curable compound”). Examples of the ionizing radiation curable functional group include an ethylenically unsaturated bond group such as a (meth) acryloyl group, a vinyl group, and an allyl group, an epoxy group, and an oxetanyl group.
As the ionizing radiation curable resin, a compound having an ethylenically unsaturated bond group is preferable, a compound having two or more ethylenically unsaturated bond groups is more preferable, and among them, having two or more ethylenically unsaturated bond groups, Polyfunctional (meth) acrylate compounds are more preferred. As the polyfunctional (meth) acrylate compound, any of a monomer and an oligomer can be used.
The ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking molecules, and usually ultraviolet (UV) or electron beam (EB) is used. Electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion beams can also be used.

Among the polyfunctional (meth) acrylate compounds, bifunctional (meth) acrylate monomers include ethylene glycol di (meth) acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, 1,6-hexane. Examples thereof include diol diacrylate.
Examples of the tri- or higher functional (meth) acrylate monomer include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, di Examples include pentaerythritol tetra (meth) acrylate and isocyanuric acid-modified tri (meth) acrylate.
The (meth) acrylate-based monomer may be modified by partially modifying the molecular skeleton, and is modified with ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl, cyclic alkyl, aromatic, bisphenol, or the like. Can also be used.

Moreover, examples of the polyfunctional (meth) acrylate oligomer include acrylate polymers such as urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate.
Urethane (meth) acrylate is obtained by reaction of polyhydric alcohol and organic diisocyanate with hydroxy (meth) acrylate, for example.
A preferable epoxy (meth) acrylate is a (meth) acrylate obtained by reacting (meth) acrylic acid with a tri- or higher functional aromatic epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin or the like. (Meth) acrylates obtained by reacting the above aromatic epoxy resins, alicyclic epoxy resins, aliphatic epoxy resins and the like with polybasic acids and (meth) acrylic acid, and bifunctional or higher functional aromatic epoxy resins, It is a (meth) acrylate obtained by reacting an alicyclic epoxy resin, an aliphatic epoxy resin or the like with a phenol and (meth) acrylic acid.
The ionizing radiation curable resin can be used alone or in combination of two or more.

When the ionizing radiation curable resin is an ultraviolet curable resin, the antiglare layer-forming coating solution preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator.
Examples of the photopolymerization initiator include one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyldimethyl ketal, benzoylbenzoate, α-acyloxime ester, thioxanthones, and the like.
The photopolymerization accelerator can reduce polymerization inhibition by air during curing and increase the curing speed. For example, p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, etc. One or more selected may be mentioned.

  Although the thickness (t) of a resin layer is not specifically limited, It is preferable that it is 1-15 micrometers, and it is more preferable that it is 2-12 micrometers.

(First area)
The surface shape of the first region of the base material layer is not particularly limited. For example, the surface shape of the first region R ₁ of the base layer 11 may be a substantially smooth as shown in FIG. 1, or may be uneven as in FIGS.
As in FIG. 1, when the surface shape of the first region R ₁ of the base layer 11 is substantially smooth, it can be made substantially smooth surface shape of the transfer layer 20 has been transferred to the transfer target, the resulting pressure The gloss of the decorative molded product can be increased.
In addition, as shown in FIGS. 2 to 4, when the uneven portion 4 is provided in the first region R ₁ , the transfer layer 20 (separated on the uneven portion 4) has a shape complementary to the uneven portion. In the case of having the mold layer 13, the transfer layer 20) having a concavo-convex complementary shape relaxed by the release layer 13 is transferred, and the concavo-convex shape can be imparted to the surface of the resulting decorative molded product.

When it has an uneven | corrugated | grooved part in a 1st area | region, it is preferable that an uneven | corrugated | grooved part and the protrusion part mentioned later satisfy | fill the relationship of [the maximum height of an uneven | corrugated part <the height of a protrusion part]. By satisfying this relationship, the colored layer can be easily adhered to the top of the protruding portion, and alignment can be performed accurately.
From the same viewpoint, [the maximum height of the uneven portion in the first region / the height of the protruding portion] is preferably 0.50 or less, and more preferably 0.40 or less. From the same viewpoint, the [average roughness of the uneven portion in the first region / height of the protruding portion] is preferably 0.20 or less, and more preferably 0.15 or less.
When there are a plurality of protrusions, it is preferable that all the protrusions satisfy the above relationship.
In the present specification, the maximum height means the maximum height roughness Rz of JIS B0601: 2001 at a cutoff value of 0.8 mm, and the average roughness means JIS B0601: 2001 at a cutoff value of 0.8 mm. Means the arithmetic average roughness Ra.
Moreover, in this specification, the numerical value regarding height, roughness, width, and thickness is an average value of values measured ten times unless otherwise specified.

  Since the surface shape imparted to the decorative molded product varies depending on the purpose, the absolute value of the degree of unevenness in the first region is not particularly limited, but the maximum height roughness Rz is about 0.2 to 4.0 μm. It is preferable to do. Similarly, the arithmetic average roughness Ra is preferably about 0.05 to 2.0 μm.

(Second area)
As shown in FIGS. 1 to 4, the release sheet 10 has a protruding portion 3 in the second region R < _b > ₂ of the base material layer 11, and further has a colored layer 12 on the protruding portion 3.
As shown in FIGS. 1-7, the second region _{R 2,} the first region _{R 1} as described above, the width direction of the release sheet 10: to be formed at different locations (TD Transverse Direction) preferable. By arranging the second region R ₂ and the first region R ₁ as described above, the colored layer 12 is not formed in the first region R _1, but on the protruding portion 3 of the second region R _2. The colored layer 12 can be easily formed.
5 to 7 illustrate a state in which the surface of the release sheet is visible through the transfer layer.

The portion having the protruding portion and the colored layer in the second region is different in light transmittance or light reflectance from the surrounding portions. Using this light transmittance or light reflectance contrast, the transfer sheet can be aligned in an arbitrary process. The light transmittance may be any of transmittance in the normal transmission direction, diffuse transmittance, and total transmittance. Similarly, the light reflectance may be any of transmittance in the regular reflection direction, diffuse reflectance, and total reflectance.
Examples of the optional step of aligning include a step of slitting the transfer sheet in a long length, a step of punching the transfer sheet into a sheet, and a step of transferring the transfer sheet to a transfer object. A specific method of alignment will be described later.

  The protruding portion is formed from an arbitrary structure, and the shape and the like of the structure are not particularly limited, but the shapes and the like exemplified below are preferable.

The height (H) of the protruding portion is preferably 1 to 10 μm, more preferably 2 to 7 μm, and further preferably 3 to 6 μm.
By setting the height of the protruding portion to 1 μm or more, even if the printing position is slightly shifted, a colored layer is formed on the protruding portion, but a colored layer is hardly formed on the peripheral portion. Can do. That is, by setting the height of the protruding portion to 1 μm or more, the alignment pattern can be easily printed at an accurate location. For this reason, the contrast of the light transmittance or the light reflectance between the portion having the protruding portion and the surrounding portion becomes clear, and the alignment can be facilitated. Further, by setting the height of the protruding portion 3 to 1 μm or more, as shown in FIGS. 1 to 4, a fine protrusion is easily formed on the surface on the transfer layer 20 side of the transfer sheet 100, and a long transfer is performed. It is possible to easily suppress blocking when winding a sheet or stacking single transfer sheets.
In addition, by setting the height of the protruding portion to 10 μm or less, the protruding portion is hardly deformed by a load, and the alignment accuracy can be easily maintained.

  When the position is detected based on the difference in light transmittance, it is preferable that the difference in light transmittance between the portion having the protrusion and the surrounding portion is 30% or more. Moreover, when detecting a position by the difference in light reflectance, it is preferable that the difference in light reflectance between the portion having the protruding portion and the surrounding portion is 30% or more.

The width (W) of the protrusion is preferably 0.1 to 10.0 mm, more preferably 1.0 to 7.0 mm, and still more preferably 3.0 to 6.0 mm.
By setting the width of the protruding portion to be 0.1 mm or more, the distinction from the peripheral portion becomes clear and alignment can be easily performed. Moreover, the effect which suppresses the blocking mentioned above also improves by making the width | variety of a protrusion part into 0.1 mm or more.
Moreover, it can suppress that the area of a 2nd area | region becomes large more than necessary by making the width | variety of a protrusion part into 10.0 mm or less.

The protrusion has a ratio of height (H) to width (W) of 1: 10,000 to 1:10 from the viewpoint of balancing the effects of height (H) and width (W) described above. Is more preferable, and is preferably 1: 3,000 to 1: 140, and more preferably 1: 1,350 to 1: 500.
In the present specification, the height (H) of the protruding portion is perpendicular to the structure forming the protruding portion in the extending direction of the structure (for example, the direction of “d” in FIGS. 5 to 7). The height of the central part of the cross section cut in the direction. In the present specification, the width (W) of the protruding portion refers to the width of the bottom portion of a cross section obtained by cutting the structure forming the protruding portion in a direction orthogonal to the extending direction of the structure.

As shown in FIGS. 5 to 7, the protrusion 3 is preferably formed from a row of structures extending in a direction parallel to any one side of the transfer sheet 100. By making the protrusion 3 have this configuration, alignment can be facilitated.
5 and 7, the row-like structures are continuously stretched without interruption, but the row-like structures may be intermittently stretched as shown in FIG. 6. When the columnar structure is extended intermittently, alignment in two directions is possible, and alignment accuracy can be improved. In the case where the row-like structures are intermittently stretched, the interval (P ₂ ) between the ends of each structure is preferably 0.1 to 10.0 mm, and is 1.0 to 7.0 mm. Is more preferable, and it is still more preferable that it is 3.0-6.0 mm.
The direction in which the row-shaped structures are stretched is preferably the flow direction (MD: Machine Direction) of the transfer sheet 100.

The on the second region R ₂ may have a protruding portion 3 alone, or may be plural have.
Also, if having a plurality of protrusions 3 in the second region R _2, as shown in FIGS. 2-7, it is preferable that at least one pair of projecting portions 3 are parallel to each other. In addition, it is more preferable that at least one pair of protrusions 3 are parallel to each other in the flow direction of the transfer sheet 100.
By arranging at least one set of protrusions 3 in parallel with each other, when forming the colored layer 12, the colored layer 12 is easily formed on the protrusions 3, while between the pair of protrusions 3. The colored layer 12 is hardly formed. For this reason, the contrast of the light transmittance or the light reflectance between the part having the protrusions 3 and the part between the pair of protrusions 3 becomes clear, and alignment can be facilitated. In addition, when at least one set of protrusions 3 is arranged in parallel to each other, the depth of the plate forming the colored layer is large, so that between the pair of protrusions 3 as shown in FIGS. Even if the colored layer 12 is formed in the peripheral portion of the protruding portion 3 excluding the portion, the colored layer 12 is difficult to be formed between the pair of protruding portions 3, so that the alignment is possible. That is, when at least one set of the protrusions 3 are arranged in parallel with each other, it is preferable in that the alignment can be performed even if the accuracy of pattern printing for alignment is slightly reduced. In addition, when at least one pair of protrusions 3 are arranged in parallel to each other, it is preferable in that the contrast for alignment can be easily clarified even if the height of the protrusions 3 is low. Furthermore, by arranging at least one pair of projecting portions 3 in parallel with each other, the contrast of light transmittance or light reflectance can be formed linearly, and the alignment accuracy can be improved, and the above-described blocking is suppressed. To improve the effect.

From the viewpoint of easily obtaining the effects described above, the interval (P ₁ ) between the ends of the pair of protruding portions 3 is preferably 0.1 to 10.0 mm, and is 1.0 to 7.0 mm. It is more preferable that the thickness is 1.5 to 5.0 mm.
Moreover, it is preferable that a set of protrusion part 3 is the row-shaped structure mentioned above. Furthermore, it is more preferable that the set of protrusions 3 is one that extends intermittently in the above-described row of structures.

  The cross section obtained by cutting the structure forming the protruding portion in a direction orthogonal to the extending direction of the structure is preferably substantially rectangular.

Further, the protrusion and the transfer layer described later preferably have a relationship of [height of the protrusion / thickness of the transfer layer] of 0.1 to 5.0, preferably 0.2 to 3.5. It is more preferable to satisfy | fill, and it is still more preferable to satisfy | fill the relationship of 0.3-1.0.
By setting the ratio to be 0.1 or more, it is possible to easily suppress blocking when winding a long transfer sheet or stacking single transfer sheets, and the ratio is set to 5.0 or less. As a result, the protruding portion is not easily deformed by the load, and the alignment accuracy can be easily maintained.

  It is preferable to remove the second region when it is transferred to the transfer object and a decorative molded product is obtained. The timing for removing the second region is, for example, (1) when the transfer sheet is slit long, (2) when the transfer sheet is cut into sheets, and (3) the transfer sheet is transferred. And the like during the trimming process after the transfer.

(Colored layer)
The colored layer is formed on the protruding portion and has a role of causing a light transmittance or a light reflectance contrast with the peripheral portion. Note that the “colored layer” in this specification includes a layer that looks whitish due to light diffusion (for example, a layer that looks like frosted glass).

The colored layer is preferably mainly composed of a binder resin and a pigment and / or a matting agent.
As the pigment of the colored layer, it is preferable to include a pigment having high concealability or a pigment having high reflectance. A black pigment such as carbon black is preferable as the pigment having high concealability. Examples of the pigment having high reflectance include barium sulfate, titanium oxide, and pearl pigment.
The matting agent for the colored layer can be used without any particular limitation as long as it provides irregularities on the surface of the colored layer and causes external haze. Specifically, examples of the matting agent include inorganic particles such as silica and alumina, and organic particles such as acrylic particles and styrene particles.
The binder resin of the colored layer is not particularly limited, and a general-purpose thermoplastic resin, a cured product of a thermosetting resin composition, or a cured product of an ionizing radiation curable resin composition can be used.

  What is necessary is just to adjust the thickness of a colored layer in the range in which the contrast for position alignment is obtained, and is about 0.3-5.0 micrometers normally.

(Other areas)
The surface of the release sheet on the transfer layer side may have other regions other than the first region and the second region. By having other regions, the alignment accuracy can be further improved, and the design of the transfer object can be further improved.

For example, as shown in FIGS. 5 and 7, in the case where the protruding portion 3 of the second region R ₂ extends continuously in the flow direction, the position in the direction orthogonal to the flow direction is higher than the configuration of the second region R _2. Alignment is possible, but alignment in the flow direction is not possible. In such a case, by forming a position detector in the other region R _n, it is possible to further improve the accuracy of the alignment.

Position detection unit, for example, as shown in FIGS. 3 and 6, the second protrusion 5 which is formed in the other region R _n of the base layer 11 is formed on the second protrusion on In addition, a configuration including the second colored layer 14 may be used.

Second protrusion may be formed on at least a portion of the other region R _n.
The second protrusion preferably has a straight line parallel to the width direction of the transfer sheet when observed from the plane direction, and has a substantially rectangular shape having a straight line parallel to the width direction of the transfer sheet. More preferably, a substantially rectangular shape having straight lines parallel to the width direction and the flow direction of the transfer sheet is more preferable. By making the 2nd protrusion part into such a shape, it is possible to facilitate alignment in the flow direction.

  When the second protrusion has a straight line parallel to the width direction and / or the flow direction, the length of the straight line is preferably 2 to 20 mm, more preferably 3 to 15 mm, and more preferably 5 to 10 mm. More preferably.

The height of the second protrusion is preferably 1 to 10 μm, more preferably 2 to 7 μm, and still more preferably 3 to 6 μm. The height of the second protrusion is preferably the same as the height of the protrusion in the second region.
By setting the height of the second protruding portion to 1 μm or more, even if the printing position is slightly shifted, a colored layer is formed on the second protruding portion, but the second portion is formed around the second protruding portion. The colored layer can be made difficult to be formed. That is, by setting the height of the second protrusion to 1 μm or more, the alignment pattern can be easily printed at an accurate location. For this reason, the contrast of the light transmittance or the light reflectance between the portion having the second protrusion and the peripheral portion thereof becomes clear, and alignment can be facilitated. Further, by setting the height of the protruding portion 3 to 1 μm or more, as shown in FIG. 3, it becomes easy to form a fine protrusion on the surface of the transfer sheet 100 on the transfer layer 20 side, and a long transfer sheet is wound. It is easy to suppress blocking when taking or stacking a single transfer sheet.
In addition, by setting the height of the protruding portion to 10 μm or less, the protruding portion is hardly deformed by a load, and the alignment accuracy can be easily maintained.

  When the position is detected based on the difference in light transmittance, it is preferable that the difference in light transmittance between the portion having the second protrusion and the surrounding portion is 30% or more. Moreover, when detecting a position by the difference in light reflectance, it is preferable that the difference in light reflectance between the portion having the second protrusion and the surrounding portion is 30% or more.

As another embodiment of the position detector, for example, as shown in FIG. 4, a second concave-convex portion 6 formed in the other region R _n of the base layer 11, the second concave-convex The structure which consists of the 2nd colored layer 14 formed on the circumference | surroundings of the part and this 2nd uneven | corrugated | grooved part is mentioned.
When the degree of unevenness of the second uneven portion 6 is reduced, the second colored layer 14 is easily formed not only on the second uneven portion 6 but also around the second uneven portion 6. And as shown in FIG. 4, the thickness of the 2nd colored layer 14 formed on the 2nd uneven | corrugated | grooved part 6 is thin, while the location corresponding to a recessed part is thick. On the other hand, the thickness of the second colored layer 14 formed around the second uneven portion 6 is thick overall. For this reason, a contrast of light transmittance or light reflectance occurs between the second uneven portion 6 and the periphery of the second uneven portion 6 due to the difference in the adhesion density of the second colored layer 14. The position can be detected.

  Further, when the degree of unevenness of the second uneven portion is increased, the second colored layer is easily formed on the protruded portion of the second uneven portion, while the recessed portion of the second uneven portion or the second It is possible to make it difficult for the second colored layer to be formed in the peripheral portion of the uneven portion. For this reason, the contrast of the light transmittance or the light reflectance is generated due to the difference in the adhesion density of the second colored layer between the portion having the second concavo-convex portion and the surrounding portion, and position detection is performed. Can be possible.

The second concave-convex portion may be formed on at least a portion of the other region R _n.
Further, the second uneven portion preferably has a straight line parallel to the width direction of the transfer sheet when observed from the plane direction, and has a substantially rectangular shape having a straight line parallel to the width direction of the transfer sheet. More preferably, it is more preferably a substantially rectangular shape having straight lines parallel to the width direction and the flow direction of the transfer sheet.
When the second uneven portion has a straight line parallel to the width direction and / or the flow direction, the length of the straight line is preferably 2 to 20 mm, more preferably 3 to 15 mm, and more preferably 5 to 10 mm. More preferably.

The second uneven portion preferably satisfies the relationship [maximum height of the second uneven portion <height of the protruding portion of the second region].
[Maximum height of the second uneven portion / height of the protruding portion of the second region] is preferably 0.50 or less, and more preferably 0.40 or less. [Average roughness of second uneven portion / height of protruding portion of second region] is preferably 0.20 or less, and more preferably 0.15 or less.
Further, the maximum height roughness Rz of the second uneven portion is preferably 0.2 to 4.0 μm. Moreover, it is preferable that arithmetic mean roughness Ra of a 2nd uneven | corrugated | grooved part is 0.05-2.0 micrometers.

The second colored layer is preferably mainly composed of a binder resin and a pigment and / or a matting agent.
The embodiment of the binder resin, pigment, and matting agent of the second colored layer is the same as the embodiment of the binder resin, pigment, and matting agent of the colored layer formed on the protruding portion.
What is necessary is just to adjust the thickness of a 2nd colored layer in the range from which the contrast for position alignment is obtained, and is about 0.3-5.0 micrometers normally.

When forming a position detecting means described above to other areas R _n, as shown in FIGS. 3, 4 and 6, is with other regions R _n, the first region R ₁ and the second region R _2, It is preferable that the release sheet 10 is formed at different places in the width direction. With this positional relationship, positioning in the flow direction when forming the second colored layer 14 becomes unnecessary (the second colored layer 14 can be continuously formed in the flow direction), and workability can be improved.

  When the above-described position detection means is formed in other regions, it is preferable to remove the other regions when they are transferred to the transfer object and a decorative molded product is obtained. Examples of the timing for removing the other regions include (1) the process of slitting the transfer sheet into a long length, (2) the process of punching the transfer sheet into a sheet, and (3) the transfer sheet to be transferred. And the like during the trimming process after the transfer.

Although not shown, a shape different from the shape of the first region may be formed in other regions. For example, (a) when the first region has a concavo-convex shape, make the shape of the other region substantially smooth, and (b) when the first region has a concavo-convex shape, change the shape of the other region to the first region. It is conceivable that the concavo-convex shape is different from the concavo-convex shape, and (c) when the shape of the first region is substantially smooth, the shape of the other region is the concavo-convex shape.
By forming a shape different from the shape of the first region in other regions, the surface shape of the transfer layer transferred to the transfer object can be changed depending on the location. For this reason, the obtained decorative molded product has different glossiness depending on the place, and can improve the design.

(Release layer)
The interface between the release sheet of the transfer sheet and the transfer layer is formed so as to be peelable when in close contact with the transfer target.
In order to improve releasability, the release sheet preferably has a release layer on at least a part of the surface in contact with the transfer layer. Further, from the viewpoint of uniform release property within the surface of the transfer sheet 100, the release sheet 10 is formed on the entire surface on the side in contact with the transfer layer 20 as shown in FIGS. 1 to 4. 13 is preferable.

Further, when the first region has an uneven portion, forming a release layer on the uneven portion reduces the unevenness and forms an uneven shape with less high-frequency components on the surface of the decorative molded product. Can suppress whitening and glare of the decorative molded product.
Here, “glare” refers to a phenomenon in which minute luminance variations are seen in image light due to the uneven structure on the surface. That is, by forming the release layer on the concavo-convex portion, glare can be suppressed when a decorative molded product is used on the front surface of the display element.

The release layer is preferably mainly composed of a resin.
The resin of the release layer is not particularly limited as long as it has a predetermined film strength and has a low adhesive strength with the transfer layer. General-purpose thermoplastic resin, cured product of thermosetting resin composition, ionizing radiation Examples include cured products of curable resin compositions. Specific examples include fluorine resins, acrylic resins, polyester resins, polyolefin resins, polystyrene resins, polyurethane resins, cellulose resins, vinyl chloride-vinyl acetate copolymer resins, and nitrified cotton. .
Among these, the hardened | cured material of a thermosetting resin composition is preferable, and the thermosetting resin composition containing an acrylic polyol and isocyanate is more preferable.

  The release layer may further contain a release agent in order to improve the release property. Examples of the release agent include waxes such as synthetic wax and natural washes. The synthetic wax is preferably a polyolefin wax such as polyethylene wax or polypropylene wax.

The thickness of the release layer is preferably from 0.1 to 5.0 μm, and more preferably from 0.3 to 1.0 μm.
Further, when the first region has a concavo-convex shape, the thickness of the release layer and the average roughness of the concavo-convex shape in the first region are 0.05 ≦ [release] from the viewpoint of the balance between the relief of the unevenness and the maintenance of the unevenness. It is preferable to satisfy the relationship of layer thickness / irregular shape average roughness of first region] ≦ 100, and 0.3 ≦ [thickness of release layer / average roughness of uneven shape of first region] ≦ 10 It is more preferable to satisfy the relationship, and it is further preferable to satisfy the relationship of 0.5 ≦ [thickness of release layer / average roughness of the unevenness of the first region] ≦ 3.0.

(Other layers)
The release sheet may have other layers.
Examples of other layers include an antistatic layer. By having the antistatic layer, it is possible to suppress the peeling electrification when peeling the release sheet, and to improve the transfer workability.

The antistatic layer preferably contains an antistatic agent such as an electron conductive antistatic agent or an ion conductive antistatic agent, and a binder resin.
The antistatic layer is preferably formed on the surface of the release sheet opposite to the surface in contact with the transfer layer.
The antistatic layer preferably has a surface resistivity adjusted to a range of 1.0 × 10 ⁻⁹ Ω / □ to 1.0 × 10 ⁻¹² Ω / □.
An antistatic agent may be contained in another layer such as a resin layer to exhibit antistatic properties.

(Manufacturing method of release sheet)
The release sheet can be produced, for example, by the following steps (A1) to (A3).
(A1) The process of apply | coating the ink for resin layer formation containing an ionizing radiation curable resin composition on a support body, and forming an uncured resin layer.
(A2) Using a plate having a shape complementary to the first region and the second region, the uncured resin layer is shaped, and simultaneously irradiated with ionizing radiation to cure the shaped resin layer and support The process of obtaining the base material layer in which the resin layer was formed on the body.
(A3) The process of forming a colored layer on the protrusion part in the 2nd area | region of a base material layer.

When the ionizing radiation curable resin composition contains a solvent, it is preferable to dry the solvent in the step (A1).
When the release sheet has a release layer, after the step (A3), (A4) a step of forming a release layer on at least part of the resin layer and / or the colored layer may be performed.

When the release sheet has other regions, a plate having a shape complementary to the first region, the second region, and the other regions may be used as the plate in the step (A2).
In addition, when the position detecting means is provided on the other region, the second colored layer is formed on the second concavo-convex portion of the other region and its peripheral portion simultaneously with the step (A3) or in a separate step. It is preferable to do.

  The plate used in the step (A2) can be obtained by engraving the surface of the cylinder into a desired shape by, for example, etching, sandblasting, cutting and laser processing, or a combination thereof. Alternatively, a long male plate (a plate having the same shape as the first region and the second region) is prepared by laser engraving, stereolithography, and the like, and is obtained by wrapping an inverted version around the cylinder surface. be able to. The surface of these plates is preferably hard-plated with chromium or the like.

Moreover, a release sheet can be manufactured also by the following (a1)-(a3) processes, for example.
(A1) A step of filling a plate having a shape complementary to the first region and the second region with resin layer forming ink.
(A2) The resin layer forming ink filled in the plate is transferred onto a support, dried and cured as necessary to form a resin layer, and a base material layer having a resin layer formed on the support is formed. Obtaining step.
(A3) The process of forming a colored layer on the protrusion part in the 2nd area | region of a base material layer.

When the release sheet has a release layer, after the step (a3), (a4) a step of forming a release layer on at least part of the resin layer and / or the colored layer may be performed.
When the release sheet has other regions, a plate having a shape complementary to the first region, the second region, and the other regions may be used as the plate in the step (a2).
In the case where the position detecting means is provided on the other region, the second colored layer is formed on the second concavo-convex part of the other region and its peripheral part simultaneously with the step (a3) or in a separate step. It is preferable to do.

  From the viewpoint of forming an accurate and precise shape, the above-described steps (A1) to (A3) are preferable.

  From the viewpoint of manufacturing efficiency, the transfer sheet is preferably manufactured with multiple impositions as shown in FIG. Similarly, it is preferable that the release sheet is also manufactured by multiple imposition. For this reason, it is preferable that the plate used in the step (A2) or the step (a1) is a plate corresponding to the multi-page imposition.

In the above-described plate, it is preferable that the first region and the second region are arranged at accurate positions. In particular, when the first region has an uneven portion, the arrangement of the first region and the second region is important.
When the first region has a concavo-convex portion, for example, a plate in which the first region and the second region are arranged at accurate positions can be produced by the following steps (y1) to (y4).

(Y1) A recess 40 having a shape complementary to the protruding portion of the second region is formed on the surface of the cylinder 30 ((a) of FIG. 9).
(Y2) Using the concave portion as a reference for alignment, the surface of the cylinder 30 is covered with a mask 50 in which a portion 60 for forming the concave portion in the first region is punched (FIG. 9B).
(Y3) Irregularities having a shape complementary to the irregularities in the first region are formed at locations not covered with the mask 50.
(Y4) The mask 50 is removed ((c) of FIG. 9), and the surface of the cylinder is hard-plated.

The step (y1) can be performed by etching, for example. For this reason, the cylinder preferably has a surface plated with a thick film.
In the case of forming other regions, in the step (y1), the recess 40 is formed, and a recess 70 having a shape complementary to the second protrusion of the other region is formed ((a of FIG. 9 )), (Y2) In the step, a mask in which a portion for forming the concavo-convex shape in other regions is punched may be used.
The step (y3) can be performed by, for example, etching or blasting. Blasting is preferred from the viewpoint of lowering the height than the protruding portion of the second region and the ease of adjusting the matte feeling. In addition, select the particle shape (spherical, indeterminate), particle diameter, particle material (glass beads, organic particles, inorganic particles, iron, sand, etc.) used for blasting, and the distance to inject the particles By adjusting the speed, time, angle, etc., the shape to be imparted by blasting can be adjusted.
Examples of the hard plating in the step (y4) include chrome plating.

<Transfer layer>
A transfer layer is formed on at least a part of the release sheet.
The transfer layer 20 is a layer to be transferred to the transfer object, and includes, for example, a protective layer 21 and an adhesive layer 22 in order from the side closer to the release sheet, as shown in FIGS.
Transfer layer 20 is preferably formed on the whole of the portion corresponding to the first region R ₁ of the base layer 11, as shown in FIGS. 1 to 4, more be formed on the entire surface of the release sheet 10 preferable.

(Protective layer)
The protective layer has a role of protecting the decorative molded product from abrasion, light, chemicals and the like after the transfer layer is transferred from the transfer sheet to the transfer object.
When it has an uneven | corrugated | grooved part in the 1st area | region of a release sheet, a shape complementary to this uneven | corrugated shape is provided to the surface of a decorative molded product. Moreover, when the 1st area | region of a release sheet is substantially smooth, the glossiness of a decorative molded product can be made high.

The protective layer preferably contains a resin component such as a thermoplastic resin, a cured product of a thermosetting resin composition, a cured product of an ionizing radiation curable resin composition as a main component. Among these resin components, a cured product of an ionizing radiation curable resin composition having excellent strength is preferable.
The embodiment of the resin component such as the ionizing radiation curable resin composition of the protective layer is the same as the embodiment of the resin component of the resin layer described above.
In addition, when using a thermosetting resin composition and / or an ionizing radiation curable resin composition as a material for forming the protective layer, the thermosetting resin composition is used at the time of forming the protective layer from the viewpoint of moldability. And / or the ionizing radiation curable resin composition is in a semi-cured state, transferred to the transfer object, and then the curing of the thermosetting resin composition and / or the ionizing radiation curable resin composition proceeds to complete curing. It is preferable to make it.

  The protective layer may contain particles such as organic particles and inorganic particles. By containing particles in the protective layer, glare and defects can be made inconspicuous due to the expression of internal haze due to the difference in refractive index from the resin component. For the same purpose, these particles may be contained in an adhesive layer, an anchor layer, etc. described later.

Examples of the organic particles include particles made of polymethyl methacrylate, polyacryl-styrene copolymer, melamine resin, polycarbonate, polystyrene, polyvinyl chloride, benzoguanamine-melamine-formaldehyde condensate, silicone, fluorine resin, and polyester resin. Can be mentioned.
Examples of the inorganic particles include particles made of silica, alumina, antimony, zirconia, titania and the like.

The average particle diameter of the particles is preferably 0.05 to 5.0 μm, more preferably 0.5 to 3.0 μm.
In the present specification, the average particle diameter is a 50% particle diameter (d50: median diameter) when the particles in the solution are measured by a dynamic light scattering method and the particle diameter distribution is represented by a cumulative distribution. The 50% particle diameter can be measured using, for example, a Microtrac particle size analyzer (manufactured by Nikkiso Co., Ltd.).

  The content of the particles is preferably 0.1 to 20 parts by mass and more preferably 1 to 10 parts by mass with respect to 100 parts by mass of the resin component of the protective layer.

  The thickness of the protective layer is preferably 0.5 to 30 μm, more preferably 1 to 20 μm, and still more preferably 3 to 10 μm, from the viewpoint of the balance between surface hardness and moldability.

(Adhesive layer)
The adhesive layer has a role of improving the transfer work by improving the adhesion between the transfer object such as a resin molded body and the transfer layer.
In addition, when the adhesiveness between the protective layer and the transfer object is good, the adhesive layer may not be provided.

For the adhesive layer, it is preferable to use a heat-sensitive or pressure-sensitive resin suitable for the material of the transfer object. For example, when the material of the transfer object is an acrylic resin, it is preferable to use an acrylic resin. If the material of the transferred material is polyphenylene oxide / polystyrene resin, polycarbonate resin, or styrene resin, use an acrylic resin, polystyrene resin, polyamide resin, or the like that has an affinity for these resins. Is preferred. Furthermore, when the material of the transferred material is a polypropylene resin, it is preferable to use a chlorinated polyolefin resin, a chlorinated ethylene-vinyl acetate copolymer resin, a cyclized rubber, or a coumarone indene resin.
You may mix | blend additives, such as a ultraviolet absorber and an infrared absorber, with an adhesive bond layer.
The thickness of the adhesive layer is preferably 0.1 to 10 μm, and more preferably 0.5 to 5 μm.

(Anchor layer)
The anchor layer is a layer provided as necessary to improve heat resistance when placed in a high temperature environment such as in-mold molding. The anchor layer is preferably formed between the protective layer and the adhesive layer.

The anchor layer preferably contains a cured product of the curable resin composition.
Examples of the curable resin composition include a thermosetting resin composition and an ionizing radiation curable resin composition.
Embodiments of the thermosetting resin composition and the ionizing radiation curable resin composition of the anchor layer are the same as those of the thermosetting resin composition and the ionizing radiation curable resin composition of the resin layer.
The thickness of the anchor layer is preferably 0.1 to 6 μm, and more preferably 0.5 to 5 μm.

(Print layer)
As shown in FIGS. 1 to 4, the transfer layer 20 may further include a printing layer 23. The printed layer 23 has a role of imparting a desired design property to the decorative molded product.

The print layer 23 is preferably arranged so as to be positioned at least in a part of the first region of the base material layer 11 when the transfer sheet 100 is observed from the planar direction.
Moreover, the position of the thickness direction of the printing layer 23 may be arrange | positioned on the adhesive bond layer 22 like FIGS. 1-4, and may be arrange | positioned between the adhesive bond layer 22 and the protective layer 21. FIG. And you may arrange | position between the protective layer 21 and the release sheet 10. FIG. From the viewpoint of protection of the printing layer 23 and adhesion to the transfer object, it is preferable to dispose the printing layer 23 between the adhesive layer 22 and the protection layer 21. Further, from the viewpoint of handling small lot products, it is preferable to dispose the printing layer 23 on the adhesive layer 22. When the printing layer 23 is disposed on the adhesive layer 22, the resin component of the printing layer 23 is a resin of the same type as the resin component of the adhesive layer from the viewpoint of uniform adhesion to the transfer target. It is preferable to use the same resin.

  The pattern of the printing layer is arbitrary, and examples thereof include wood grain, stone grain, cloth grain, grain grain, circle, square, polygon, geometric pattern, character, solid printing, and the like.

The printed layer preferably contains a binder resin such as a polyvinyl resin, a polyester resin, an acrylic resin, a polyvinyl acetal resin, or a cellulose resin, and a pigment and / or a dye.
The thickness of the printing layer is preferably 0.5 to 40 μm, more preferably 1 to 30 μm from the viewpoint of design.

  In addition, when forming the print layer, alignment is important, but the print layer is formed at an accurate position by the protruding portion of the second region, the colored layer on the protruding portion, and the position detecting portion of the other region. be able to.

  Each layer such as a protective layer, an adhesive layer, an anchor layer, and a printing layer constituting the transfer layer is prepared, for example, by adjusting ink containing the constituent components of each layer, and on the release sheet, such as a gravure coating method and a roll coating method. It can be formed by coating and drying by a printing method such as a coating method, a gravure printing method, a screen printing method, etc., and curing by irradiation with ionizing radiation as required.

[Transfer sheet manufacturing method]
In the method for producing a transfer sheet of the present invention, a release sheet is produced by the following steps (A1) to (A3), and then a transfer layer is formed on at least a part of the release sheet.
(A1) The process of apply | coating the ink for resin layer formation containing an ionizing radiation curable resin composition on a support body, and forming an uncured resin layer.
(A2) Using a plate having a shape complementary to the first region and the second region, the uncured resin layer is shaped, and simultaneously irradiated with ionizing radiation to cure the shaped resin layer and support The process of obtaining the base material layer in which the resin layer was formed on the body.
(A3) The process of forming a colored layer on the protrusion part in the 2nd area | region of a base material layer.

When the ionizing radiation curable resin composition contains a solvent, it is preferable to dry the solvent in the step (A1).
From the viewpoint of manufacturing efficiency, the transfer sheet is preferably manufactured with multiple impositions as shown in FIG. The transfer sheet manufactured in such a multi-face manner is subjected to a transfer process as a long transfer sheet or a single sheet transfer sheet.

  The transfer sheet manufactured by the above process can easily form a colored layer, which is a pattern printing for alignment, on the protruding portion, and the light transmittance or light between the portion having the protruding portion and its peripheral portion. The contrast of the reflectivity becomes clear and can be easily aligned.

Examples of the optional step of aligning include a step of slitting the transfer sheet in a long length, a step of punching the transfer sheet into a sheet, and a step of transferring the transfer sheet to a transfer object.
For example, if a second projecting portion 3 of the region R ₂ are formed continuously in the flow direction of the transfer sheet, the contrast occurring in a direction perpendicular to the flow direction of the second region R ₂ as shown in FIG. 7 By utilizing the (light transmittance difference or light reflectance difference), the position in the direction orthogonal to the flow direction of the transfer sheet can be aligned, and the transfer sheet can be accurately slit in a long length.
Further, in FIG. 7, and a position detecting means to other regions R _n. Utilizing said position detecting means aligned in the flow direction of the transfer sheet, further, the combined use of alignment in the direction perpendicular to the flow direction of the transfer sheet based on the second region R ₂ as described above, the transfer sheet It can be accurately punched into single wafers.
Also, orthogonal in slitting step and die cutting step described above, if leaving the second region R ₂ and / or other regions R _n, in transferring the transfer sheet to the transfer target, in the flow direction of the transfer sheet Can be aligned in the direction and / or flow direction and transferred to the correct position.
The contrast of the light transmittance difference can be detected by, for example, a light source installed below the transfer sheet and a light detection unit installed at a position facing the light source above the transfer sheet. The contrast of the light reflectance difference can be detected by, for example, a light source and a light detection unit installed at an arbitrary angle above the transfer sheet.

[Method of manufacturing decorative molded product]
The method for producing a decorative molded product of the present invention includes a step of transferring the transfer layer of the transfer sheet of the present invention described above to a transfer target, and a step of peeling the release sheet of the transfer sheet.
Examples of the material to be transferred include a resin molded body.

  A known transfer method can be used for the method of manufacturing the decorative molded product. For example, (i) a method in which a transfer sheet is attached to a preliminarily molded transfer object, the transfer layer of the transfer sheet is transferred, and then the release sheet of the transfer sheet is peeled off; A method of sticking a transfer sheet to a transfer material, transferring the transfer layer of the transfer sheet, peeling off the release sheet of the transfer sheet, and then forming a transfer material on which the transfer layer is laminated, (iii) ) A method of integrating a transfer material with a transfer sheet at the time of injection molding and then peeling the release sheet of the transfer sheet [in-mold molding (injection molding simultaneous transfer decoration method)]. Among them, according to in-mold molding (injection molding simultaneous transfer decoration method), it is possible to perform decorative molding on a resin molded body having a complicated surface shape such as a three-dimensional curved surface.

As one embodiment of the method for producing a decorative molded product using the transfer sheet of the present invention by in-mold molding,
(Z1) a step of disposing the transfer layer side of the transfer sheet toward the inside of the in-mold mold,
(Z2) a step of injecting a resin into the in-mold mold,
(Z3) integrating the transfer sheet and the resin, and transferring the transfer layer of the transfer sheet onto the surface of a resin molded body (transfer object);
(Z4) After removing the resin molded body (transfer object) from the mold, there is a step of peeling the release sheet of the transfer sheet.

(Z1) If the position detectors of the second region and / or other regions remain at the time of the arrangement in the step, the transfer sheet is arranged at an accurate position of the mold using these contrasts. be able to.
Note that after the step (z4), it is preferable to trim (remove) unnecessary portions as necessary. When the position detectors of the second region and / or other regions remain, it is preferable to trim (remove) these regions.

(Resin molding)
As the resin molding, it is preferable to use a thermoplastic resin or a thermosetting resin that can be injection-molded, and various known resins can be used.
When the decorative molded product according to the present invention is manufactured by in-mold molding, it is preferable to use a thermoplastic resin. Examples of such thermoplastic resins include polystyrene resins, polyolefin resins, ABS resins (including heat-resistant ABS resins), AS resins, AN resins, polyphenylene oxide resins, polycarbonate resins, polyacetal resins, acrylic resins, Examples thereof include polyethylene terephthalate resin, polybutylene terephthalate resin, polysulfone resin, and polyphenylene sulfide resin.

  FIG. 8 is a cross-sectional view showing an embodiment of a decorative molded product according to the present invention. The decorative molded product 300 has a printed layer 23, an adhesive layer 22, and a protective layer 21 on one surface of a resin molded body (transfer object) 200. In FIG. 8, only the portion corresponding to the first region of the transfer sheet is transferred to the resin molded body.

1. Preparation of plate A cylinder having a copper plating layer having a thickness of 200 μm was prepared. The surface of the cylinder was etched to form two grooves 40 as a set, and two sets of grooves 40 were formed in the flow direction (FIG. 9A). The depth of each groove was 5.0 μm and the width was 5.0 mm. The distance between ends of a pair of grooves _{(P 1)} was 3.0 mm. Furthermore, the shape when observed from the plane direction by the etching process is a substantially square shape (a substantially square having a straight line parallel to both the flow direction and the width direction. The length of one side is 6 mm), and the depth is 5. A 0.0 μm recess 70 was formed at the same time (FIG. 9A).
Using the groove 40 as a reference for alignment, the entire surface of the cylinder was covered with a mask 50 in which a portion (60) for forming the concavo-convex portion in the first region was cut (FIG. 9B). The uneven portion of the first region has a substantially rectangular shape 60 as shown in FIG.
Next, irregularities were formed at locations not covered with the mask 50 by blasting using glass beads. The maximum height roughness Rz of the irregularities obtained by reversing the irregularities was 1.5 μm, and the arithmetic average roughness Ra was 0.5 μm.
Next, the mask 50 was removed (FIG. 9C), and the surface of the cylinder was hard-plated (chrome plating) to obtain a two-sided plate.

2. Production of Release Sheet On a polyethylene terephthalate film having a thickness of 50 μm, a resin layer forming ink having the following formulation was applied and dried to form an uncured resin layer having a thickness of 8.0 μm.
<Resin layer forming ink>
-60 parts by mass of ionizing radiation curable resin composition (manufactured by Kyoei Chemical Co., ES105M)
・ Methyl ethyl ketone 40 mass parts ・ Silicone leveling agent 0.5 mass parts

Next, using the plate produced in the above “1”, an uncured resin layer is shaped, and at the same time, ionizing radiation is irradiated from the polyethylene terephthalate film side to cure the shaped resin layer. A base material layer having a resin layer formed thereon was obtained.
Next, the black ink is applied so that the amount of adhesion after drying is 1 g / m ² (about 1 μm) on the protrusions in the second region of the base material layer and on the second protrusions in the other regions. A colored layer forming ink obtained by diluting (made by Showa Ink Co., Ltd., trade name: EIS (NT) black) with a solvent was applied and dried to form a colored layer. There was substantially no ink in the colored layer between the set of protrusions in the second region.

Next, a release layer forming ink having the following formulation was applied to the entire surface and dried to form a release layer having a thickness of 0.5 μm, thereby obtaining a release sheet.
<Ink for forming release layer>
Acrylic polyol 70 parts by mass (manufactured by Soken Chemical Co., Ltd., trade name: Thermolac SU100A)
・ Isocyanate 25 parts by mass (Mitsui Chemicals, trade name: Takenate D-110N)
・ Ethyl acetate 161 parts by mass ・ Methyl isobutyl ketone 56 parts by mass

3. Formation of transfer layer (production of transfer sheet)
On the release sheet obtained in the above “2”, a protective layer forming ink having the following formulation was applied so that the adhesion amount after drying was 6.5 g / m ² (6.0 μm). After the formation, the protective layer was semi-cured by irradiating the light source with a fusion UV lamp system under conditions of an H bulb, a conveyance speed of 20 m / min, and an output of 40%. The integrated light quantity at this time was 15 mJ / m ² when measured by an illuminance meter (trade name: UVPF-A1) manufactured by Eye Graphics.
<Protective layer forming ink>
・ 70 parts by mass of urethane acrylate UV curable resin composition (manufactured by Dainichi Seika Co., Ltd., trade name: Seika Beam HT-X)
(Solid content 35%, toluene / ethyl acetate mixed solvent)
-30 parts by mass of urethane acrylate ultraviolet curable resin composition (manufactured by Dainichi Seika Co., Ltd., trade name: Seika Beam EXF-HT-1)
(Solid content 40%, toluene / methyl ethyl ketone mixed solvent)

Next, the anchor layer forming ink having the following formulation was applied onto the protective layer so that the amount of adhesion after drying was 3.0 g / m ^2, and after forming a coating film, the film was dried at 40 ° C. for 72 hours and cured. An anchor layer having a thickness of 2 μm was formed.
<Ink for anchor layer>
Acrylic polyol 100 parts by mass (manufactured by Dainichi Seika Co., Ltd., trade name: TM-VMAC, solid content 25%)
(Toluene / ethyl acetate / methyl ethyl ketone mixed solvent)
-10 parts by mass of xanthethylene diisocyanate (manufactured by Dainichi Seika Co., Ltd., trade name: PTC-RC3)
(Solid content 75%, solvent: ethyl acetate)

Next, an adhesive layer forming ink having the following formulation was applied onto the anchor layer so that the adhesion amount after drying was 2.5 g / m ² to form a coating film. The coating film was dried to form an adhesive layer having a thickness of 2 μm to obtain a two-sided transfer sheet.
<Coating solution for adhesive layer>
-100 parts by mass of acrylic resin (manufactured by Dainichi Seika Co., Ltd., trade name: TM-R600, solid content 20%)
(Ethyl acetate / n-propyl / methyl ethyl ketone mixed solvent)
・ Methyl ethyl ketone 40 parts by mass

4). Slit processing of transfer sheet and punching out of single sheet The two-sided transfer sheet obtained in the above “3” was slit using the contrast of the light transmittance difference in the second region. As a result, it was possible to slit at an accurate position.
Further, the two-sided transfer sheet obtained in the above “3” was punched into sheets using the contrast of the light transmittance difference between the second region and other regions. As a result, it was possible to perform punching at an accurate position.

5. Production of a decorative molded product In the slit processing and punching processing of “4” above, the first region and other regions were processed so as to remain. A decorative molded product was prepared by the following steps (z1) to (z5) using a slit sheet and a transfer sheet punched into a single sheet.

(Z1) a step of disposing the transfer layer side of the transfer sheet toward the inside of the in-mold mold (z2) a step of injecting and injecting resin into the in-mold mold,
(Z3) a step of integrating the transfer sheet and the resin, and transferring the transfer layer of the transfer sheet onto the surface of the resin molded body (transfer object);
(Z4) Step of peeling the release sheet of the transfer sheet after taking out the resin molded body (transfer object) from the mold (z5) Step of trimming (removing) the second region and / or other regions

In the above step, when the transfer sheet is arranged in the step (z1), the transfer sheet is arranged at an accurate position of the mold using the contrast of the light transmittance difference between the second region and / or other regions. I was able to. For this reason, the transfer layer was able to be transferred to the exact position of the material to be transferred (resin molded product).
The transfer sheet in which the second region remained had a fine protrusion formed on the transfer layer side surface of the transfer sheet. For this reason, blocking can be suppressed even if the slit-processed transfer sheet in which the second region remains is wound or a large number of single-sheet transfer sheets in which the second region remains are stacked.

  The transfer sheet of the present invention can be suitably used for the production of decorative molded products such as communication devices such as mobile phones, information devices inside automobiles, and home appliances.

DESCRIPTION OF SYMBOLS 1 Support body 2 Resin layer 3 Protrusion part 4 Uneven part 5 2nd protrusion part 6 2nd uneven part 11 Base material layer 12 Colored layer 13 Release layer 14 Second colored layer 10 Release sheet 21 Protective layer 22 Adhesion Agent layer 20 Transfer layer 23 Print layer 100 Transfer sheet 200 Transfer object 300 Decorated molded product

Claims (13)

  A transfer sheet having a transfer layer on a release sheet, the release sheet having a base material layer having a first region and a second region on a surface on the transfer layer side, The transfer sheet which has a protrusion part in 2 area | region, and also has a colored layer on the said protrusion part.   The transfer sheet according to claim 1, wherein the protrusion is formed of a structure having a height of 1 to 10 μm.   The transfer sheet according to claim 1, wherein the protrusion is formed from a structure having a ratio of height to width of 1: 10,000 to 1:10.   The transfer sheet according to any one of claims 1 to 3, wherein the protruding portion is formed from a row of structures extending in a direction parallel to any one side of the transfer sheet.   5. The transfer sheet according to claim 1, wherein a plurality of the projecting portions are provided in the second region of the base material layer, and at least one set of projecting portions are arranged in parallel to each other.   The transfer sheet according to claim 5, wherein an interval between the ends of the pair of protruding portions is 0.1 to 10.0 mm.   The transfer according to claim 1, wherein the substrate layer has an uneven portion in the first region, and satisfies a relationship of [maximum height of the uneven portion <height of the protruding portion]. Sheet.   The transfer sheet according to claim 1, wherein the height of the protruding portion / the thickness of the transfer layer is 0.1 to 5.0.   The transfer sheet according to any one of claims 1 to 8, wherein the release sheet has a release layer on at least a part of a surface in contact with the transfer layer.   The transfer sheet according to any one of claims 1 to 9, wherein the transfer layer has a protective layer and an adhesive layer in order from the side close to the release sheet.   The transfer sheet according to claim 10, wherein the protective layer contains a cured product of an ionizing radiation curable resin composition. The manufacturing method of the transfer sheet of Claim 1 which forms a transfer layer in at least one part of a release sheet, after manufacturing a release sheet by the following (A1)-(A3) process.
(A1) The process of apply | coating the ink for resin layer formation containing an ionizing radiation curable resin composition on a support body, and forming an uncured resin layer.
(A2) Using a plate having a shape complementary to the first region and the second region, the uncured resin layer is shaped, and simultaneously irradiated with ionizing radiation to cure the shaped resin layer and support The process of obtaining the base material layer in which the resin layer was formed on the body.
(A3) The process of forming a colored layer on the protrusion part in the 2nd area | region of a base material layer.   Production of a decorative molded article, comprising: a step of transferring a transfer layer of the transfer sheet according to any one of claims 1 to 10 to a transfer target; and a step of peeling the release sheet of the transfer sheet. Method.