JP7779017B2 - Transfer sheet, and manufacturing method of cosmetic material using the same, and cosmetic material - Google Patents

Description

The present invention relates to a transfer sheet, a method for manufacturing a cosmetic material using the same, and the cosmetic material.

Traditionally, decorative materials or decorative sheets have been used as articles to decorate and protect the surfaces of, for example, interior building components such as walls, ceilings, and floors; exterior building components such as exterior walls, eaves ceilings, roofs, fences, and railings; fittings or fixtures such as window frames, doors, door frames, handrails, baseboards, moldings, and other components; general furniture such as chests of drawers, shelves, and desks; kitchen furniture such as dining tables and sinks; surface decorative panels for cabinets and other appliances and office equipment; and interior or exterior vehicle components. Such decorative materials include, for example, those with a surface layer that has the desired function.

For decorative materials used in these applications, a common technique is to enhance the texture by using a matte effect to improve their design. For example, Patent Document 1 proposes a decorative sheet with a pattern layer and a concealing layer on one side of a base sheet, and a gloss-adjusting layer (matte layer, gloss layer) on the other side as an example of a decorative material that uses a matte effect. The decorative sheet in Patent Document 1 achieves a design effect by highlighting the pattern layer and concealing layer due to the difference in gloss between the matte and gloss layers of the gloss-adjusting layer. In one example, the matte layer applied over the entire surface uses a matte ink containing 50 parts by weight of matting agents, consisting of 10 parts by weight of spherical alumina and 40 parts by weight of calcium carbonate per 100 parts by weight of resin.

Patent Document 2 also proposes a decorative material that has a printed layer and a transparent resin layer, in that order, on a substrate, with an embossed pattern on the outermost surface of the transparent resin layer.

Japanese Patent Application Laid-Open No. 2000-062081 JP 2011-073207 A

Examples of methods for improving texture by a matte effect include a method in which a matting agent (also referred to as a "matting agent") is used to obtain a matte effect by the light diffusion effect of the agent itself, as in Patent Document 1, and a method in which an uneven shape is formed on the outermost surface by embossing, as in Patent Document 2.
However, when a matting agent is used as in Patent Document 1, the amount used must be increased to improve the matting effect. However, as the amount used increases, the matting agent tends to fall off the coating film and scratch the coating film, reducing scratch resistance. Furthermore, scratches become more noticeable due to changes in gloss caused by the loss of the matting agent. Alternatively, contaminants may penetrate into the minute gaps at the interface between the matting agent and the resin, and the matting agent itself may adsorb contaminants, reducing stain resistance. On the other hand, reducing the amount used to prevent the deterioration of surface properties tends to reduce the matting effect. Therefore, surface properties and matting effect are in a trade-off relationship. Therefore, there are limitations to the matte effect achieved using a matting agent.

Furthermore, when using embossing as in Patent Document 2, creating an embossing plate is laborious and not easy, and a plate must be created for each desired pattern. Therefore, it cannot be said to be a method that adequately meets the diverse needs of customers. Furthermore, the embossing in Patent Document 2 restricts the manufacturing process, and depending on the material of the item to which the textured pattern is to be applied, it may be difficult to apply the textured pattern. Furthermore, with embossing, depending on the combination of the type of substrate to be embossed, the embossing conditions, and the textured pattern on the embossing plate, the matte textured pattern on the embossing plate may not be faithfully transferred onto the substrate, resulting in an insufficient matte finish.

However, customer demands are diverse, and they are now seeking not only the visual matte effect described above, but also a tactile feel. For example, when using a matting agent as in Patent Document 1, increasing the amount used can cause the contours of the matting agent to appear on the surface of the decorative sheet, resulting in a somewhat rough surface feel, or a "grainy" feel. Furthermore, when embossing is used as in Patent Document 2, a tactile feel can be created due to the uneven shape of the surface created by the embossing plate. However, neither method focuses on the expression of the tactile feel, and it cannot be said that a sufficient expression is achieved in terms of tactile feel. In other words, conventional decorative sheets and decorative materials have not been able to achieve both an excellent matte effect and a good tactile feel. In the present invention, we focus on the tactile feel in particular, that of a "grainy" feel.

The objective of the present invention is to provide a transfer sheet that can impart excellent visibility and texture of a matte effect and a rough feel to the touch, a method for producing a cosmetic material that has excellent visibility and texture of a matte effect and a rough feel to the touch, and the cosmetic material.

In order to solve the above problems, the present invention provides the following [1] to [14].
[1] A transfer sheet having a transfer layer on a releasable support,
A transfer sheet having a surface shape in which, on at least a portion of the surface of the transfer layer facing the releasable support, Spc (arithmetic mean curvature of protrusion apexes) as defined in ISO 25178 is greater than 4000 mm ⁻¹ and Rsm (average length of curved elements) as defined in JIS B0601:2013 is 30 μm or greater.
[2] The transfer sheet according to [1], wherein the surface shape has a profile peak and height parameter Rz (maximum height) defined in JIS B0601:2013 of 8.00 μm or more and 30.00 μm or less.
[3] The transfer sheet according to [1] or [2], wherein the surface shape has a Ra (arithmetic mean roughness), which is a parameter in the height direction of a profile curve defined in JIS B0601:2013, of 1.00 μm or more and 5.50 μm or less.

[4] The transfer sheet according to any one of [1] to [3], wherein the surface of the transfer layer that forms the surface shape has an uneven shape formed by irregular wrinkles.
[5] The transfer sheet according to [4], wherein the irregular wrinkles are composed of a plurality of convex portions formed by a plurality of linear protrusions and a concave portion formed by being surrounded by the plurality of linear protrusions.
[6] The transfer sheet according to any one of [1] to [5], wherein the transfer layer has a release layer and an adhesive layer in this order from the releasable support side.

[7] The transfer sheet according to [6], which has one or more layers selected from a primer layer and a decorative layer between the release layer and the adhesive layer.
[8] The transfer sheet according to [6] or [7], wherein the release layer contains a cured product of a resin composition containing an ionizing radiation curable resin.
[9] The transfer sheet according to any one of [6] to [8], wherein the release layer contains an ultraviolet absorber or a light stabilizer.

[10] The transfer sheet according to any one of [6] to [9], wherein the release layer is substantially free of particles.
[11] The transfer sheet according to any one of [1] to [10], wherein the releasable support has a release layer on the support.
[12] The transfer sheet according to [11], wherein the release layer contains a cured product of a resin composition containing an ionizing radiation curable resin.
[13] A method for producing a decorative material, comprising the following steps (1) and (2):
(1) A step of obtaining a laminate in which the transfer layer of the transfer sheet according to any one of [1] to [12] is closely attached to an adherend.
(2) A step of peeling off the releasable support from the laminate to obtain a decorative material having a transfer layer on the adherend.
[14] A decorative material having a transfer layer on an adherend,
A decorative material having a surface shape in at least a part of the surface of the transfer layer opposite to the adherend, in which Spc (arithmetic mean curvature of protrusion apexes) as defined in ISO 25178 is greater than 4000 mm ^-1 , and Rsm (average length of curved elements) as defined in JIS B0601:2013 is 30 μm or greater.

The present invention provides a transfer sheet that can impart excellent visibility and texture of a matte effect, as well as a rough feel to the touch. Furthermore, the present invention makes it possible to easily produce a decorative material that has excellent visibility and texture of a matte effect, as well as a rough feel to the touch.

FIG. 2 is a schematic diagram illustrating the surface shape of the transfer sheet of the present invention. FIG. 2 is a schematic diagram illustrating the surface shape of the transfer sheet of the present invention. 1 is a cross-sectional view showing one embodiment of a transfer sheet of the present invention. 1 is a schematic plan view illustrating one embodiment of a transfer sheet of the present invention. 1 is a cross-sectional view showing one embodiment of a transfer sheet of the present invention. 1 is a cross-sectional view showing one embodiment of a transfer sheet of the present invention. 1 is an optical microscope image of the surface of the decorative material obtained in Example 1. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 1. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 2. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 3. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 4. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 5. 1 is an optical microscope image of the surface of the decorative material obtained in Comparative Example 6.

[Transfer sheet]
Hereinafter, an embodiment of the present invention (hereinafter, sometimes referred to as "the present embodiment") will be described. In this specification, the numerical values relating to "greater than or equal to,""less than or equal to," and "to" in describing a numerical range are numerical values that can be arbitrarily combined, and the numerical values in the examples are numerical values that can be used as the upper and lower limits of the numerical range.

The transfer sheet of the present embodiment comprises a transfer layer on a releasable support, and is characterized in that at least a portion of the surface of the transfer layer on the releasable support side has a surface shape in which Spc (arithmetic mean curvature of the apexes of protrusions) is greater than 4000 mm ⁻¹ and Rsm (average length of curved elements) is 30 μm or greater.

Figure 3 is a cross-sectional view showing one embodiment of a transfer sheet 100 of the present invention. The transfer sheet 100 in Figure 3 has a transfer layer 20 on a releasable support 10. Also in Figure 3, the releasable support 10 has a release layer 12 on a support 11. Also in Figure 3, the transfer layer 20 has, in this order from the side closest to the releasable support 10, a peel layer 21, a primer layer 22, a decorative layer 23, and an adhesive layer 24.

In the transfer sheet of Fig. 3, a release layer 21 is located on the side of the transfer layer 20 facing the releasable support 10. Therefore, in the transfer sheet of Fig. 3, at least a portion of the surface of the release layer 21, which is the surface of the transfer layer 20 facing the releasable support 10, has a surface shape in which Spc (arithmetic mean curvature of the apexes of the protrusions) is greater than 4000 mm ^-1 and Rsm (average length of the curved elements) is 30 µm or greater.

[Surface shape]
The transfer sheet of this embodiment will be described starting with the surface shape of at least a part of the surface of the transfer layer on the releasable support side (hereinafter also simply referred to as "surface shape of the transfer layer" or "surface shape").
The surface shape of the transfer layer is reflected in the surface shape of the decorative material obtained by transferring the transfer layer to an adherend. As mentioned above, the surface shape of the transfer layer is reflected in the surface shape of the decorative material obtained by transferring the transfer layer to an adherend, but the surface shape of the transfer layer and the surface shape of the decorative material are not limited to being completely identical and may vary slightly depending on the heat and pressure conditions during transfer, but the visibility and texture of the matte effect, and the "rough tactile feel" of an Spc greater than 4000 mm-1 and an Rsm of 30 μm or more are maintained.

The surface shape of the transfer layer must have an Spc (arithmetic mean curvature of the apex of the protrusion) as defined in ISO 25178 greater than 4000 mm ^-1 and an Rsm (average length of the curved element) as defined in JIS B0601:2013 of 30 μm or greater. By having such a surface shape of the transfer layer, the transfer sheet of this embodiment can impart excellent matte visibility and texture (hereinafter, these may be collectively referred to as the "matte effect") to the adherend, and can also impart a particularly "rough" tactile feel to the adherend. While the "rough" tactile feel is a sensual expression, "rough" in this specification encompasses all tactile feels that are generally perceived as "rough." Specifically, it refers to the tactile feel felt when touching a rough surface with the pad of a finger, and can be described as a tactile feel that is not rough or smooth, but rather feels rough and rough. Examples of fabrics that have a "rough" feel include coarse cotton fabrics such as Oxford cloth made with thick threads of about 10 to 50 count (thick to medium count), and linen fabrics made with thick threads of about 10 to 50 count.

(Spc (arithmetic mean curvature of the apex of the protrusion))
Spc (arithmetic mean curvature of protrusion apexes) is one of the three-dimensional surface texture parameters defined in ISO 25178 , and is the mean curvature (average sharpness) of the tip of a peak, calculated from the arithmetic mean value of the curvature radii of the peaks (peaks of protrusions) of parts classified as mountains (convex parts) in the feature image included in the reference area. Therefore, Spc is the reciprocal (mm ^-1 ) of the radius (mm).

The larger the Spc value, the greater the curvature of the tip of the peak (protrusion) (1a in Figure 1) (the reciprocal of the curvature radius is smaller, and the shape of the tip is sharper). On the other hand, the smaller the Spc value, the smaller the curvature of the apex of the protrusion (1b in Figure 1) (the reciprocal of the curvature radius is larger, and the shape of the tip is blunter). In other words, the smaller the Spc value, the more rounded the protrusion is, and the closer it is to a flat surface, and the greater the gloss. Therefore, in order to suppress gloss by focusing only on the Spc value, a surface shape with a large Spc (a surface shape with sharp protrusion apexes), that is, a flat shape greater than 4000 mm ^-1 , will increase light scattering on the surface and reduce gloss.

A surface shape with a small Spc value has rounded protrusion apexes, resulting in a soft feel. However, when the Spc value is large, i.e., greater than 4000 mm ^-1 (radius of curvature less than 0.25 mm), the sharp tip shape can be felt with a moderate contact frequency when touched with the pad of a finger. This is thought to lead to the tactile sensation felt when touching a rough surface with the pad of a finger, which is not a soft feel but a rough, rough feel, i.e., a "rough" feel. However, if the average spacing between such sharp protrusion apexes is too close, the presence of each sharp tip shape falls below the threshold of the tactile resolution of the finger pad, and the sharp feel of each protrusion is lost, resulting in a smooth, soft feel. Therefore, in addition to the requirement of Spc > 4000 mm ^-1 , the surface shape of a matte article must also satisfy the requirement of Rsm (average length of curved elements) ≥ 30 μm, which corresponds to the average protrusion spacing, as described below.

In relation to Rsm (average length of curved elements) described below, from the viewpoint of improving the matte effect and rough feel, Spc is preferably 4200 mm ^-1 or more, more preferably 4250 mm ^-1 or more, more preferably 4300 mm ^-1 or more, with the upper limit preferably being 7000 mm ^-1 or less, preferably 5000 mm ^-1 or less, more preferably 4500 mm ^-1 or less, and even more preferably 4200 mm ^-1 or less. In measuring Spc in this specification, the cutoff value is 0.8 mm.

Spc is measured using a shape analysis laser microscope on a rectangular area (1024 μm x 768 μm) at any location on the surface shape of the transfer layer. Measurement conditions can be adjusted as appropriate; for example, measurements can be performed under the conditions described in the Examples. Rsm (average length of curved elements), Rz (maximum height), and Ra (arithmetic mean roughness), which will be described later, can also be measured in a similar manner.

(Rsm (average length of curved element))
Rsm (average length of curved elements) is a parameter of the horizontal direction of the profile curve among the three-dimensional surface texture parameters defined in JIS B0601:2013, and is the average length of the profile curve elements in the reference length. The larger the Rsm, the fewer the convex portions (2a and 2b in Figure 2) included in the reference length. Therefore, a surface shape with a large Rsm will have sparsely distributed protruding apexes of the convex portions. By dispersing the convex portions in this way, i.e., by making them 30 μm or more, a sharp tip shape can be felt with a moderate contact frequency when touched with the pad of a finger. This is thought to lead to the tactile sensation felt when touching a rough surface with the pad of a finger, which is not a soft feel but a rough and rough feel, i.e., a "rough" tactile sensation. In addition, the relatively concave portions are thought to provide a matte effect.

Furthermore, if Rsm is reduced, the number of convex portions included within the reference length increases. This results in the formation of many convex portions on the surface, requiring a precise manufacturing process. For this reason, setting Rsm to 30 μm or more makes it possible to simplify the manufacturing process.

In this embodiment, by increasing Spc, it is possible to improve the matte effect while obtaining a "rough" feel, but even if Spc is large, if Rsm is small, the apexes of the protrusions are densely located, and when the surface is stroked with a finger, the area of contact with the finger increases, resulting in a soft touch. For this reason, it is believed that by making Spc (the arithmetic mean curvature of the apexes of the protrusions) greater than 4000 mm ^-1 and making Rsm (the average length of the curved elements) 30 μm or more, it is possible to achieve both a high level of matte effect and a "rough" feel.

In relation to the Spc, from the viewpoint of improving the matte effect and the "rough" feel, the lower limit of Rsm is preferably 32.0 μm or more, more preferably 35.0 μm or more, and even more preferably 37.5 μm or more, and the upper limit is preferably 60.0 μm or less, more preferably 50.0 μm or less, and even more preferably 40.0 μm or less. By setting the upper limit within the above range, the planar shape will exhibit a "rough" feel, and manufacturing will not become excessively difficult, which is preferable. Note that the cutoff value for measuring Rsm in this specification is 0.8 mm.

(Wrinkles)
The surface shape of the transfer layer of this embodiment preferably has minute wrinkles (wrinkles) visible in a plan view as shown in FIG. 4, which will be described later. These wrinkles preferably have an irregular, uneven shape. With regard to the surface shape of the transfer layer of this embodiment, Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved elements), preferably Rz (maximum height) and Ra (arithmetic mean roughness), which will be described later, are likely to fall within a specific numerical range due to the presence of these minute wrinkles (wrinkles). On the other hand, these minute wrinkles (wrinkles) are more likely to be formed by having Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved elements), and preferably Rz (maximum height) and Ra (arithmetic mean roughness), within a specific numerical range. In this way, it can be said that Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved elements), etc., and minute wrinkles (wrinkles) are inextricably linked. Such a surface shape provides a "rough" feel to the touch and improves the matte effect.

(Rz (maximum height))
In this embodiment, the surface shape of the transfer layer preferably has a Rz (maximum height), which is a parameter in the horizontal direction of the profile curve defined in JIS B0601:2013, of 8.00 μm or more and 30.00 μm or less.
Rz (maximum height) is one of the peak and height parameters of a profile curve, and is the sum of the height of the highest peak and the depth of the deepest valley in the profile curve over a reference length. The larger the Rz (maximum height) value, the more likely it is that there are large (high) convex portions when viewed from the valleys (concave portions), and this indicates a tendency for a large number of such convex portions to be present. Therefore, in a surface shape that satisfies the Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved element), if the Rz (maximum height) is 8.00 μm or more and 30.00 μm or less, the sharp tip shape of the convex portions as defined by the Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved element) is emphasized, improving the rough tactile feel. The matte effect is also improved.

From the standpoint of improving the matte effect and rough texture, Rz (maximum height) is preferably 8.50 μm or more, more preferably 9.00 μm or more, and even more preferably 9.50 μm or more, with the upper limit being preferably 26.00 μm or less, more preferably 24.00 μm or less, and even more preferably 22.00 μm or less. Note that the cutoff value for measuring Rz (maximum height) in this specification is 0.8 mm.

(Ra (arithmetic mean roughness))
In this embodiment, the surface shape of the transfer layer preferably has an Ra (arithmetic mean roughness), which is a parameter in the horizontal direction of a profile curve defined in JIS B0601:2013, of 1.00 μm or more and 5.50 μm or less.
Ra (arithmetic mean roughness) is one of the parameters in the height direction of the profile curve, and is the average value of the height difference from the mean plane in the profile curve over a reference length. The smaller the Ra (arithmetic mean roughness) value, the smaller the height difference of the convex portions in the surface shape of the transfer layer and the concave portions formed accordingly, which indicates a tendency for the shape to be smoother and more uniform. Therefore, in the surface shape of the transfer layer that satisfies the Spc (arithmetic mean curvature of the apex of the convex portions) and Rsm (average length of the curved elements), if Ra (arithmetic mean roughness) is 1.00 μm or more and 5.50 μm or less, the shape of the convex portions on the surface shape of the transfer layer will be more uniform and gentle, thereby suppressing the unusual tactile feel, and particularly improving the rough tactile feel. The matte effect is also improved.

From the viewpoint of improving the matte effect and rough texture, Ra (arithmetic mean roughness) is preferably 5.25 μm or less, more preferably 5.00 μm or less, and even more preferably 4.50 μm or less, with the lower limit preferably being 1.00 μm or more, more preferably 1.50 μm or more, and even more preferably 1.75 μm or more. Note that the cutoff value for measuring Ra (arithmetic mean roughness) in this specification is 0.8 mm.

(Surface shape of transfer layer)
The surface shape of the transfer layer of this embodiment preferably has wrinkles. As described above, stable wrinkle formation on the surface of the transfer layer results in a layer that exhibits a stable matte effect due to the light diffusion effect caused by the wrinkle shape, and also exhibits a rough texture. Figure 4 is a schematic plan view of one embodiment of the transfer sheet of this embodiment, and is a schematic image of the surface of the transfer layer side of the decorative material obtained in the examples. Figure 4 shows that wrinkles are formed on the surface of the transfer layer of this embodiment. Here, "plan view" means viewing the surface of the transfer layer from the positive Z-axis direction in the XYZ coordinate system shown in Figures 3, 5, and 6.

The wrinkles that appear on at least one surface of the transfer layer are not particularly limited as long as they have the above-mentioned surface shape, i.e., a surface shape having Spc and Rsm within the above-mentioned specific numerical ranges, and preferably other Rz and Ra within the above-mentioned specific numerical ranges, and since the surface shape is obtained by the appearance of wrinkles, a stable matte effect is exhibited and a rough texture is also exhibited.
Regarding wrinkles, from the viewpoint of realizing the surface shape, improving the matte effect, and enhancing the rough tactile feel, it is preferable that at least one surface of the transfer layer has an uneven shape constituted by irregular wrinkles, and the irregular wrinkles are preferably constituted by a plurality of convex portions formed by a plurality of protrusions and concave portions formed by being surrounded by the plurality of protrusions, and it is preferable that the protrusions have linear protrusions. In this specification, "linear protrusions" (hereinafter also referred to as "linear protrusions") means that the ratio of the length to the width of the protrusions (length/width) is 3 or more, preferably 5 or more, and more preferably 10 or more, and the method for determining the length and width is as described below.
In this embodiment, more preferable irregular wrinkles are those constituted by a plurality of convex portions formed by a plurality of linear protrusions and a concave portion formed by being surrounded by the plurality of linear protrusions.

An example of the wrinkle configuration is shown in Figure 4. Figure 4 shows that the surface of the transfer layer has irregular wrinkles in a planar view, and that the irregular wrinkles are configured to include multiple convex portions 2 formed by multiple curved linear protrusions and recessed portions 3 formed by being surrounded by the multiple protrusions (multiple convex portions 2). It also shows that at least a portion of the multiple curved convex portions 2 are each formed by a serpentine linear protrusion, and that the serpentine recessed portions 3 are formed so as to be surrounded by the serpentine linear protrusions. The transfer layer that constitutes the transfer sheet of this embodiment consistently exhibits a matte effect and also exhibits a rough texture due to the stable formation of wrinkles as shown in Figure 4.

Here, "curved" means that, in a planar view, there is one or more portions where the extension direction of the continuous linear protrusions 2 reverses from one side to the other. Examples of portions where the extension direction reverses from one side to the other include a shape that has an inflection point when the linear protrusions 2 are approximated by a continuous curve when the width of the planar view shape is ignored (when the width is considered to be 0). Also included are forms that have a portion that is approximated by a V-shaped folded line or two sides of a triangle that sandwich one vertex when the linear protrusions 2 are approximated by a straight line when the width of the planar view shape is ignored.

"Meandering" also means that, in a plan view, there are at least two or more portions where the extension direction of the continuous linear protrusions 2 reverses from one side to the other (hereinafter also referred to as "reversed portions"). When proceeding along the extension direction of the linear protrusions 2, there are portions where the extension direction of the linear protrusions 2 reverses alternately in opposite directions at two adjacent portions. For example, when the width of the planar shape of the linear protrusions 2 is approximated by a continuous curve, ignoring the width of the planar shape, examples include a shape having a portion that can be approximated by the Roman letter "S." Furthermore, when the width of the planar shape of the linear protrusions 2 is approximated by a straight line, ignoring the width of the planar shape, examples include a shape having a portion that can be approximated by the Roman letter "W."

In this specification, "irregular" means a shape that does not follow a set pattern or is not arranged according to a set pattern. A typical example of a non-irregular shape (a regular shape) is a shape that is arranged with a set periodicity in a specific direction, such as a so-called "lenticular lens," in which multiple cylindrical unit lenses are arranged adjacent to each other in a direction perpendicular to their longitudinal direction. Therefore, the irregular wrinkles in this embodiment encompass a shape in which the shape of a single protrusion itself is irregular and not formed according to a set pattern such as periodicity; a shape in which the shapes of multiple convex portions formed by multiple protrusions are irregular and not formed or arranged according to a set pattern; and a shape in which a concave portion surrounded by such multiple protrusions is also irregular.

In the transfer layer constituting the transfer sheet of this embodiment, if any of the shape of a single protrusion (a single convex portion), the shape and arrangement of each of the multiple protrusions (multiple convex portions), or the shape of the recess surrounded by the multiple protrusions is irregular, a matte effect and a rough feel can be obtained due to the irregular wrinkles, but it is preferable that all of them are irregular. By having irregular wrinkles on the surface of the transfer layer, the transfer sheet of this embodiment improves the visibility and texture of the matte effect, and stably exhibits an extremely excellent matte effect and a rough feel.

As previously mentioned, the transfer layer has wrinkles, i.e., an uneven shape, on at least one surface. The convex and concave portions of the uneven shape can be distinguished by, for example, using the brightness difference in the image of the transfer layer surface in this embodiment, binarizing the image by assigning the darkest part of the density distribution image to gradation 255 and the lightest part to gradation 0, with gradations 0 to 255 representing concave portions (gradations 0 to 127) and convex portions (gradations 128 to 255). The image can be captured after the transfer layer has been transferred to the adherend.

In this embodiment, the surface of the transfer layer preferably has irregular wrinkles formed on at least a portion thereof, and more preferably has irregular wrinkles formed over the entire surface. The location where the wrinkles are formed is not particularly limited as long as it is on the surface of the transfer layer, and is not limited to, for example, only locations corresponding to a pattern (on the pattern) described below, but the matte effect and rough texture due to the formation of wrinkles are realized as long as it is on at least a portion of the surface of the transfer layer.
For example, if the product has a decorative layer as described below and irregular wrinkles are formed in some areas, forming the wrinkles in areas that correspond to the pattern on the decorative layer (for example, on the pattern) will cause the pattern to appear as a more matte area than the surrounding area, thereby improving the design.

As shown in Figure 4, it is also preferable to have multiple convex portions formed by multiple protrusions that are irregular but have a certain degree of uniformity, and concave portions surrounded by the convex portions. Therefore, a single convex portion (protrusion) with a shape in which the width changes drastically is unlikely to achieve the above-mentioned surface shape and is not a preferred form for achieving the visibility and texture of the matte effect, nor is it a preferred form for achieving a rough tactile feel. Specific forms of the shapes of convex portions (protrusions) and concave portions that form irregular wrinkles that can be advantageous for consistently improving the matte effect and improving the rough tactile feel are described below. When the wrinkles have the following shape, the above-mentioned surface shape is more likely to be achieved, improving the matte effect and the rough tactile feel.

Regarding the shape of the wrinkles formed on at least one surface of the transfer layer, the height of the convex portions (height of the protrusions) is preferably 0.5 μm or more, more preferably 1 μm or more, and even more preferably 2 μm or more, with an upper limit of approximately 10 μm or less. Furthermore, the width of the convex portions is preferably 0.1 μm or more, more preferably 0.3 μm or more, and even more preferably 0.5 μm or more, with an upper limit of preferably 10 μm or less, more preferably 4 μm or less, and even more preferably 3 μm or less. When the height and width of the convex portions are within the above ranges, the surface shape described above is more easily achieved, and in relation to the concave portions, the matte effect is stably improved and the rough texture is improved.

The above dimensions of the convex portions are the average values of 10 convex portions (protrusions) at any 10 locations (100 μm square areas x 10 locations) on the transfer sheet of this embodiment, i.e., a total of 100 convex portions. As shown in Figure 3, the width of a single convex portion (protrusion) is not uniform, but varies between wide and narrow, so the width of a single convex portion (protrusion) is the average value of the widths at any 5 locations on that single convex portion (protrusion). The same applies to the height of the convex portions (protrusions).

The depth of the recesses is preferably 0.5 μm or more, more preferably 1 μm or more, and even more preferably 2 μm or more, with an upper limit of about 10 μm or less. The width of the recesses is preferably 0.1 μm or more, more preferably 0.2 μm or more, and even more preferably 0.3 μm or more, with an upper limit of preferably 10 μm or less, more preferably 3 μm or less, and even more preferably 2 μm or less. When the depth and width of the recesses are within the above ranges, the surface shape is easily exhibited, and in relation to the protrusions, the matte effect is stably improved and the rough tactile feel is improved.
Here, the dimensions of the recessed portion are determined in the same manner as the dimensions of the protruding portion described above.

The distance from the top of the convex portion to the bottom of the concave portion (height difference between the convex portion and the concave portion) is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 4 μm or more, with the upper limit being preferably 20 μm or less, more preferably 8 μm or less, and even more preferably 7 μm or less. When the distance is within the above range, the surface shape is easily exhibited, the matte effect is stably improved, and the rough texture is improved.
Here, the dimensions of the recessed portion are determined in the same manner as the dimensions of the protruding portion described above.

The proportion of the convex portions is preferably 15% or more, more preferably 20% or more, and even more preferably 30% or more, with the upper limit being preferably 80% or less, more preferably 70% or less, and even more preferably 60% or less. When the proportion of the convex portions is within the above range, the surface shape is easily exhibited, and in relation to the proportion of the concave portions surrounded by the convex portions, the matte effect is stably improved and the rough tactile feel is improved.
Here, the occupancy rate of the convex portions is the average value of the occupancy rate of the convex portions at any 10 locations (100 μm square area×10 locations) on the transfer sheet of this embodiment.

The convex portions and concave portions may have portions of approximately the same direction and width, but from the viewpoint of improving the matte effect and the rough texture, it is preferable that the length be short. Specifically, the length of the continuous convex portions and concave portions of approximately the same direction and width is preferably 95 μm or less, more preferably 80 μm or less, and even more preferably 70 μm or less, with the lower limit being preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 15 μm or more. When the length is within the above range, the wrinkles become more irregular, thereby stably improving the matte effect and improving the rough texture.
Here, of any 10 convex portions and concave portions (i.e., a total of 100 convex portions and concave portions) in any 10 locations (100 μm square areas × 10 locations) on the transfer sheet of this embodiment, it is preferable that 80% or more of them satisfy the above conditions, more preferably 85% or more, even more preferably 90% or more, and even more preferably 95% or more. Furthermore, in this specification, the "substantially the same" means roughly the same, without branching, meaning a difference of within ±3° in the direction, and within ±5% in the width.

The number of convex portions (projections) in a 100 μm square area is preferably 10 or more, more preferably 20 or more, and even more preferably 30 or more, with the upper limit being preferably 200 or less, more preferably 100 or less, and even more preferably 70 or less. When the number of convex portions is within the above range, the matte effect is stably improved and the rough texture is also improved.
The number of convex portions is the average number of convex portions in 10 locations (100 μm square area×10 locations) on the transfer sheet of this embodiment.

FIG. 5 is a cross-sectional view showing one embodiment of the transfer layer 20 constituting the transfer sheet of this embodiment, in which the transfer layer is cut along a plane parallel to its thickness direction (Z direction in the drawing).
The shape of the recess may be, for example, an acute angle as shown in 3a in Fig. 5, a semicircular or semielliptical shape as shown in 3b, or a combination of these.Furthermore, a shape such as 3c in Fig. 5, in which one protrusion has a recess in a part thereof, may also be used.
On the other hand, the shape of the convex portion is semicircular or semielliptical, although the width varies as shown in 2c and 2d of FIG.

(Formation of surface shape of transfer layer)
The surface shape of the transfer layer is preferably formed based on the surface shape of the basic matte layer described below. By first preparing the basic matte layer and then forming the surface of the transfer layer, the desired surface shape can be formed without the inclusion of wrinkle formation stabilizers, etc. In other words, the transfer layer does not need to contain wrinkle formation stabilizers, etc., which are necessary for forming the basic matte layer described below. Furthermore, the resin constituting the transfer layer is different from that of the basic matte layer, providing more options. By preparing the basic matte layer in this manner, the transfer layer can be made into a resin composition that improves weather resistance by adding ultraviolet absorbers, radical scavengers, etc., which is preferable.

Regarding the surface shape of the transfer layer, it is preferable to design the surface shape of the releasable support so that Spc (arithmetic mean curvature of the apex of the protrusion), Rsm (average length of the curved element), Rz (maximum height), and Ra (arithmetic mean roughness) satisfy preferred ranges, since the surface structure of the transfer layer will have a shape that reflects the surface shape of the releasable support.
Of the above parameters, the value of Spc is preferably adjusted to the shape of the recesses of the releasable support, since the shape of the recesses of the releasable support becomes the shape of the protrusions of the transfer layer.

A method for adjusting the shape of the recesses in the releasable support will be described.
When the surface shape A of the article is inverted once, it becomes a surface shape complementary to the shape A. Then, when the complementary surface shape is inverted again, it returns to the same surface shape as the surface shape A (the above-mentioned "same" does not necessarily mean completely the same, but means that the Spc and Rsm fall within a specific range, allowing for a degree of error so that the visibility of the matte effect, the texture, and the rough tactile feel of the initial surface shape are maintained). In other words, when the surface shape of the article is inverted twice, it returns to the original surface shape. This double inversion can be used to adjust the convex shape of the surface shape of the transfer layer.
For this reason, it is preferable to first prepare a basic matte layer (hereinafter also referred to as "basic matte layer"), and then form the surface shape of the release support into a shape that is the inverse of the surface shape of the basic matte layer.Release supports having a surface shape that is the inverse of the surface shape of the basic matte layer can be produced, for example, by the following three methods (1-1) to (1-2), (2-1) to (2-3), and (3-1) to (3-2).

(1-1) A basic matte layer A is prepared that satisfies parameters such as Spc and Rsm.
(1-2) The basic matte layer A is pressed against the surface of a releasable support, and the surface of the releasable support is molded into a shape that is an inverse of the surface shape of the basic matte layer A. The basic matte layer A corresponds to the basic matte layer described below.
As the release support, a laminate having a release layer on a support is preferably used, and when the basic matte layer A is pressed against the surface of the release layer, the release layer is left in an uncured state, and then cured, so that the surface of the release layer (= the surface of the release support) can be molded into a shape that is the inverse of the surface shape of the basic matte layer A.

(2-1) A basic matte layer A is prepared that satisfies parameters such as Spc and Rsm.
(2-2) Mold A is prepared with the same surface shape as the basic matte layer A. Mold A with the same surface shape as the basic matte layer A can be obtained, for example, by preparing mold B by inverting the surface shape of the basic matte layer A, and then preparing a mold by inverting the surface shape of mold B. The mold A is the mold obtained by inverting the surface shape of mold B. Molds A and B can be prepared by a general-purpose mold preparation method such as electroforming.

(2-3) Mold A is pressed against the surface of the release support, and a shape that is the inverse of the surface shape of mold A (= the surface shape of basic matte layer A) is imprinted on the surface of the release support. A laminate having a release layer on a support is preferably used as the release support, and by leaving the release layer in an uncured state when mold A is pressed against the surface of the release layer and then curing it, it is possible to imprint a shape that is the inverse of the surface shape of mold A (= the surface shape of basic matte layer A) on the surface of the release layer (= the surface of the release support).

(3-1) A surface shape that satisfies parameters such as Spc and Rsm is designed by simulation, and a mold C is produced that reproduces the designed surface shape by laser micromachining.
(3-2) Mold C is pressed against the surface of a releasable support, and a shape that is the inverse of the surface shape of mold C (= a surface shape that satisfies parameters such as Spc and Rsm) is imparted to the surface of the releasable support. As the releasable support, a laminate having a release layer on a support is preferably used, and when mold C is pressed against the surface of the release layer, the release layer is left in an uncured state, and then cured, so that a shape that is the inverse of the surface shape of mold C (= a surface shape that satisfies parameters such as Spc and Rsm) can be imparted to the surface of the release layer (= the surface of the releasable support).
As the above (3-1), the surface shape to be molded by the mold C of the above (3-2) may be designed by simulation, and the designed surface shape may be reproduced by laser micromachining to create a mold C', which may be used as a releasable support to mold an inverted shape.

There are no particular restrictions on the thickness of the basic matte layer, so long as it is thick enough to consistently produce a matte effect and allow the aforementioned wrinkles to be formed to the extent that a rough feel can be achieved. However, taking into consideration factors such as ease of production, the thickness is usually 1 μm or more, preferably 2 μm or more, more preferably 3 μm or more, even more preferably 4 μm or more, and even more preferably 5 μm or more, with the upper limit being preferably 300 μm or less, more preferably 200 μm or less, even more preferably 150 μm or less, and even more preferably 100 μm or less.

In this specification, the thickness of the matte layer is determined by measuring the thickness at 20 points on an image of the cross section of the transfer sheet taken with a scanning electron microscope (SEM), and averaging the 20 values. The SEM acceleration voltage is 3 kV, and the magnification is set according to the thickness. The same applies to the thicknesses of the other layers.

The basic matte layer is a layer that exhibits the above-mentioned surface shape over its entire surface, and since the transfer layer of this embodiment has a surface shape over at least a part of its surface, it is sufficient that it is provided on at least a part of the surface of the transfer layer, and it may be provided over the entire surface. When the transfer layer of this embodiment has the release layer, it is sufficient that it is provided on at least a part of the surface of the release layer, and it may be provided over the entire surface.
As long as the matte layer is provided in a location on the transfer layer that is visible and touched by the consumer, i.e., as long as the surface shape is provided in a location on the cosmetic material that is visible and touched by the consumer, the effects of the invention, namely, the matte effect and rough texture, will be obtained.

Also, even when the substrate is in the form of a film, sheet, or plate, the basic matte layer only needs to be provided in a location on the decorative material that is visible and touched by the consumer, and only needs to be provided on at least a portion of one of its surfaces, or it may be provided on its entire surface. From the perspective of improving the matte effect and rough tactile feel, it is preferable that the basic matte layer be provided over the entire surface of one of its surfaces, as shown in Figures 3, 5, and 6.

(Basic matte layer)
Regarding the manufacturing methods (1-1) to (1-2) and (2-1) to (2-3), the basic matte layer used in "preparing the recessed shape of the release support" is
(1) Forming a fine wrinkle structure on the surface of the basic matte layer;
It is preferable.
Furthermore, the basic matte layer is
(2) The composition of the resin composition for forming the basic matte layer, in particular the type of polymerizable monomer and polymerizable oligomer, the number of functional groups, the molecular weight, the presence or absence of a wrinkle formation stabilizer, and, if a wrinkle formation stabilizer is used, the particle size and content of the wrinkle formation stabilizer, are optimized.
(3) Optimizing the irradiation conditions of the resin composition for forming the basic matte layer, particularly the wavelength of light having a wavelength of 100 nm or more and 380 nm or less that can cure and shrink the surface portion of the basic matte layer, the cumulative weight, the ultraviolet output density, etc.
(4) In addition to the above, the type and thickness of the substrate on which the basic matte layer is formed, the thickness of the basic matte layer, etc. are optimized.
It is preferable.
By optimizing these, it becomes easier to keep the Spc (arithmetic mean curvature of the apex of the protrusion) and Rsm (average length of the curved element) of the surface shape of the basic matte layer (= the surface shape of the transfer layer in this embodiment) within the above-mentioned specific numerical ranges, and preferably to keep the Rz (maximum height) and Ra (arithmetic mean roughness) described below within specified numerical ranges.

The basic matte layer is preferably a layer composed of a cured product of a resin composition, preferably a cured product of a curable resin composition containing a cured resin.

The resin composition forming the basic matte layer is preferably a resin composition containing a resin and a wrinkle formation stabilizer (hereinafter sometimes referred to as the "resin composition for forming the basic matte layer"), from the perspective of obtaining a basic matte layer that has an excellent matte effect and an excellent rough feel. In other words, the basic matte layer is preferably a layer containing a resin and a wrinkle formation stabilizer.

(Wrinkle formation stabilizer)
The wrinkle formation stabilizer stabilizes wrinkle formation on at least one surface of the basic matte layer, thereby achieving uniform visibility of the matte effect across the entire surface of the basic matte layer and reducing localized gloss variations, thereby imparting stable visibility of the matte effect (hereinafter, simply referred to as "stable visibility of the matte effect" or equivalent expressions) and uniformity of the surface condition (also referred to as "texture"). Furthermore, wrinkles formed in the basic matte layer directly become wrinkles in the transfer layer (peeling layer), which significantly contributes to the development of a rough texture in the transfer sheet. In other words, the improvement in the visibility, texture, and rough texture of the matte effect of the basic matte layer (described below) also significantly contributes to the development of the visibility, texture, and rough texture of the matte effect that can be imparted by the transfer sheet of this embodiment.

Therefore, even if the so-called "matting agents" of the prior art and the "wrinkle formation stabilizers" of this embodiment have the same constituent substances and average particle diameter, they differ in the matting mechanism (action), the structure for achieving matting, and the relationship between the amount used and the level of surface gloss (gloss value). They also differ from "matting agents" in that they create a rough texture by forming wrinkles.

In prior art such as Patent Document 1, matting agents used to achieve a matte finish themselves provide a visible matte finish due to the light diffusion effect resulting from their physical shape. Specifically, what is commonly referred to as a matting agent generally has a refractive index difference between the matting agent particles and the surrounding resin and air, and the visible matte finish is achieved through the light diffusion effect of the reflective and refractive interfaces corresponding to the particle's contours. In contrast, the wrinkle formation stabilizer of this embodiment does not provide a visible matte finish due to the light diffusion caused by the reflection and refraction of light by the particles themselves. Instead, the wrinkle formation stabilizer stabilizes the formation of wrinkles on the surface of the matte layer, and the light diffusion effect at the refractive index difference interface between the surface and air consistently imparts a texture to the matte layer along with the visible matte finish. Therefore, the wrinkle formation stabilizer used in this embodiment differs from matting agents that themselves provide a visible matting effect (even if the constituent substances and average particle diameters of both are the same), in terms of the matting mechanism (action) and structure for achieving the matting effect.

Furthermore, "wrinkle formation stabilizers" and "matting agents" also differ in the relationship between their content and surface gloss (gloss value). When the same substance A is used as a wrinkle formation initiator AW (W: wrinkles) and a specific amount C is added to form wrinkles on the surface, the 60° gloss value G _60° ^AW (C) of the surface is clearly lower than the 60° gloss value G 60° AM (C) of the surface when the same substance A is used simply as a matting _agent ^AM and the specific amount C is added, but no wrinkles are formed on the surface. That is, the following relationship holds:
G _60° ^AW (C)<G _60° ^AM (C)

The release layer may contain an agent that has conventionally been used as a matting agent, but preferably does not contain a matting agent. Thus, the release layer of this embodiment can be said to have extremely excellent visibility and texture of the matting effect even if it does not substantially contain a matting agent that has conventionally been used to obtain visibility of the matting effect. Here, "not containing a matting agent" means not only that it does not contain any matting agent, but also that even if it does contain one, the matting effect based on the action and effect of the matting agent itself is not visible. Specifically, the content of the matting agent is less than 15.0 parts by mass, preferably 10.0 parts by mass or less, more preferably 3.0 parts by mass or less, per 100 parts by mass of the resin.
In this specification, the term "matting agent" refers to particles having an average particle diameter whose lower limit is the smaller of more than 100% of the thickness of the layer in which the matting agent can be contained, i.e., more than 30 μm, from the viewpoint of forming convex portions by the head-exposing effect as described above.

The wrinkle formation stabilizer can be any one that is not a matting agent and has an average particle size of 100% or less of the thickness of the basic matte layer or 30 μm or less, whichever is smaller.
From the viewpoint of improving the matte effect and the rough tactile feel, it is preferable to use at least one of two types of wrinkle formation stabilizers distinguished by their average particle diameters for the wrinkle formation stabilizer having an upper limit of the smaller of 100% or less of the thickness of the basic matte layer or 30 μm or less. Specifically, the two types of wrinkle formation stabilizers are Wrinkle Formation Stabilizer 1, which has an average particle diameter of 1 μm or more and an upper limit of the smaller of 100% or less of the thickness of the matte layer or 30 μm or less, and Wrinkle Formation Stabilizer 2, which has an average particle diameter of less than 1 μm. In this embodiment, the use of at least one of the two types of wrinkle formation stabilizers stabilizes wrinkle formation, provides a stable and excellent matte effect, and also provides a rough tactile feel. In this embodiment, wrinkle formation stabilizer 1 and wrinkle formation stabilizer 2 can be used alone, or wrinkle formation stabilizer 1 and wrinkle formation stabilizer 2 can be used in combination. From the viewpoint of improving the matte effect and rough texture, wrinkle formation stabilizer 1 is preferred, and wrinkle formation stabilizer 1 and wrinkle formation stabilizer 2 can also be used in combination.

As the wrinkle formation stabilizer, for example, organic particles or inorganic particles can be used.
Examples of organic materials that may be used to form the organic particles include polymethyl methacrylate, acrylic-styrene copolymer resin, melamine resin, polycarbonate, polystyrene, polyvinyl chloride resin, benzoguanamine-melamine-formaldehyde condensate, silicone, fluorine-based resin, and polyester-based resin.
Examples of inorganic substances constituting the inorganic particles include silica, alumina, calcium carbonate, aluminosilicate, and barium sulfate, and among these, silica is preferred because of its excellent transparency.

The shape of the wrinkle formation stabilizer is not particularly limited, but examples include spherical, polyhedral, scaly, and irregular shapes.

The average particle size of the wrinkle stabilizer 1 is 1 μm or more, with an upper limit of either 100% or less of the thickness of the basic matte layer or 30 μm or less, whichever is smaller. From the perspective of consistently improving the matte effect and enhancing the rough feel, the average particle size of the wrinkle stabilizer 1 is preferably 1.3 μm or more, more preferably 1.5 μm or more, and even more preferably 1.8 μm or more. The upper limit, relative to the thickness of the basic matte layer, is preferably 90% or less of the thickness of the basic matte layer, more preferably 80% or less of the thickness of the basic matte layer, and even more preferably 70% or less of the thickness of the basic matte layer. The absolute value is preferably 20 μm or less, more preferably 10 μm or less, even more preferably 8 μm or less, and even more preferably 7 μm or less. The smaller of any combination of the upper limit relative to the thickness of the basic matte layer and the upper limit of the absolute value may be used. For example, the upper limit may be the smaller of 90% or less of the thickness of the basic matte layer or 20 μm or less, or the smaller of 90% or less of the thickness of the basic matte layer or 10 μm or less. The thickness of the basic matte layer will be described later.

The average particle size of the wrinkle formation stabilizer 2 is less than 1 μm. From the viewpoints of stabilizing wrinkle formation, stably improving the matte effect, and improving the rough texture, the average particle size of the wrinkle formation stabilizer 2 is preferably 1 nm or more, more preferably 3 nm or more, and even more preferably 5 nm or more, with the upper limit being preferably 900 nm or less, more preferably 700 nm or less, and even more preferably 500 nm or less.
In this specification, the average particle size of the wrinkle formation stabilizer is measured as the mass average value d50 in particle size distribution measurement by laser light diffraction method.

From the viewpoint of stabilizing wrinkle formation by the wrinkle formation stabilizer, stably improving the matte effect, and enhancing the rough texture, the content of the wrinkle formation stabilizer (the total content of wrinkle formation stabilizer 1 and wrinkle formation stabilizer 2 when they are used in combination) is basically preferably at least 0.5 parts by mass, more preferably at least 0.75 parts by mass, even more preferably at least 1.0 part by mass, and even more preferably at least 1.2 parts by mass, per 100 parts by mass of the resin that forms the matte layer. There is no particular upper limit from the viewpoint of enhancing the stable matte effect and enhancing the rough texture, but from the viewpoint of, for example, improving the productivity of the cosmetic material through the coatability of the resin composition for forming the basic matte layer, and efficiently improving the visibility and texture of the matte effect, the content is preferably at most 25.0 parts by mass, more preferably at most 15.0 parts by mass, even more preferably at most 10.0 parts by mass, even more preferably at most 7.5 parts by mass, and particularly preferably at most 6.0 parts by mass.

When Wrinkle Formation Stabilizer 1 and Wrinkle Formation Stabilizer 2 are used in combination, there are no particular restrictions on the individual contents of Wrinkle Formation Stabilizer 1 and Wrinkle Formation Stabilizer 2 as long as the total content is within the aforementioned range. However, the content of Wrinkle Formation Stabilizer 2 is preferably at least 0.1 part by mass, more preferably at least 0.5 part by mass, and even more preferably at least 1.0 part by mass, relative to 100 parts by mass of resin. The upper limit is preferably 10.0 parts by mass or less, more preferably 7.5 parts by mass or less, even more preferably 5.0 parts by mass or less, and even more preferably 3.5 parts by mass or less. Furthermore, the blending ratio of Wrinkle Formation Stabilizer 1 and Wrinkle Formation Stabilizer 2, relative to the total amount of these agents taken as 100 parts by mass, is preferably 0.05 to 0.95 parts by mass, more preferably 0.10 to 0.90 parts by mass, even more preferably 0.20 to 0.80 parts by mass, and even more preferably 0.30 to 0.70 parts by mass.

As previously mentioned, organic and inorganic particles can be used as wrinkle stabilizers. However, these particle types themselves can also be considered to include those conventionally used as matting agents. For example, the matte layer of the decorative sheet described in Patent Document 1 uses matting agents such as spherical alumina and calcium carbonate. In order for matting agents such as spherical alumina and calcium carbonate to exhibit a visible matting effect due to the light diffusion effect resulting from their physical shape, they must be used in a total content of approximately 50 parts by weight, consisting of 10 parts by weight of spherical alumina and 40 parts by weight of calcium carbonate per 100 parts by weight of resin, as described in Patent Document 1. However, in this embodiment, even at a small content, as previously described, i.e., a content less than the content required to exhibit a visible matting effect due to the light diffusion effect resulting from their physical shape, a matting effect significantly superior to that achieved by matting agents is obtained, and a rough tactile feel is also achieved. Therefore, although the matte layer of this embodiment does not substantially contain a matting agent, wrinkles are stably formed on the surface, which means that a more excellent matte effect is stably visible compared to when a matting agent is used, and at the same time, texture is also achieved, and a rough feel is also achieved.

(resin)
The resin forming the basic matte layer may be any resin that can be formed by forming a resin composition for forming the basic matte layer containing a predetermined amount of the wrinkle formation stabilizer and curing it to form a cured product that constitutes the basic matte layer. Examples of such resins include ionizing radiation curable resins. As described above, when the basic matte layer itself is used as a mold-transfer sheet (see 1-2 above), a mold may be manufactured based on the basic matte layer (see 2-2 above). For this reason, the resin forming the matte layer is preferably one that easily exhibits surface properties such as processing characteristics, and ionizing radiation curable resins are preferred from these perspectives. The basic matte layer maintains a matte effect and a rough texture and can impart a desired shape to the transfer sheet, so that the desired shape can also be imparted to the decorative material obtained using the transfer sheet.

The ionizing radiation curable resin is a resin having an ionizing radiation curable functional group, which is a group that crosslinks and cures upon irradiation with ionizing radiation, and preferred examples thereof include functional groups having an ethylenic double bond, such as a (meth)acryloyl group, a vinyl group, and an allyl group. In this specification, the term "(meth)acryloyl group" refers to an acryloyl group or a methcroyl group. In this specification, the term "(meth)acrylate" refers to an acrylate or a methacrylate.
Furthermore, ionizing radiation refers to electromagnetic waves or charged particle beams that have an energy quantum capable of polymerizing and/or crosslinking molecules. Typically, ultraviolet rays (UV) or electron beams (EB) are used, but other examples include electromagnetic waves such as X-rays and gamma rays, and charged particle beams such as alpha rays and ion beams.

Examples of the ionizing radiation curable resin include electron beam curable resins and ultraviolet curable resins, and ultraviolet curable resins are preferred from the viewpoint of stabilizing the formation of wrinkles by the wrinkle formation stabilizer, stably improving the matte effect, and improving the rough texture.
Specifically, the ionizing radiation curable resin can be appropriately selected from polymerizable monomers and polymerizable oligomers that have been conventionally used as ionizing radiation curable resins.

As the polymerizable monomer, a (meth)acrylate monomer having a radically polymerizable unsaturated group in the molecule is preferred, and among them, a polyfunctional (meth)acrylate monomer is preferred. Here, "(meth)acrylate" means "acrylate or methacrylate."
The polyfunctional (meth)acrylate monomer includes a (meth)acrylate monomer having two or more ionizing radiation-curable functional groups in the molecule, and having at least a (meth)acryloyl group as the functional group.

From the viewpoint of stabilizing wrinkle formation and stably improving the matte effect, improving the rough texture, and steadily imparting a shape having a matte effect and a rough texture to the transfer sheet, the number of functional groups in the polyfunctional (meth)acrylate monomer is preferably from 2 to 8, more preferably from 2 to 6, even more preferably from 2 to 4, and even more preferably from 2 to 3. Furthermore, with the above-mentioned number of functional groups, the above-mentioned surface shape is particularly easily obtained and the rough texture is easily improved.
These polyfunctional (meth)acrylates may be used alone or in combination of two or more kinds.

Examples of polymerizable oligomers include (meth)acrylate oligomers that have two or more ionizing radiation-curable functional groups in the molecule, and that have at least a (meth)acryloyl group as one of the functional groups. Examples include urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers.

Other polymerizable oligomers include highly hydrophobic polybutadiene (meth)acrylate oligomers with (meth)acrylate groups in the side chains of polybutadiene oligomers, silicone (meth)acrylate oligomers with polysiloxane bonds in the main chain, aminoplast resin (meth)acrylate oligomers modified with aminoplast resins that have many reactive groups in their small molecules, and oligomers with cationically polymerizable functional groups in the molecules of novolac epoxy resins, bisphenol epoxy resins, aliphatic vinyl ethers, aromatic vinyl ethers, etc.

These polymerizable oligomers may be used alone or in combination of two or more kinds.
From the viewpoint of stabilizing wrinkle formation and stably improving the matte effect, improving the rough texture, and reliably imparting a shape having a matte effect and a rough texture to a transfer sheet, urethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, polyether (meth)acrylate oligomers, polycarbonate (meth)acrylate oligomers, and acrylic (meth)acrylate oligomers are preferred, urethane (meth)acrylate oligomers and polycarbonate (meth)acrylate oligomers are more preferred, and urethane (meth)acrylate oligomers are even more preferred.

The number of functional groups of these polymerizable oligomers is determined from the viewpoints of stabilizing wrinkle formation and stably improving the matte effect, improving the rough texture,
From the viewpoint of steadily imparting a matte effect and a texture having a rough feel to the transfer sheet, the number is preferably 2 or more and 8 or less, more preferably 6 or less, and even more preferably 4 or less.
From the same viewpoint, the weight average molecular weight of these polymerizable oligomers is preferably from 2,500 to 7,500, more preferably from 3,000 to 7,000, and even more preferably from 3,500 to 6,000. Here, the weight average molecular weight is an average molecular weight measured by GPC analysis and converted into standard polystyrene.

In this embodiment, the resin forming the basic matte layer can be the polymerizable oligomer alone, the polymerizable monomer alone, or a combination of the polymerizable oligomer and the polymerizable monomer. However, from the perspective of stabilizing wrinkle formation and consistently improving the matte effect, enhancing the rough feel, and reliably imparting a matte effect and a rough feel to the transfer sheet, it is preferable to use the polymerizable monomer alone or a combination of the polymerizable oligomer and the polymerizable monomer. As the polymerizable oligomer, a polyfunctional urethane (meth)acrylate oligomer is preferred, and a polyfunctional urethane acrylate oligomer is more preferred. As the polymerizable monomer, a polyfunctional polymerizable monomer is preferred, a polyfunctional (meth)acrylate monomer is more preferred, and a polyfunctional acrylate monomer is even more preferred.

When used in combination, from the same viewpoint, the content of the polymerizable oligomer per 100 parts by mass of the total of the polymerizable oligomer and polymerizable monomer is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, even more preferably 55 parts by mass or more, and even more preferably 60 parts by mass or more, with the upper limit being preferably 90 parts by mass or less, more preferably 80 parts by mass or less, and even more preferably 70 parts by mass or less.

(Resin composition)
The basic matte layer is preferably composed of a cured resin composition containing the wrinkle formation stabilizer in a predetermined content, and the resin composition preferably contains the resin and the wrinkle formation stabilizer in a predetermined content. In addition to the wrinkle formation stabilizer and resin, the resin composition may contain other components depending on the desired performance, etc.
The resin composition for forming the basic matte layer may contain a monofunctional (meth)acrylate, for example, for the purpose of reducing its viscosity, etc. These monofunctional (meth)acrylates may be used alone or in combination of two or more kinds.

Furthermore, when the resin is an ultraviolet-curable resin that cures with ultraviolet light, it preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. By including these additives, the resin can be cured using ultraviolet light (without ionizing radiation), and surface properties suitable for practical use can be obtained.

The photopolymerization initiator may be one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzil dimethyl ketal, benzoyl benzoate, α-acyloxime ester, thioxanthones, and the like.
The photopolymerization accelerator can reduce polymerization inhibition caused by air during curing and increase the curing rate, and examples thereof include one or more selected from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, and the like.

(Basic Matte Layer Forming Method)
The method for forming the basic matte layer includes a basic matte layer forming step of irradiating a layer of a resin composition for forming the basic matte layer, which contains the resin and the wrinkle formation stabilizer, with light having a wavelength of at least 100 nm or more and 380 nm or less.
This formation method can form a basic matte layer having a surface shape such as that shown in Fig. 5 (the transfer layer in Fig. 5 is obtained by inverting the surface shape of the basic matte layer twice. That is, the surface shape of the transfer layer in Fig. 5 is identical to the surface shape of the basic matte layer. "Identical" here has the same meaning as described above.) For example, a laminate having a substrate and a basic matte layer can be produced by applying the resin composition for forming the basic matte layer to a substrate, forming a layer of the resin composition on the substrate, and irradiating the substrate with light of the wavelength described above to form the basic matte layer.
This forming method is suitable for forming a basic matte layer having a matte effect with a 60° gloss value of 20.0 or less, 10.0 or less, or even less than that, and having a rough feel to the touch.

When a liquid matte layer-forming resin composition is applied to a fibrous substrate such as paper, the liquid composition may penetrate the substrate, causing the unevenness of the fibers on the substrate surface to appear on the matte layer surface, preventing the desired Spc and Rsm values from being achieved. In such cases, it is preferable to form a known penetration-blocking resin layer by coating or other methods on the surface of the fibrous substrate on the side where the matte layer will be formed. Examples of resins for forming such penetration-blocking resin layers include two-component curing urethane resins.

This matte layer formation method makes it easy to obtain a basic matte layer. Specifically, when forming the basic matte layer, ultraviolet light with a short wavelength of at least 100 nm to 380 nm is irradiated onto a matte-forming resin composition containing a wrinkle-formation stabilizer that forms the basic matte layer. This causes wrinkles to form on at least one surface of the basic matte layer, imparting a matte effect and a rough texture to the basic matte layer.

The details of how irradiating the resin composition used to form the matte layer with such short-wavelength ultraviolet light essentially causes wrinkles to form on at least one surface of the matte layer, resulting in a matte effect and a rough texture, are unknown, but are presumed to be due to the following mechanism.

When a layer of resin composition for forming the basic matte layer, applied to a specified thickness, is irradiated with short-wavelength ultraviolet light, the energy of the ultraviolet light penetrates only the surface portion and does not reach the layers below. As a result, only the surface portion of the resin composition begins to harden, causing shrinkage during hardening only at the surface, resulting in the formation of wrinkles. In this way, wrinkles are thought to form when the resin composition for forming the basic matte layer is hardened only in a certain thickness direction from the surface due to irradiation with short-wavelength ultraviolet light.

Furthermore, a comparison of the Examples and Comparative Examples described below reveals that when a wrinkle formation stabilizer is not included, wrinkle formation becomes unstable, the visibility and texture of the matte effect are not stably and sufficiently manifested across the entire surface of the basic matte layer, and the rough texture is not sufficiently manifested. Therefore, the stable manifestation of the matte effect and rough texture cannot be explained solely by hardening of only the surface portion by short-wavelength ultraviolet light. In other words, the inclusion of a wrinkle formation stabilizer is essential for the basic matte layer to stably retain wrinkles and thereby manifest the matte effect and rough texture. Considering that the stable matte effect and rough texture caused by wrinkles are not obtained when the wrinkle formation stabilizer is not included, it is thought that the wrinkle formation stabilizer functions like a nucleus that triggers wrinkle formation, with the resin on the surface of the resin composition gathering around this nucleus, forming convex wrinkles (protrusions), and as the convex wrinkles (protrusions) form, concave wrinkles also form, resulting in stable wrinkle formation and a stable matte effect and rough texture.

In the method for forming the basic matte layer, the resin composition for forming the basic matte layer is irradiated with light having a wavelength of at least 100 nm to 380 nm. As described above, this irradiation allows the ultraviolet energy to penetrate only the surface, preventing the energy from reaching the layers below. As a result, only the surface of the resin composition begins to harden. This causes shrinkage on cure only at the surface, stabilizing the formation of wrinkles. The surface layer of the resin composition then hardens, forming the basic matte layer. Subsequently, hardening progresses from the surface-side portion, where hardening proceeds slowly, to the deeper portions, further away in the depth direction. The resin composition layer then hardens, forming a hardened product. The resin composition thus hardens throughout its entire thickness, exhibiting a light-diffusing effect on the surface and forming a basic matte layer with wrinkles that create a rough texture. To promote hardening in the deeper portions, it is preferable to perform additional irradiation treatments after irradiation with light having a wavelength of 100 nm to 380 nm, as described below.

Examples of light with a wavelength of at least 100 nm or more and 380 nm or less include "excimer light," which includes light in the ultraviolet wavelength range from excited dimers formed by discharge of rare gases such as Ar, Kr, Xe, and Ne, halides of rare gases such as halogens F, Cl, I, and Br, or mixed gases thereof, i.e., excimers. Examples of wavelengths and excimer light sources that can be used include light with a wavelength of 126 nm radiated from the excimer of _Ar2 (hereinafter abbreviated as "126 nm ( _Ar2 )"), 146 nm ( _Kr2 ), 157 nm ( _F2 ), 172 nm ( _Xe2 ), 193 nm (ArF), 222 nm (KrCl), 247 nm (KrF), 308 nm (XeCl), and 351 nm (XeF). The excimer light can be either spontaneous emission light or laser light with high coherence due to stimulated emission, but spontaneous emission light is usually sufficient. Note that discharge lamps that emit this light (ultraviolet light) are also called "excimer lamps."

Excimer light has a single wavelength peak and is characterized by a narrower half-width wavelength than regular ultraviolet light (e.g., ultraviolet light emitted from metal halide lamps, mercury lamps, etc.). Using such excimer light stabilizes wrinkle formation, consistently improves the matte effect, and also improves the rough texture.

From the viewpoint of stabilizing wrinkle formation, stably improving the matte effect, and improving the rough texture, the wavelength is preferably 120 nm or more, more preferably 140 nm or more, even more preferably 150 nm or more, and even more preferably 155 nm or more, with the upper limit being preferably 320 nm or less, more preferably 300 nm or less, even more preferably 250 nm or less, still more preferably less than 200 nm, and most preferably 172 nm (Xe ₂ ). Thus, in this embodiment, from the viewpoint of stably improving the matte effect and improving the rough texture, it is preferable to use light with a shorter wavelength, and it can be said that medium-wavelength ultraviolet light (wavelength: 280 to 320 nm) or short-wavelength ultraviolet light (wavelength: 280 nm or less) is more preferable, and short-wavelength ultraviolet light is even more preferable. It is preferable that the short-wavelength ultraviolet light has a wavelength of less than 200 nm.

The integrated light amount of the wavelength light is preferably 1 mJ/cm2 or more, more preferably 10 mJ/ ^cm2 or more, even more preferably 30 mJ/ ^cm2 or more, and still more preferably 50 mJ/ ^cm2 or ^more , from the viewpoints of stabilizing wrinkle formation, stably improving the matte effect, and improving the rough texture. There is no particular upper limit, and from the viewpoints of reducing the number of lamps required for irradiating the wavelength light and improving productivity such as improving production efficiency, the upper limit is preferably 1,000 mJ/ ^cm2 or less, more preferably 500 mJ/ ^cm2 or less, and even more preferably 300 mJ/ ^cm2 or less. From the same viewpoint, the ultraviolet light output density is preferably 0.001 W/cm2 or more, more preferably 0.01 W/cm2 or more, and even more preferably 0.03 W/cm2 or more, and the upper limit is preferably 10 W/cm2 or less, more preferably 5 W/cm2 or less, and even more preferably 3 W/cm2 or less.
Furthermore, the oxygen concentration during irradiation with light of the above wavelengths is preferably lower, preferably 1,000 ppm or less, more preferably 750 ppm or less, even more preferably 500 ppm or less, and even more preferably 300 ppm or less.

In the basic matte layer forming step, in addition to the irradiation with light having a wavelength of at least 100 nm or more and 380 nm or less, other treatments that contribute to curing of the resin composition for forming the basic matte layer may be carried out.
For example, in order to stabilize the formation of wrinkles due to the difference in the degree of curing between the surface portion and the deep portion away from the surface in the depth direction and to promote the progress of curing in the deep portion, the resin composition for forming the basic matte layer may be pre-cured overall by pre-irradiating with light having a wavelength of more than 380 nm, preferably light having a wavelength of 385 nm to 400 nm, and then irradiated with light having a wavelength of 100 nm to 380 nm. Alternatively, after irradiation with light having a wavelength of 100 nm to 380 nm, post-curing may be performed to further cure the resin composition. The necessity of pre-curing and post-curing can be determined appropriately depending on the desired properties required for the basic matte layer (e.g., surface properties such as processing characteristics and contamination resistance). Furthermore, although the wavelength light is ultraviolet, other ionizing radiations, such as electron beams, can also be used. For example, electron beams are preferably used in post-curing in order to improve the surface properties of the basic matte layer.

The basic matte layer can be formed by applying a resin composition for forming the matte layer using a known method such as gravure printing, bar coating, roll coating, reverse roll coating, or comma coating to form a coated layer (uncured resin layer), and then irradiating the layer with light having a wavelength of at least 100 nm or more and 380 nm or less.

<Releasable Support>
The release support is peeled off from the transfer layer after the transfer layer is transferred to the adherend. The surface shape of the release support is the inverse of the surface shape that the transfer sheet of this embodiment can impart to the adherend, i.e., the inverse of the surface shape of the transfer layer. Furthermore, as described above, the surface shape of the release support is preferably formed by a basic matte layer.
The releasable support may have a single layer structure or a two or more layer structure, and is preferably configured to have a release layer on the support.

[Support]
The material of the support is not particularly limited, and examples thereof include paper, fiber, metal, glass, ceramics, and resin. Among these, a support made of resin is preferred because it is easy to form a release layer and has good peeling workability after transfer. Hereinafter, a support made of resin will be referred to as a plastic sheet. Films, sheets, and plates are referred to as films, sheets, and plates in order of relative thickness, but there is no significance in strictly distinguishing between these three types in this specification, and differences between these three types do not cause any difference in interpretation of the rights of the present invention.

There is no particular limitation on the thickness of the support. That is, the support in this embodiment may be a support having a thickness on the order of micrometers, or a support having a thickness on the order of millimeters or more.
The support may be colored or uncolored. When the support is colored, the coloring mode is not particularly limited, and the support may be transparently colored or opaquely colored (hiding colored).

Resins that can be used to make plastic films include olefin resins such as polyethylene, polypropylene, polymethylpentene, ionomers, and various olefin-based thermoplastic elastomers; vinyl chloride resins such as polyvinyl chloride, polyvinylidene chloride, and vinyl chloride-vinyl acetate copolymers; polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene glycol-terephthalic acid-isophthalic acid copolymers, and polyester-based thermoplastic elastomers; acrylic resins such as polymethyl (meth)acrylate, polyethyl (meth)acrylate, polybutyl (meth)acrylate, and methyl (meth)acrylate-butyl (meth)acrylate copolymers; polyamide resins such as nylon 6 and nylon 66; cellulose resins such as cellulose triacetate, cellophane, and celluloid; styrene resins such as polystyrene, acrylonitrile-styrene copolymers, and acrylonitrile-butadiene-styrene copolymers (ABS); polyvinyl alcohol, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, polycarbonate resins, polyarylate resins, and polyimide resins. Of these, polyester resins are preferred, and among polyester resins, polyethylene terephthalate is preferred.

The thickness of the plastic film is not particularly limited, but to improve the handleability of the transfer sheet, it is preferably between 10 μm and 200 μm, more preferably between 15 μm and 150 μm, and even more preferably between 30 μm and 125 μm.

To enhance adhesion to the release layer, the support may be subjected to a surface treatment such as physical surface treatment (oxidation, roughening, etc.) or chemical surface treatment, or an easy-adhesive layer may be formed on one or both sides.

[Release layer]
The release layer is a layer that is provided as needed to improve the releasability between the releasable support and the transfer layer, and to function as a "mold" for giving the transfer layer (release layer) a surface shape.
The release layer is preferably provided over the entire surface of the support in order to improve the releasability from the transfer layer and to give a surface shape to the entire surface of the transfer layer (release layer).
The release layer preferably contains a resin, and more preferably contains a resin and a release agent.

(resin)
The release layer preferably contains a resin as its main component, which means that the resin accounts for 50% by mass or more of the total solid content constituting the release layer, preferably 70% by mass or more, more preferably 80% by mass or more, more preferably 90% by mass or more, and more preferably 95% by mass or more.

In order to improve durability, the release layer preferably contains, as the resin, a cured product of a resin composition containing a curable resin.
The proportion of the cured product of the resin composition containing the curable resin relative to the total amount of resin contained in the release layer is preferably 50% by mass or more, more preferably 70% by mass or more, more preferably 90% by mass or more, more preferably 95% by mass or more, and more preferably 100% by mass.

Examples of the cured product of a resin composition containing a curable resin include a cured product of a resin composition containing a thermosetting resin and a cured product of a resin composition containing an ionizing radiation curable resin.
A cured product of a resin composition containing an ionizing radiation curable resin is preferred in that it is easier to improve scratch resistance.

A resin composition containing a thermosetting resin is a composition that contains at least a thermosetting resin and cures when heated. Examples of thermosetting resins include acrylic resins, urethane resins, urethane acrylic resins, phenolic resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. These can be used alone or in combination. Furthermore, a resin composition containing a thermosetting resin may contain a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent.

Examples of the ionizing radiation curable resin for the release layer include those exemplified as the ionizing radiation curable resin for the matte layer.

(Release agent)
Examples of the release agent include fluorine-based release agents and silicone-based release agents, and silicone-based release agents are preferred from the viewpoint of obtaining lower cost and higher releasability.

Silicone-based release agents include those with a polysiloxane structure as their basic structure. Among these, modified silicone oils with organic groups introduced into at least one of the side chains and terminals are preferred, with modified silicone oils with organic groups introduced into both terminals being even more preferred. From the perspective of achieving a more sophisticated design, preferred organic groups include reactive functional groups such as (meth)acrylic groups, amino groups, epoxy groups, mercapto groups, carbinol groups, phenol groups, and carboxyl groups, as well as non-reactive functional groups such as polyether groups, aralkyl groups, fluoroalkyl groups, alkyl groups, fatty acid amide groups, and phenyl groups. Among these, reactive functional groups are preferred, with (meth)acrylic groups being particularly preferred, i.e., (meth)acrylic-modified silicone oils being particularly preferred. Furthermore, these organic groups may contain substituents such as nitrogen atoms, sulfur atoms, hydroxyl groups, and alkyl groups.

The content of the release agent is preferably 0.1 to 5 parts by mass, more preferably 0.5 to 3 parts by mass, and even more preferably 1 to 2 parts by mass, per 100 parts by mass of the resin that forms the release layer. When the content of the release agent is within this range, the effect of adding the release agent can be efficiently achieved.

The surface shape of the release layer is the inverse of the surface shape of the transfer layer. For this reason, it is preferable that the release layer have a specified thickness. The thickness of the release layer is usually 1 μm or more, preferably 2 μm or more, more preferably 3 μm or more, even more preferably 4 μm or more, and still more preferably 5 μm or more, with the upper limit being preferably 300 μm or less, more preferably 200 μm or less, even more preferably 150 μm or less, and still more preferably 100 μm or less.

In this specification, the thickness of the release layer is determined by measuring the thickness at 20 points on an image of the cross section of the transfer sheet taken with a scanning electron microscope (SEM), and averaging the values at these 20 points. The SEM acceleration voltage is 3 kV, and the magnification is set according to the thickness. The same applies to the thicknesses of other layers.

[Other layers]
The releasable support constituting the transfer sheet of this embodiment may have layers other than the support and the release layer. Examples of layers other than the support and the release layer include an antistatic layer and an easy-adhesion layer.

<Transfer Layer>
The transfer layer is a layer that is transferred to an adherend.
The transfer layer preferably has at least a release layer. Furthermore, the transfer layer more preferably has a release layer and an adhesive layer in this order from the releasable support side. Furthermore, the transfer layer more preferably has one or more layers selected from a primer layer and a decorative layer between the release layer and the adhesive layer. When a primer layer and a decorative layer are present between the release layer and the adhesive layer, it is preferable that the primer layer be positioned closer to the release layer than the decorative layer.

The transfer layer may further include other functional layers. Examples of such layers include an antiglare layer, an antifouling layer, a stress relaxation layer, an antistatic layer, a gas barrier layer, an antifogging layer, and a transparent conductive layer.

[Release layer]
The release layer is a layer located on the outermost surface of the transfer layer when transferred to an adherend, and is a layer that can impart a surface shape to the adherend. For this reason, the release layer preferably has good surface properties such as scratch resistance, weather resistance, and contamination resistance.

The release layer preferably contains a resin as its main component. By "main component," we mean that the resin accounts for 50% or more by weight of the total solid content of the release layer, preferably 70% or more by weight, more preferably 80% or more by weight, and even more preferably 90% or more by weight.

The release layer preferably contains a cured product of a resin composition containing a curable resin as the resin, so that it can obtain surface properties such as scratch resistance, easily maintain the surface shape, and easily impart a desired surface shape.
The proportion of the cured resin composition containing the curable resin relative to the total amount of resin contained in the release layer is preferably 50% by mass or more, more preferably 70% by mass or more, more preferably 90% by mass or more, more preferably 95% by mass or more, and more preferably 100% by mass.

Examples of the cured product of the resin composition containing a curable resin include a cured product of a resin composition containing a thermosetting resin and a cured product of a resin composition containing an ionizing radiation curable resin.
A cured product of a resin composition containing a thermosetting resin is preferred in that it is easy to improve weather resistance since there is no restriction on the use of an ultraviolet absorber.
A cured product of a resin composition containing an ionizing radiation curable resin is preferred because it can provide surface properties such as scratch resistance, easily maintains its surface shape, and can easily impart a desired surface shape. Among these, a cured product of a resin composition containing an electron beam curable resin is preferred because it can easily improve weather resistance while providing better scratch resistance and is not limited by the use of an ultraviolet absorber.

Examples of the resin composition containing a thermosetting resin for the release layer include those exemplified as the resin composition containing a thermosetting resin for the release layer.
The composition contains at least a thermosetting resin, and is a resin composition that hardens when heated.
Examples of the resin composition containing an ionizing radiation curable resin for the release layer include those exemplified as the resin composition containing an ionizing radiation curable resin for the matte layer.

The release layer may contain particles such as matting agents and wrinkle formation stabilizers, but preferably does not substantially contain such particles. By substantially not containing particles in the release layer, it is possible to prevent the release layer from having a decrease in scratch resistance, weather resistance, stain resistance, etc., which may be caused by the particles falling off. Furthermore, even if a matting agent is not contained, a sufficient matting effect can be obtained due to the surface shape, so a matting agent is not particularly necessary.
When the release layer is substantially free of particles, it means that the particle content is 1% by mass or less of the total solid content constituting the release layer, preferably 0.1% by mass or less, more preferably 0.01% by mass or less, and more preferably 0% by mass.

To improve weather resistance, the release layer preferably contains an ultraviolet absorber or a light stabilizer, and more preferably contains an ultraviolet absorber and a light stabilizer. General-purpose compounds can be used as the ultraviolet absorber and light stabilizer. Among ultraviolet absorbers, hydroxyphenyltriazine compounds are preferred. Among light stabilizers, hindered amine compounds are preferred.

The content of the ultraviolet absorber in the release layer is preferably 0.01 parts by mass or more and 15 parts by mass or less, more preferably 0.1 parts by mass or more and 10 parts by mass or less, and even more preferably 1 part by mass or more and 7 parts by mass or less, relative to 100 parts by mass of the resin of the release layer.
The content of the light stabilizer in the release layer is preferably 0.01 parts by mass or more and 15 parts by mass or less, more preferably 0.1 parts by mass or more and 10 parts by mass or less, and even more preferably 1 part by mass or more and 7 parts by mass or less, per 100 parts by mass of the resin of the release layer.

The thickness of the release layer is preferably 1.5 μm or more and 30 μm or less, more preferably 2 μm or more and 20 μm or less, and even more preferably 3 μm or more and 15 μm or less, in order to improve the handleability of the transfer sheet and the scratch resistance and weather resistance of the release layer.

[Adhesive layer]
The adhesive layer is a layer formed as needed to facilitate the transfer of the transfer layer to the adherend. For example, when transferring the transfer layer of the transfer sheet to the adherend, if a separately prepared adhesive is used between the adherend and the transfer sheet, the transfer layer does not need to have an adhesive layer. Furthermore, if the transfer layer and the adherend can be closely attached without using an adhesive, the transfer layer does not need to have an adhesive layer.
When the transfer layer has an adhesive layer, it is preferable that the adhesive layer is formed at a position farthest from the releasable support among the layers constituting the transfer layer. The adhesive layer can also function as a decorative layer, which will be described later.

Adhesive layers include pressure-sensitive adhesive layers, curable adhesive layers, and heat-sensitive adhesive layers. Of these, a heat-sensitive adhesive layer is preferred to improve the handleability of the transfer sheet and the adhesion between the transfer layer and the substrate. A heat-sensitive adhesive layer is also sometimes called a heat-seal layer.

When the adhesive layer is a pressure-sensitive adhesive layer, it is preferred that the adhesive layer contains a pressure-sensitive adhesive.
The adhesive may be selected appropriately from acrylic, urethane, silicone, rubber, and other adhesives.

When the adhesive layer is a curable adhesive layer, it is preferable that the adhesive layer contains a thermosetting adhesive.
The thermosetting adhesive is preferably one that contains a composition that has the property of undergoing a chemical reaction due to heat and becoming crosslinked, and examples thereof include two-component curing urethane adhesives, polyester urethane adhesives, polyether urethane adhesives, acrylic adhesives, polyester adhesives, polyamide adhesives, polyvinyl acetate adhesives, epoxy adhesives, rubber adhesives, etc. The urethane resin that constitutes the two-component curing urethane adhesive is a polyurethane that uses polyol (polyhydric alcohol) as the main component and isocyanate as the crosslinking agent (curing agent).

When the adhesive layer is a heat-sensitive adhesive layer, the adhesive layer preferably contains a thermoplastic resin.
Examples of thermoplastic resins include acrylic resins, urethane resins, vinyl chloride resins, vinyl acetate resins, vinyl chloride-vinyl acetate copolymers, styrene-acrylic copolymers, polyester resins, amide resins, cyanoacrylate resins, and epoxy resins, which can be used alone or in combination. Among these, acrylic resins, which have good weather resistance, are preferred.

The weight-average molecular weight of the thermoplastic resin is preferably 10,000 or more and 200,000 or less, more preferably 50,000 or more and 150,000 or less, and more preferably 80,000 or more and 120,000 or less. When the weight-average molecular weight of the thermoplastic resin is within this range, the coating suitability is improved, and it becomes easier to form an adhesive layer in good condition. Furthermore, when the weight-average molecular weight of the thermoplastic resin is within this range, it becomes easier to improve the adhesion between the adhesive layer and the adherend.

The thickness of the adhesive layer is preferably 1 μm or more and 10 μm or less, more preferably 2 μm or more and 8 μm or less, and even more preferably 3 μm or more and 7 μm or less. Having a thickness of the adhesive layer within this range facilitates good adhesion between the adhesive layer and the adherend, and also facilitates good handling of the transfer sheet.

The adhesive layer may contain a colorant, if necessary.
By including a colorant in the adhesive layer, the adhesive layer alone, or in combination with the decorative layer described below, can enhance the design of the transfer layer and improve the hiding properties of the transfer layer, thereby hiding the color and appearance of the surface of the adherend.

There are no particular restrictions on colorants, and examples include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments or dyes such as quinacridone red, isoindolinone yellow, nickel azo complex, phthalocyanine blue, and azomethine azo black; metal pigments such as flaky flakes of aluminum, brass, etc.; and pearlescent pigments such as flaky flakes of titanium dioxide-coated mica and basic lead carbonate, etc.

The content of the colorant is preferably 5 parts by mass or more and 90 parts by mass or less, more preferably 15 parts by mass or more and 80 parts by mass or less, and even more preferably 20 parts by mass or more and 70 parts by mass or less, relative to 100 parts by mass of the resin constituting the adhesive layer.
When the content of the colorant is 5 parts by mass or more, the design of the transfer layer can be easily improved, and when the content of the colorant is 90 parts by mass or less, a decrease in the adhesive strength of the adhesive layer can be easily suppressed.

[Primer layer]
To improve the adhesion between the layers constituting the transfer layer, each layer of the transfer layer may be subjected to a surface treatment such as the physical surface treatment (oxidation method, roughening method, etc.) or chemical surface treatment, as necessary. A primer layer may be provided between each of these layers as an easy-adhesion layer, or these surface treatments may be used in combination with the primer layer. The primer layer may be formed, for example, between the release layer and the adhesive layer. When a primer layer and a decorative layer are present between the release layer and the adhesive layer, it is preferable to position the primer layer closer to the release layer than the decorative layer.
By forming the primer layer between the release layer and the adhesive layer, the interlayer adhesion of the transfer layer is improved, and the weather resistance and durability of the transfer layer can be improved.

The primer layer is primarily composed of a binder resin, and may contain additives such as ultraviolet absorbers and light stabilizers as needed.

Preferred examples of the binder resin include urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, polycarbonate-based urethane-acrylic copolymer (urethane-acrylic copolymer derived from a polymer (polycarbonate polyol) having a carbonate bond in the polymer main chain and two or more hydroxyl groups at the terminals and side chains), vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, chlorinated propylene resin, nitrocellulose resin (nitrocellulose), and cellulose acetate resin, and these can be used alone or in combination of two or more types.
The binder resin may be a resin obtained by adding a curing agent such as an isocyanate-based curing agent or an epoxy-based curing agent to the resin and crosslinking the resin to harden it.
Among these, polycarbonate-based urethane-acrylic copolymers are preferred.

The polycarbonate-based urethane acrylic copolymer can be obtained, for example, by the following steps (1) and (2). The polycarbonate-based urethane acrylic copolymer is preferable in that it has good flexibility, easily follows the cure shrinkage of the release layer, and has good weather resistance.
(1) A polycarbonate-based polyurethane polymer is obtained by reacting a polycarbonate diol with a (di)isocyanate.
(2) The polycarbonate-based polyurethane polymer and an acrylic monomer are radically polymerized to obtain a polycarbonate-based urethane acrylic copolymer.

(Di)isocyanates include, for example, aromatic isocyanates such as 4,4'-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 1,5-naphthalene diisocyanate, n-isocyanatophenylsulfonyl isocyanate, and o- or p-isocyanatophenylsulfonyl isocyanate; aliphatic isocyanates such as 1,6-hexamethylene diisocyanate; alicyclic isocyanates; and the like.

Acrylic monomers include (meth)acrylic acid, alkyl (meth)acrylate esters such as methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, and isobutyl (meth)acrylate.

The mass ratio of the acrylic component to the urethane component in the polycarbonate-based urethane acrylic copolymer is preferably in the range of 95:5 to 30:70, more preferably 93:7 to 50:50, and even more preferably 90:10 to 60:40. By maintaining the mass ratio of the acrylic component to the urethane component in this range, the primer layer does not become an excessively hard coating, sufficient processability is achieved, and when a primer layer is formed on a release layer, adhesion between the release layer and the primer layer is improved, which is preferable.

The primer layer preferably contains an anti-blocking agent. Examples of anti-blocking agents include inorganic particles such as silica, alumina, aluminum hydroxide, barium sulfate, talc, and calcium carbonate, as well as organic particles. Of these, inorganic particles are preferred, and of the inorganic particles, silica is preferred.

The average particle size of the anti-blocking agent is preferably about 0.1 to 10 μm, more preferably 0.5 to 8 μm, and even more preferably 0.5 to 5 μm. The particle size of the anti-blocking agent is measured as the mass average value d50 in particle size distribution measurement by laser diffraction method.
The content of the antiblocking agent is preferably in the range of 0.1 to 30 parts by mass, more preferably 1 to 25 parts by mass, even more preferably 3 to 20 parts by mass, and particularly preferably 5 to 15 parts by mass, per 100 parts by mass of the binder resin.

The thickness of the primer layer is preferably 0.5 μm or more and 10 μm or less, more preferably 1 μm or more and 8 μm or less, and even more preferably 2 μm or more and 6 μm or less.

[Decorative layer]
The transfer layer may have a decorative layer to enhance the design, and the decorative layer is preferably formed between the release layer and the adhesive layer.

The decorative layer may be formed over the entire surface of the transfer sheet, or only over a portion of it.

Examples of the decorative layer include a colored layer formed by applying ink in a solid manner, a patterned layer formed by printing ink as a pattern, and a thin metal film.
Examples of patterns (designs) that can be expressed by the decorative layer include wood grain patterns such as tree rings and vessel grooves on the surface of a wooden board; stone grain patterns on the surface of stone slabs such as marble and granite; fabric grain patterns on the surface of fabric; leather grain patterns on the surface of leather; tile patterns including grooves; brickwork patterns including grooves; sand grain patterns; pear-skin patterns; patterns consisting of an arrangement of multiple concave and convex stripes extending in parallel directions (so-called ``line-like concave and convex patterns'' or ``ray-carved patterns''); and abstract patterns such as geometric patterns, letters, figures, polka dots, and floral designs.

The ink used for the colored layer and the design layer is a mixture of a binder resin with an appropriate amount of a colorant such as a pigment or dye, an extender pigment, a solvent, a stabilizer, a plasticizer, a catalyst, a curing agent, an ultraviolet absorber, a light stabilizer, etc.
The binder resin for the colored layer and the design layer is not particularly limited, and examples thereof include urethane resin, acrylic polyol resin, acrylic resin, ester resin, amide resin, butyral resin, styrene resin, urethane-acrylic copolymer, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, chlorinated propylene resin, nitrocellulose resin, cellulose acetate resin, etc. Furthermore, various types of resins can be used, such as one-component curing resins and two-component curing resins containing a curing agent such as an isocyanate compound.

The colorant is not particularly limited, and the colorants exemplified for the adhesive layer can be suitably used.
The content of the colorant is preferably 5 parts by mass or more and 90 parts by mass or less, more preferably 15 parts by mass or more and 80 parts by mass or less, and even more preferably 30 parts by mass or more and 70 parts by mass or less, relative to 100 parts by mass of the resin constituting the decorative layer.

The color layer and the design layer may contain additives such as ultraviolet absorbers, light stabilizers, and colorants.
The thickness of the colored layer and the patterned layer may be appropriately selected depending on the desired pattern, but in order to improve the design, it is preferably 0.5 μm to 20 μm, more preferably 1.0 μm to 10 μm, and even more preferably 1.5 μm to 5 μm. In particular, when it is necessary to conceal the color and appearance of the adherend, the thickness of the colored layer and the patterned layer is preferably 1.5 μm or more, although this depends on the type and content of the colorant contained.

Examples of metal thin films include thin films of simple metal elements such as gold, silver, copper, tin, iron, nickel, chromium, and cobalt, and thin films of alloys containing two or more of the above metal elements. Examples of alloys include brass, bronze, and stainless steel.
The thickness of the metal thin film can be set to about 0.1 μm or more and 1 μm or less.

The release layer, primer layer, adhesive layer, and decorative layer described above can be formed, for example, by applying a coating liquid containing the composition that will form each layer onto a releasable support using a known method such as gravure printing, bar coating, roll coating, reverse roll coating, or comma coating, and then drying and curing the coating as necessary.

<Separator>
The transfer sheet may have a separator on the side of the transfer layer opposite to the releasable support.
When the adhesive layer is a pressure-sensitive adhesive layer, having a separator on the transfer layer makes it easier to prevent blocking when the transfer sheet is wound into a roll, and makes it easier to prevent the transfer sheet from accidentally sticking to other objects.
For example, when the transfer sheet of this embodiment has the layer structure shown in Fig. 3, the separator is provided so as to contact the adhesive layer 24. When using the transfer sheet, the separator is peeled off, and the exposed adhesive layer is brought into contact with the adherend, and the sheets are used by laminating them together.

The material of the separator is not particularly limited as long as it is a material that can be peeled off from the transfer layer, and a plastic film is preferably used.
The plastic film used as the separator may be the same as that exemplified for the support described above. The surface of the separator that comes into contact with the transfer layer is preferably treated with a release agent or the like. As the release agent, known release agents such as fluorine-based release agents and silicone-based release agents can be used.
The thickness of the separator is not particularly limited, but in order to improve the handleability of the transfer sheet, it is preferably 10 μm or more and 200 μm or less, more preferably 15 μm or more and 150 μm or less, and even more preferably 20 μm or more and 100 μm or less.

[60° gloss value]
The transfer sheet of this embodiment is capable of forming a transfer layer on an adherend that has an excellent matte effect and is easily visible. In this specification, "matte" means that the gloss is difficult to see, and although it cannot be generalized because it varies depending on the color tone of the transfer layer, for example, a 60° gloss value of 20.0 or less, preferably 10.0 or less, is generally considered to be "matte." Furthermore, since the transfer sheet of this embodiment imparts matte, the 60° gloss value refers to the 60° gloss value that can be imparted by the transfer sheet of this embodiment (the 60° gloss value of a decorative material obtained by transferring a transfer layer to an adherend).

If the transfer layer constituting the transfer sheet of this embodiment has a stable matte effect and texture due to stable wrinkle formation, the cosmetic material obtained by transferring the transfer layer to an adherend can also be a luxurious cosmetic material with a stable matte effect visibility and texture.
The 60° gloss value of the releasable support constituting the transfer sheet and the 60° gloss value of the decorative material obtained by transferring the transfer layer to the adherend will be basically the same if the color tones of the two are similar, although there will be some differences.

Until now, for decorative materials exhibiting dark colors such as black, it has been possible to impart excellent matte visibility, with a 60° gloss value of 20.0 or less, preferably 10.0 or less, by incorporating a matting agent into the matte layer. "Dark color" refers to a low lightness, typically with an L ^* value (hereinafter sometimes simply referred to as "L ^* value") of about 40 or less, preferably 30 or less, in the CIE (Commission Internationale de l'Eclairage) L ^* a ^* b ^* color system measured in accordance with JIS Z8781-4:2013. However, the use of a large amount of matting agent results in streaks and unevenness during matte layer formation, making it difficult to manufacture and reducing the strength of the matte layer. Furthermore, for decorative materials exhibiting colors other than dark colors, there has been a limit to the reduction in 60° gloss value even when a matte agent is incorporated into the matte layer.

This tendency becomes more pronounced as the 60° gloss value decreases. Therefore, in conventional technologies that use matting agents, it is necessary to limit the amount of matting agent used for manufacturing reasons, etc., and it has not been possible to achieve a more visible matting effect.

In this embodiment, when forming the basic matte layer, two types of wrinkle formation stabilizers with specified average particle sizes are used in combination, and the amount contained is kept small as described above. This not only achieves a stable, extremely excellent matte effect in terms of visibility and texture, but also provides a rough feel to the touch. Furthermore, by keeping the amount of wrinkle formation stabilizer used to an extremely small amount, a significant increase in the viscosity of the resin composition is suppressed, thereby improving the productivity of the matte layer.

The 60° gloss value of a decorative material obtained using the transfer sheet of this embodiment cannot be generally defined because, as mentioned above, it varies depending on the color tone. However, for example, in the case of black or other dark colors, the 60° gloss value on the transfer layer side can be 10.0 or less, and even 7.5 or less, 5.0 or less, 4.0 or less, 3.6 or less, or 2.0 or less, thereby achieving an extremely excellent visibility of the matte effect. Furthermore, decorative materials in colors other than black or other dark colors can also have the above-mentioned 60° gloss values.

In this specification, the 60° gloss value on the transfer layer side refers to the 60° specular gloss measured in accordance with JIS K 5600-4-7:1999, and is the average of values that can be measured from the transfer layer side using a gloss meter or similar at any 10 locations. When measuring the 60° gloss value, it is preferable to attach a black plate to the back of the measurement sample via an adhesive layer in order to suppress reflection from the back of the sample.

[Transfer sheet manufacturing method]
The transfer sheet of this embodiment can be produced, for example, as follows: The following production method is intended to produce a transfer sheet having the layer structure shown in FIG.
The optical film can be produced through the steps of forming a releasable support, a release layer, a primer layer, a decorative layer, and an adhesive layer.
The process for forming the release support is as described in the method for forming the surface shape of the transfer layer. A basic matte layer is prepared separately, a resin composition for forming the release layer is applied to the support, the surface shape of the basic matte layer is imprinted on the applied surface, and the resin composition is cured by irradiating with ultraviolet light or the like. It goes without saying that when the release support does not have a release layer and is only a support, the surface shape can be provided on the support. The conditions for curing the release layer can be appropriately selected depending on the type of resin composition of the release layer, and the resin composition can be cured by heating, irradiating with ultraviolet light, electron beams, or other ionizing radiation.

When using electron beams as the ionizing radiation, the acceleration voltage can be selected appropriately depending on the resin used and the layer thickness, but it is usually preferable to cure the uncured resin layer at an acceleration voltage of approximately 70 to 300 kV. The exposure dose is preferably an amount that saturates the crosslink density of the ionizing radiation-curable resin, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).

The electron beam source is not particularly limited, and various electron beam accelerators such as Cockcroft-Walton type, Van de Graaf type, resonant transformer type, insulating core transformer type, linear type, dynamitron type, and high frequency type can be used.
When ultraviolet light is used as the ionizing radiation, ultraviolet light having a wavelength of 190 to 380 nm is emitted. There are no particular limitations on the source of ultraviolet light, and examples that can be used include high-pressure mercury lamps, low-pressure mercury lamps, metal halide lamps, and carbon arc lamps.

Next, the resin composition for forming the release layer is applied onto the cured release layer and cured in the same manner as the release layer described above.

The primer layer, adhesive layer, and decorative layer described above can be formed, for example, by applying a coating liquid containing the composition that will form each layer onto each layer using a known method such as gravure printing, bar coating, roll coating, reverse roll coating, or comma coating, and then drying and curing as necessary.

[Manufacturing method of cosmetic material]
The method for producing a decorative material of this embodiment includes the following steps (I) and (II).
(I) A step of obtaining a laminate in which the transfer layer side of the transfer sheet of the present embodiment described above is tightly attached to an adherend.
(II) A step of peeling off the releasable support from the laminate to obtain a decorative material having a transfer layer on an adherend.

The adherend in step (I) is not particularly limited, and adherends made of resin, paper, nonwoven fabric, woven fabric, wood, metal, nonmetallic inorganic material, etc. can be appropriately selected.
When a resin is used as the adherend, physical or chemical surface treatments such as oxidation and roughening can be applied to one or both sides as desired to improve adhesion between the transfer layer of the transfer sheet and the adherend.
The shape of the adherend is not particularly limited, and may be a flat plate such as a sheet, or may have a three-dimensional shape such as a curved plate or polygonal pillar.

In step (I), the transfer layer side of the transfer sheet and the adherend can be adhered together, for example, by an adhesive layer on the transfer layer. If the transfer layer does not have an adhesive layer, an adhesive can be interposed between the transfer layer and the adherend in step (I).

One embodiment of step (I) is a lamination method having the following steps (a1) and (a2) in order:
(a1) A step of contacting and superimposing the transfer layer side of the transfer sheet on an adherend on a flat plate.
(a2) A step of applying heat and/or pressure from the releasable support side of the transfer sheet to bring the adherend on the flat plate and the transfer layer of the transfer sheet into close contact with each other.

Another embodiment of step (I) is an in-mold molding method that requires the following steps (z1) to (z4) in order. In in-mold molding, the resin poured in step z2 serves as the adherend.
(z1) A step of placing the transfer layer side of the transfer sheet facing the inside of the in-mold forming die.
(z2) A step of injecting a resin into the in-mold molding die.
(z3) A step of integrating the transfer sheet and the resin to bring the transfer layer of the transfer sheet and the resin into close contact with each other, thereby forming a resin molded body.
(z4) A step of removing the resin molded body from the in-mold molding die.

When the transfer sheet has a separator on the side of the transfer layer opposite to the releasable support, it is preferable to have the following step (0) before the step (1).
(0) A step of peeling the separator from the transfer sheet.

The decorative material obtained as described above can be cut as desired and the surface or end grain can be decorated as desired, such as by groove processing or chamfering, using a cutting machine such as a router or cutter. It can be used for a variety of applications, such as interior components for buildings such as walls, ceilings, and floors; exterior components such as exterior walls, eaves ceilings, roofs, fences, and fences; fittings or fixtures such as window frames, doors, door frames, handrails, baseboards, moldings, and other fixtures; general furniture such as chests of drawers, shelves, and desks; kitchen furniture such as dining tables and sinks; surface decorative panels for cabinets and the like for home appliances and office automation equipment; interior and exterior components for vehicles; signboards; soundproof walls; and even packaging materials and antiglare films for displays. That is, the transfer sheet of this embodiment is suitable for use as a transfer sheet for transferring uneven shapes to these various components.
Among the decorative materials, resin decorative panels are preferably used mainly as surface decorative panels for general furniture such as chests of drawers, shelves, and desks, as well as for fixtures such as doors, and as various counters.

[Cosmetic materials]
The decorative material of this embodiment is a decorative material having a transfer layer on an adherend, and at least a portion of the surface of the transfer layer opposite the adherend has a surface shape in which Spc (arithmetic mean curvature of the apexes of protrusions) as defined in ISO 25178 is greater than 4000 mm ⁻¹ and Rsm (average length of curved elements) as defined in JIS B0601:2013 is 30 μm or greater.

Fig. 6 is a cross-sectional view showing one embodiment of a decorative material 200 of the present invention. The decorative material 200 in Fig. 6 has a transfer layer 20 on an adherend 30. In Fig. 6, the transfer layer 20 has, in this order from the side closest to the adherend 30, an adhesive layer 24, a decorative layer 23, a primer layer 22, and a release layer 21.
In the decorative material of Fig. 6, a release layer 21 is located on the surface of the transfer layer 20 opposite the adherend 30. Therefore, in the decorative material of Fig. 6, at least a portion of the surface of the release layer 21 opposite the adherend 30 has a surface shape in which Spc (arithmetic mean curvature of the apexes of the protrusions) is greater than 4000 mm ^-1 and Rsm (average length of the curved elements) is 30 µm or greater.

The adherend constituting the decorative material of this embodiment includes the adherends exemplified in the manufacturing method for the decorative material of this embodiment. The transfer layer constituting the decorative material of this embodiment includes the transfer layer exemplified in the transfer sheet of this embodiment.

Next, the present invention will be explained in more detail using examples, but the present invention is not limited to these examples in any way.

1. Evaluation 1-1. Measurement of Surface Profile The surface profile of the peelable layer side of the decorative materials obtained in the Examples and Comparative Examples was measured for Spc (arithmetic mean curvature of the apex of the protrusions), Rsm (average length of the curved elements), Rz (maximum height), and Ra (arithmetic mean roughness). The measurement area was a rectangle (1024 μm × 768 μm) at an arbitrary location on the surface of the decorative material, and was measured using a shape analysis laser microscope ("VK-X150 (controller) / VK-X160 (measurement unit)", manufactured by Keyence Corporation) with an objective lens of 50x magnification, a laser wavelength of 658 nm, measurement mode: surface profile mode, measurement pitch: 0.13 μm, and measurement quality: high-speed mode.

The cutoff values for Rsm (average length of curved elements), Rz (maximum height) and Ra (arithmetic mean roughness) were set to 0.8 mm.
The surface shape of the release layer side of the decorative material can be considered to be the surface shape of the transfer layer on the releasable support side.

1-2. 60° Gloss Value Samples were prepared by laminating a black plate to the back of the polycarbonate resin plate of the decorative material obtained in the Examples and Comparative Examples via an adhesive layer. The 60° specular gloss of the sample was measured from the release layer side using a gloss meter ("Microgloss (model name)" manufactured by BYK Gardner) in accordance with K 5600-4-7:1999.

1-3. Evaluation of Texture Before Weather Resistance Test The surface texture (uniformity of surface condition) of the decorative materials obtained in the Examples and Comparative Examples was evaluated by 20 random adults, and was evaluated according to the following criteria.
A: 18 or more people evaluated that the surface condition was uniform and the matte effect was highly visible.
B: 15 or more and 17 or less judged that the surface condition was uniform and the matte effect was highly visible.
C: 14 or less people evaluated that the surface condition was uniform and the matte effect was highly visible.

1-4. Evaluation of Texture After Weather Resistance Test The following weather resistance test was carried out on the decorative materials obtained in the Examples and Comparative Examples. After the weather resistance test, the decorative materials were evaluated for surface texture (uniformity of surface condition) using the same criteria as in 1-3.

<Weather resistance test>
A weather resistance test was carried out using a weather resistance tester (trade name "Metal Weather" manufactured by Daipla Wintes Co., Ltd.) In the weather resistance test, the following "ultraviolet light irradiation step,""condensationstep," and "water spray step" were defined as one cycle, and this cycle was repeated until 500 hours had elapsed.

《Ultraviolet irradiation process》
Illuminance: 60 mW/cm ² , Black panel temperature: 63°C, Humidity inside the chamber: 50% RH, Time: 20 hours (Condensation process)
Illuminance: 0 mW/cm ² , Black panel temperature: 30°C, Humidity in chamber: 98% RH, Time: 4 hours (Water spray process)
Spray water for 10 seconds before and after the condensation process.

(Evaluation of rough texture)
For the cosmetic materials obtained in the Examples and Comparative Examples, an Oxford cloth made of 40-count cotton yarn was used as a standard for the rough texture, and 20 random adults were asked to evaluate the surface texture, and the evaluation was based on the following criteria.
A: 18 or more people evaluated that the texture was close to the standard and that it was rough to the touch.
B: 15 to 17 panelists evaluated the texture as close to the standard and as rough to the touch.
C: 14 or less people evaluated that the texture was close to the standard and that it was rough to the touch.

2. Preparation of matte layer, preparation of mold from matte layer [basic matte layer]
A colored thin paper base paper for building materials (thickness: 30 μm) was used as a substrate, and a resin composition containing an acrylic resin and a urethane resin as binder resins was applied to one side of the substrate and dried to form an easy-adhesion layer (thickness: 2 μm).
The resin composition 1 for forming the basic matte layer described below was applied onto the easy-adhesion layer by gravure (coating amount: 5 μm (when dry)), then irradiated with ultraviolet light using a UV irradiation device composed of LEDs (wavelength: 395 nm, ultraviolet light amount: 6 W/cm ² ), then irradiated with ultraviolet light using an excimer light irradiation device (wavelength: 172 nm (Xe ₂ ), ultraviolet light output density: 1 W/cm 2 , cumulative light amount: 10 to 100 mJ/cm ² , nitrogen atmosphere (oxygen concentration 200 ppm or less)), and then further irradiated with ultraviolet light using a high-pressure mercury lamp (ultraviolet light output density: 200 W/cm 2 ) to obtain a laminate (1) having a matte layer on the substrate.

A resin composition containing an acrylic resin and a urethane resin as binder resins was applied to one surface of a support (a PET sheet subjected to corona discharge treatment, thickness: 100 μm) and dried to form an easy-adhesion layer (thickness: 2 μm).
Next, the curable resin of the following laminate (2) (for forming a release layer) was applied onto the easy-adhesion layer by a gravure method to form a coating film (coating amount: 5 μm (when dried)), thereby obtaining a laminate (2) having an easy-adhesion layer and an uncured release layer on the support.

Next, the surface of the obtained laminate (1) on the side of the basic matte layer was dry laminated onto the uncured coating film (uncured release layer) of the laminate (2), to obtain a laminate (2').
Next, the PET side of the laminate (2) constituting the laminate (2') was irradiated with an electron beam (applied voltage: 175 KeV, 5 Mrad (50 kGy)) to cure the uncured curable resin.
Next, the laminate (1) was peeled off from the laminate (2') to obtain a release support having an easy-adhesion layer and a release layer on the support, which was used in Example 1. The surface of the release support was molded with a shape that was the inverse of the surface shape of the basic matte layer.

<Resin composition 1 for forming basic matte layer>
60 parts by weight of multifunctional urethane acrylate oligomer (number of functional groups: 4) 30 parts by weight of multifunctional acrylate monomer (bifunctional) 10 parts by weight of monofunctional acrylate monomer 3 parts by weight of wrinkle formation stabilizer (silica particles, average particle size: 5 nm) 0.8 parts by weight of photopolymerization initiator (benzophenone type)

<Curable Resin of Laminate (2) (for Forming Release Layer)>
Urethane acrylate oligomer 100 parts Reactive acrylic modified silicone oil 0.5 parts (used as a release agent)

3. Preparation of transfer sheet and decorative material [Example 1]
On the release layer of the releasable support obtained above, a resin composition 1 for forming a release layer described below was applied to form an uncured resin layer, and the uncured resin layer was cured by irradiating with an electron beam (applied voltage: 175 KeV, 5 Mrad (50 kGy)) to form a release layer (thickness: 5 μm). Thereafter, corona irradiation was performed on the release layer.

Next, a resin composition for forming a primer layer, which will be described later, was applied onto the corona-irradiated release layer and dried to form a primer layer having a thickness of 2.5 μm.
Next, an acrylic resin (PMMA, weight average molecular weight: 96,000) was applied onto the primer layer and dried to form a 4 μm thick heat-sealable adhesive layer. After forming the adhesive layer, the resulting sheet was aged at room temperature for 24 hours to obtain a transfer sheet of Example 1.

The adhesive layer of the transfer sheet of Example 1 was placed opposite one side of the adherend, a polycarbonate plate (thickness: 2 mm, manufactured by AGC, product name "Carbopolish"), and laminated. Then, using a laminator (a roll-type thermal transfer machine manufactured by Navitas Co., Ltd., product name "RT-300"), pressure was applied from the transfer sheet side while heating under conditions of a lamination roll temperature of 160°C and a conveyance speed of 1.5 m/min, to obtain a laminate in which the transfer layer of the transfer sheet and the adherend were in close contact with each other.
Next, the releasable support was peeled off from the laminate to obtain the decorative material of Example 1. The decorative material of Example 1 has a transfer layer on the adherend.

<Resin composition 1 for forming release layer>
Ionizing radiation curable resin (bifunctional urethane oligomer): 100 parts by mass Ultraviolet absorber (BASF, trade name: Tinuvin 479): 0.5 parts by mass Light stabilizer (BASF, trade name: Tinuvin 123): 0.3 parts by mass

<Resin composition for forming primer layer>
Polycarbonate-based urethane acrylic copolymer: 100 parts by mass (weight average molecular weight 50,000)
UV absorber (BASF, trade name: Tinuvin 479): 20 parts by mass UV absorber (BASF, trade name: Tinuvin 400): 15 parts by mass Light stabilizer (BASF, trade name: Tinuvin 123): 3.5 parts by mass Antiblocking agent (silica with an average particle size of 3 μm): 10 parts by mass Solvent: appropriate amount

[Example 2]
A decorative material of Example 2 was obtained in the same manner as in Example 1, except that Resin composition 1 for forming a release layer was changed to Resin composition 2 for forming a release layer.
<Resin composition 2 for forming release layer>
Bifunctional urethane acrylate oligomer: 40 parts by mass Hexafunctional urethane acrylate oligomer: 60 parts by mass Ultraviolet absorber (BASF, trade name: Tinuvin 479): 2 parts by mass Light stabilizer (Nippon Nyukazai Co., Ltd., trade name: Sanol LS-3410): 3 parts by mass

[Comparative Example 1]
In the [Matte layer 1] of "2" above, the substrate was changed to a PET sheet (Cosmoshine (registered trademark) A4160 (50 μm) manufactured by Toyobo Co., Ltd.), and the resin composition 1 for forming the matte layer was applied to the easy-adhesion surface of the substrate by a gravure method (application amount: 18 μm (when dried)). In the same manner as in Example 1, a release support, a transfer sheet, and a decorative material of Comparative Example 1 were obtained.

[Comparative Example 2]
A releasable support, a transfer sheet and a decorative material of Comparative Example 2 were obtained in the same manner as in Comparative Example 1, except that the coating amount of the resin composition 1 for forming the matte layer was changed to 5 μm (when dried).

[Comparative Example 3]
In Example 1, the substrate of [Matte layer 1] of the above "2" was changed to a polypropylene sheet (PP, thickness: 100 μm) that had been subjected to a corona discharge treatment, a resin composition for forming a primer layer (urethane resin, coating amount: 2 μm (when dried)) was applied to one side of the substrate, and the resin composition 1 for forming the matte layer was applied on the primer layer (coating amount: 5 μm (when dried)). In the same manner as in Example 1, except for this, a release support, a transfer sheet, and a decorative material of Comparative Example 3 were obtained.

[Comparative Example 4]
In Comparative Example 2, the release support, transfer sheet and decorative material of Comparative Example 4 were obtained in the same manner, except that ultraviolet light was not irradiated using a UV irradiation device consisting of the LED of [Matte layer 1] of "2" above.

[Comparative Example 5]
In Comparative Example 1, the release support, transfer sheet and decorative material of Comparative Example 5 were obtained in the same manner, except that Resin composition 1 for forming the matte layer was changed to Resin composition 2 for forming the basic matte layer described below.
<Resin composition 2 for forming basic matte layer>
60 parts by weight of multifunctional urethane acrylate oligomer (number of functional groups: 7) 30 parts by weight of multifunctional acrylate monomer (bifunctional) 10 parts by weight of monofunctional acrylate monomer 15 parts by weight of wrinkle formation stabilizer (silica particles, average particle size: 5 nm) 0.8 parts by weight of photopolymerization initiator (benzophenone type)

[Comparative Example 6]
A release support, a transfer sheet and a decorative material of Comparative Example 6 were obtained in the same manner as in Comparative Example 5, except that the coating amount of the resin composition 2 for forming the matte layer was changed to 5 μm (when dried).

The releasable supports, transfer sheets, and decorative materials obtained in Examples 1 and 2 and Comparative Examples 1 to 6 were evaluated for Spc (arithmetic mean curvature of the apexes of the protrusions), Rsm (average length of the curved elements), Rz, Ra, and 60° gloss, as well as for texture (before weather resistance test), texture (after weather resistance test), and roughness to the touch. These results are shown in Table 1.
7 to 13 show micrographs of the surfaces of the decorative materials obtained in Example 1 and Comparative Examples 1 to 6.

From the results in Table 1, it was confirmed that the matte article of this embodiment has a 60° gloss value of 1.3 to 1.4 on the matte layer side, making it an article with extremely excellent visibility of the matte effect and also having an excellent texture. It was also confirmed that it has an excellent rough texture.

On the other hand, the matte articles of Comparative Examples 1 to 3, which had an Rsm of less than 30 μm, were found to have inferior texture and no rough feel to the touch. The matte articles of Comparative Examples 4 to 6, which had an Rsm of 30 μm or more but an Spc of 4000 mm ⁻¹ or less, had 60° gloss values of 3.5 to 5.6, and were found to have textures even inferior to the matte articles of Comparative Examples 1 to 3. The matte articles of Comparative Examples 4 to 6 were also found to have a rough feel to the touch inferior to Example 1.

The transfer sheet of this embodiment provides excellent matte visibility and texture, and also provides a rough feel, making it suitable for a variety of applications, including interior building components such as walls, ceilings, and floors; exterior building components such as exterior walls, eaves ceilings, roofs, fences, and fences; fixtures and fittings such as window frames, doors, door frames, handrails, baseboards, moldings, and other building components; general furniture such as chests of drawers, shelves, and desks; kitchen furniture such as dining tables and sinks; surface decorative panels for cabinets for home appliances and office equipment; and interior and exterior components for vehicles. In addition to decorative materials and decorative materials used in the aforementioned buildings, etc., the transfer sheet of this embodiment can be laminated, composited, or combined with other materials (adherends) and suitably used as packaging materials, anti-glare films for displays, whiteboards or blackboards, various cards such as credit cards, cash cards, telephone cards, and various certificates, various keyboard keys, transparent panels (window glass, etc.) for windows, doors, partitions, etc., signs, soundproof walls, artificial leather, etc.

1a: Protrusion apex (Spc large)
1b: Protrusion apex (Spc small)
2: Convex part 2a: Convex part (small Rsm)
2b: Convex part (large Rsm)
2c, 2d: Convex portions 3: Concave portions 3a to 3c: Concave portions 10: Releasable support 11: Support 12: Release layer 20: Transfer layer 21: Peel layer 22: Primer layer 23: Decorative layer 24: Adhesive layer 30: Adherend 100: Transfer sheet 200: Decorative material

Claims (14)

A transfer sheet having a transfer layer on a releasable support,
A transfer sheet having a surface shape in which, on at least a portion of the surface of the transfer layer on the side of the releasable support, the Spc (arithmetic mean curvature of the apexes of protrusions) as defined in ISO 25178 is greater than 4000 mm ^-1 , and the Rsm (average length of curved elements) at a cutoff value of 0.8 mm as defined in JIS B0601:2013 is 30 μm or greater. The transfer sheet according to claim 1, wherein the surface shape has a profile peak and height parameter Rz (maximum height) specified in JIS B0601:2013 of 8.00 μm or more and 30.00 μm or less. The transfer sheet according to claim 1 or 2, wherein the surface shape has an arithmetic mean roughness (Ra), which is a parameter in the height direction of the profile curve as defined in JIS B0601:2013, of 1.00 μm or more and 5.50 μm or less. The transfer sheet according to any one of claims 1 to 3, wherein the surface of the transfer layer that forms the surface shape has an uneven shape formed by irregular wrinkles. The transfer sheet of claim 4, wherein the irregular wrinkles are composed of multiple convex portions formed by multiple linear protrusions and concave portions formed by being surrounded by the multiple linear protrusions. The transfer sheet according to any one of claims 1 to 5, wherein the transfer layer has, from the releasable support side, a release layer and an adhesive layer in this order. The transfer sheet according to claim 6, which has one or more layers selected from a primer layer and a decorative layer between the release layer and the adhesive layer. The transfer sheet according to claim 6 or 7, wherein the release layer comprises a cured product of a resin composition containing an ionizing radiation-curable resin. The transfer sheet according to any one of claims 6 to 8, wherein the release layer contains an ultraviolet absorber or a light stabilizer. The transfer sheet according to any one of claims 6 to 9, wherein the release layer is substantially free of particles. The transfer sheet according to any one of claims 1 to 10, wherein the releasable support has a release layer on the support. The transfer sheet according to claim 11, wherein the release layer comprises a cured product of a resin composition containing an ionizing radiation-curable resin. A method for producing a decorative material, comprising the following steps (1) and (2):
(1) A step of obtaining a laminate in which the transfer layer of the transfer sheet according to any one of claims 1 to 12 is closely attached to an adherend.
(2) A step of peeling off the releasable support from the laminate to obtain a decorative material having a transfer layer on the adherend. A decorative material having a transfer layer on an adherend,
A decorative material having a surface shape in which, on at least a portion of the surface of the transfer layer opposite to the adherend, Spc (arithmetic mean curvature of the apexes of protrusions) as defined in ISO 25178 is greater than 4000 mm ^-1 , and Rsm (average length of curved elements) at a cutoff value of 0.8 mm as defined in JIS B0601:2013 is 30 μm or greater.