JP2001063290A - Transfer sheet for molding and method for transfer using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To attain compatibility of the moldability and releasability of a transfer sheet for molding. SOLUTION: In a transfer sheet S for molding which has a transfer layer 20 on a substrate sheet 10, the substrate sheet 10 is constituted of three ethylene- propylene random copolymer layers of a central layer 11, a surface outer layer 12 and a rear outer layer 13 and the ethylene content of a ethylene-propylene random copolymer is made larger in the central layer than in the surface and rear layers. In the form wherein a substrate sheet 10A is constituted of two ethylene-propylene random copolymer layers of a surface layer 14 on the side facing the transfer layer and a rear layer 15 on the side not facing the transfer layer, the ethylene content of the ethylene-propylene random copolymer is made smaller in the surface layer than in the rear layer. As for a method for transfer, the transfer sheet for molding having this constitution is used, while a solid particle impact pressure or an elastic body roller is used for a transfer pressure.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transfer sheet used for producing interior materials such as floors, walls, ceilings and the like of buildings, exterior materials, furniture, and various decorative materials such as various cabinets. In particular, the present invention relates to a transfer sheet for molding suitable for transferring an uneven surface.

[0002]

2. Description of the Related Art Conventionally, as a transfer sheet for molding capable of following and transferring to a three-dimensionally formed transfer surface, a transfer sheet using a polyolefin resin sheet has been tried in order to ensure the formability of a support sheet. . Of course, vinyl chloride resin can also be used as the support sheet, but the purpose of using a polyolefin-based resin-based resin sheet is that the above-mentioned resin sheet, which does not contain chlorine and has moldability, can be used from an environmental point of view. This is because it is preferable. In the case of a polyolefin-based resin sheet, if the moldability is improved, the releasability may be deteriorated. Therefore, in order to achieve both of these, for example, Japanese Patent Application Laid-Open No. 10-217692 discloses an amorphous polyolefin resin layer. A transfer sheet using a support sheet composed of different types of resin layers in which the front and back surfaces are sandwiched between resin layers made of crystalline polypropylene resin and / or ethylene-based resin has been proposed. The amorphous polyolefin-based resin layer is, for example, an atactic polypropylene or an ethylene-propylene copolymer or a propylene-butene copolymer, and is poor in releasability, solvent resistance, blocking resistance, and the like necessary for forming a transfer layer. Formability is a good layer. On the other hand, the crystalline polypropylene resin is, for example, isotactic polypropylene and the like, and the ethylene-based resin is, for example, high-density polyethylene and the like. The solvent resistance and the blocking resistance are good.

[0003]

However, in the structure proposed in Japanese Patent Application Laid-Open No. Hei 10-216792, the outer resin layer made of crystalline polypropylene resin or high-density polyethylene reduces the moldability of the entire support sheet. It will hinder you. It covers the local stress concentration (e.g., necking) due to elongation and the sharp change in fluidity (plasticity) with respect to temperature changes near the melting point (narrowness of the processing area) with the amorphous polyolefin resin layer in the center layer. There was a problem that it could not be done.

It is an object of the present invention to provide a transfer sheet for molding using a polyolefin-based resin as a support sheet while ensuring both moldability and releasability while ensuring moldability.

[0005]

In order to solve the above-mentioned problems, a transfer sheet for molding according to the present invention comprises a transfer sheet for molding having a transfer layer on a support sheet, wherein the support sheet has a central layer. And an ethylene-propylene random copolymer layer composed of three layers of an outer surface layer and a back outer layer, and the ethylene content of the ethylene-propylene random copolymer in each layer is larger in the center layer than in the outer layer and the back outer layer. The configuration was adopted.

As described above, all layers of the support sheet are unified to a resin layer composed of an ethylene-propylene random copolymer in an intermediate state between perfect crystal and perfect amorphous, so that necking can be performed to some extent as a whole. The moldability is ensured by eliminating, and on top of that, the moldability, the releasability and the anti-blocking property are both balanced to balance, and on the side facing the transfer layer and the side not facing the transfer layer By making the ethylene content of the back outer layer smaller than that of the center layer (shifting toward a higher crystallization direction), the releasability (in the case of the outer layer on the transfer layer side), and the blocking resistance (the opposite side of the transfer layer) (In the case of the back outer layer) more preferentially, while increasing the ethylene content of the central layer (the inner layer not in contact with the transfer layer) (shifting to a lower crystallization direction) to improve the moldability ( (The ability to follow irregular shapes) is given higher priority That it became possible. Further, since the support sheet has a structure in which the center layer is sandwiched between the front and back outer layers and the back and outer layers, the support sheet is unlikely to warp when a transfer layer is formed. As described above, the present invention finds that the moldability, the releasability, the blocking resistance, and the like are greatly different depending on the operation of the ethylene content of the ethylene-propylene random copolymer. Everything was satisfied.

Further, the molding transfer sheet of the present invention is a molding transfer sheet having a transfer layer on a support sheet, wherein the support sheet has a surface layer on the side facing the transfer layer and a surface layer on the transfer layer. The structure was made up of two ethylene-propylene random copolymer layers of the back layer on the side not to be used, and the ethylene content of the ethylene-propylene random copolymer of both layers was smaller in the surface layer than in the back layer.

This structure is a molding transfer sheet using a two-layered support sheet with respect to the molding transfer sheet composed of the three-layered support sheet. To give preferentially releasability on the surface layer,
Formability can be preferentially imparted to the back layer on the opposite side that does not face the transfer layer, so that all layers of the support sheet can be realized with a uniform structure of ethylene-propylene random copolymer.
In this configuration, although the resin content of the back layer corresponds to the center layer of the transfer sheet for molding, even if such a configuration does not pose a problem of anti-blocking, the desired effect can be obtained at a lower cost with a smaller layer configuration. There is an advantage that can be obtained.

In the transfer method of the present invention, the transfer is performed at a transfer pressure of solid particle collision pressure using any one of the transfer sheets for molding. By transferring the solid particle collision pressure as the transfer pressure in this manner, the transfer can be performed reliably and easily even on a deep uneven surface, which is impossible with a transfer method using an elastic roller, without transfer failure such as transfer omission. . as a result,
Transfer products such as high-design decorative materials can be easily manufactured.

Further, in the transfer method of the present invention, any one of the above-described transfer sheets for molding is used, and transfer is performed by a transfer pressure by an elastic roller. By performing the transfer with the transfer pressure by the elastic roller in this manner, the transfer can be easily performed on a relatively flat uneven surface.

[0011]

Embodiments of the transfer sheet for molding of the present invention will be described below. FIG. 1 is a cross-sectional view illustrating an embodiment of the transfer sheet for molding of the present invention, FIG. 2 is a conceptual diagram illustrating a transfer method for transferring by a transfer pressure by solid particle collision pressure, and FIG. 3 is a transfer by an elastic roller. FIG. 4 to FIG. 6 are illustrations of an ejector used for ejecting solid particles, and FIG. 7 is an uneven shape of an object used for evaluation of formability by a vacuum molding transfer method. FIG. 8 is a perspective view showing an uneven shape of a transferred body used for evaluation of formability in a transfer method using solid particle collision pressure, FIG. 9 is a conceptual diagram illustrating a method for measuring peel strength, and , FIG.
FIG. 3 is a cross-sectional view showing a decorative material obtained by a vacuum forming transfer method.

[Support Sheet] The support sheet has a three-layer structure (see FIG. 1A) and a two-layer structure (see FIG. 1B). In the case of the support sheet 10 having a three-layer structure, the support sheet 10 has three ethylene-propylene random copolymer layers of a center layer 11, an outer surface layer 12 (facing the transfer layer 20), and a back outer layer 13. Consisting of, and ethylene content of the ethylene-propylene random copolymer of each layer,
The central layer 11 is larger than the front outer layer 12 and the back outer layer 13. On the other hand, in the case of the support sheet 10 </ b> A having a two-layer structure, the support sheet 10 </ b> A
And the back layer 15 on the side not facing the transfer layer 20 is composed of two ethylene-propylene random copolymer layers, and the ethylene content of the ethylene-propylene random copolymer in both layers is lower than that of the back layer 15. The surface layer 14 is small.

As described above, according to the present invention, the support sheet 10
(Or 10A), the outer layer 1 facing the transfer layer 20
2 (or the surface layer 14) is smaller in ethylene content than the center layer 11 (or the back layer 15) not facing the transfer layer, thereby improving the moldability and the releasability of the support sheet 10 (or 10A). Can be compatible. In particular, in the case of a three-layer structure, by providing a back outer layer having a smaller ethylene content as in the outer layer than in the center layer, it is possible to prevent the occurrence of blocking during winding and preservation and to more reliably impart blocking resistance.
It is also possible to effectively prevent the occurrence of warpage and curl during production, storage, use, and the like due to differences in heat shrinkage and elongation, which can occur in the case of a layer structure.

The ethylene content of the ethylene-propylene random copolymer used for the ethylene-propylene random copolymer layer serving as the center layer 11, the outer layer 12, the outer layer 14, the outer layer 13 and the back layer 15 is an appropriate value. What is necessary is just to realize a size relationship. Usually, the ethylene content is 1
-5% by weight, at most about 10% by weight. As shown in Table 1, the degree of crystallinity changes depending on the magnitude of the ethylene content, and it is possible to control moldability and peelability (peel strength). The peel strength was measured at room temperature (2
0 [deg.] C.) at a peeling angle [theta] = 90 [deg.], Usually 5-1.
00 gf / 25 mm width, preferably 20 to 50 gf / 2
It is preferable that the width is set to about 5 mm from the viewpoint of preventing the occurrence of foil burrs and ensuring good foil breakability.

[0015]

[Table 1]

In the three-layer structure, the ethylene-propylene random copolymer of the outer layer 12 and the outer layer 13 is
Copolymers having different contents (ethylene content, average molecular weight, additives, etc.) may be used, but from the viewpoint of curl prevention, ethylene-propylene random copolymers having exactly the same or substantially the same It is preferred to use.

The total thickness of the support sheet is not particularly limited as long as it is a thickness suitable for the intended use, but is usually 50 to 100 μm from the balance between the strength of the support sheet and moldability.
m. In addition, the outer layer 12 and the outer layer 14
Is a layer that imparts good peeling properties as surface properties, so that it can be formed into a film reliably and has a minimum thickness necessary for performing stable peeling. If the thickness is too large, the moldability of the entire support sheet is reduced. Therefore, the thickness is usually at least about 5 μm and at most about 20% of the total thickness of the support sheet. In this connection, since the center layer 11 in the three-layer configuration and the back layer 15 in the two-layer configuration are layers that give moldability preferentially, they do not hinder the peeling of the transfer layer. It is preferable that the thickness (thickness ratio is large) be as long as not provided. Therefore, even in the case of a three-layer structure, the thickness is at least 60% of the total thickness of the support sheet.

The support sheet having a multilayer structure as described above can be prepared as a sheet (film) by a conventionally known film forming method such as a calendar method, an inflation method, or a T-die extrusion method. Among these, the method of laminating each layer simultaneously with the film formation by the co-extrusion method of the T-die extrusion method is preferable in that the layers can be laminated with good adhesion.

By using the support sheet having the above structure, the support sheet can be formed with good moldability and releasability without using a vinyl chloride resin. In some cases, it does not generate hydrochloric acid gas and is also a preferable support sheet in terms of environmental measures.

Further, various additives such as a stabilizer, an ultraviolet absorber, a light stabilizer, an antioxidant, an antistatic agent, and a filler are appropriately added to the above-mentioned layers of the support sheet as needed. Is also good. These may be appropriately selected from known additives.

Further, an uneven pattern may be provided on the surface of the support sheet. For example, if an uneven pattern such as a squeezed pattern is provided on the back outer layer or the surface of the back layer (the side of the support sheet not facing the transfer layer), the anti-blocking property when wound up and the slip property of the transfer sheet for molding are obtained. Can be improved. In addition, if a concavo-convex pattern such as a squeezed pattern is provided on the outer surface layer or the surface of the surface layer (the surface facing the transfer layer) (the surface on which the transfer layer is formed is a polyolefin-based resin, which is more difficult to wet). In addition, when the transfer layer is formed by printing, coating, or the like, the transferability of the ink or coating liquid (from the plate surface in printing) can be improved. The unevenness pattern for imparting the function of improving blocking resistance and transferability has a center line average roughness Ra (JIS B
0601) gives a good result with an uneven shape of about 0.1 to 5 μm. In addition, as a squeezing pattern, there are a grain of sand and a pear-skin.

Further, it is possible to form a concave and convex pattern provided on the transfer layer side of the support sheet on the surface of the transfer layer after the transfer, so that it is possible to express a design by a concave and convex pattern such as a matte wood groove pattern. Become. Examples of the concavo-convex pattern used in the design expression include a grain of sand, a satin finish, a hairline, a linear groove, a skin squeezing, a texture on a cloth surface, a character, and a geometric pattern. The concavo-convex pattern used for imparting the function or expressing the design may be formed by a known shaping method such as embossing by hot pressing, hairline processing, and sandblasting.

[Transfer Layer] The transfer layer 20 to be laminated on the support sheet 10 is not particularly limited, and the material and structure of the transfer layer in various conventionally known transfer sheets can be adopted.

That is, when the transfer layer 20 is transferred from the transfer sheet for molding to the transfer-receiving body side by transfer,
Usually, the transfer layer is composed of at least a decorative layer, and a release layer, an adhesive layer, and the like may be appropriately used as a component of the transfer layer.
The transfer layer may be a functional layer such as an antibacterial layer, an antifungal layer, or a conductive layer. Further, as in the case of sublimation transfer, the entire transfer layer may not move to the transfer object side, and only the transfer transfer material such as a sublimable dye in the transfer layer may move to the transfer object side. The transfer layer is formed by an arbitrary forming means such as a conventionally known printing method, coating method, or hand-drawing.

The decorative layer may be formed by, for example, a conventionally known method such as gravure printing, silk screen printing, offset printing, gravure offset printing, or ink jet printing, a pattern layer formed by printing a pattern or the like with a material, aluminum,
A metal thin film layer or the like in which a metal such as chromium, gold, silver or the like is partially or entirely formed by using a known vapor deposition method or the like. A wood pattern, a stone pattern, a cloth pattern, a tile pattern, a tile pattern, a brick pattern, a leather pattern, a character, a geometric pattern, a solid pattern, or the like is used in accordance with the surface irregularities of the transfer target. The ink (or coating liquid) for the picture layer, like a general ink (or coating liquid), includes a vehicle made of a binder and the like, a coloring agent such as a pigment and a dye, and various additives appropriately added thereto. Acrylic resin, vinyl chloride-vinyl acetate copolymer,
A simple substance such as a polyester resin, a cellulosic resin, or a polyurethane resin or a mixture containing these is used. As a coloring agent, titanium white, carbon black, red iron oxide, graphite, inorganic pigments such as ultramarine blue, aniline black, quinacridone, isoindolinone, organic pigments such as phthalocyanine blue,
Bright pigments such as aluminum foil powder, titanium dioxide-coated mica foil powder, and other dyes are used.

The release layer may be formed in the same manner as a conventionally known transfer sheet in order to adjust the releasability between the support sheet and the transfer layer and to protect the surface of the transfer layer after the transfer. May be provided as needed on the side of the support sheet. For the release layer, for example, a resin or the like used as a binder of the picture layer ink is used. The release layer is transferred to the substrate side together with the decorative layer at the time of transfer, and covers the surface of the decorative layer.

[Adhesive] The adhesive may be used as an adhesive layer constituting a transfer layer of a transfer sheet for molding or as an adhesive layer on an object to be transferred. Off-line coating can be applied as needed. In the case of applying to an object to be transferred, the adhesive layer on the molding transfer sheet side can be omitted. As the adhesive used, for example,
Sensitivity with heat-sensitive adhesive, moisture-curable heat-sensitive adhesive, hot-melt adhesive, moisture-curable hot-melt adhesive, two-component curable adhesive, ionizing radiation-curable adhesive, water-based adhesive, or adhesive Pressure-sensitive adhesives and the like. As the heat-sensitive adhesive, there are a heat-sealing type using a thermoplastic resin and a thermosetting type using a thermosetting resin. The adhesive may be diluted with a solvent or without a solvent, or may be a liquid or a solid at room temperature. In the case of an adhesive other than a pressure-sensitive adhesive exhibiting tackiness, a transfer layer can be formed with only a single adhesive layer. For example, heat-sensitive adhesives include polyvinyl acetate resin, vinyl chloride-vinyl acetate copolymer, acrylic resin, thermoplastic polyester resin, thermoplastic urethane resin, polyamide resin obtained by polycondensation of dimer acid and ethylenediamine, etc. Is used.
In addition, the thermosetting adhesive, phenolic resin, urea resin, diallyl phthalate resin, thermosetting urethane resin,
Epoxy resin or the like is used.

The adhesive is applied to a sheet to be a transfer sheet for molding or an object to be transferred by a conventionally known solution coating means such as a gravure roll coat, a spray coat, and a flow coat.
Melt coating (melt coating) means using a hot melt adhesive with an applicator or the like can also be applied to the transferred object. The amount of the adhesive to be applied varies depending on the composition of the adhesive, the type of the object to be transferred, and the surface condition, but is usually about 10 to ²⁰⁰ g / m ² (solid content).

[Transfer Method] The transfer sheet of the present invention described above can be transferred to a transfer target by various conventionally known transfer methods, for example, as described below. They are,
What is necessary is just to select suitably according to a to-be-transferred object, the surface unevenness of a to-be-transferred surface, a use, etc.

In particular, the transfer method (transfer pressure pressing method) adopted as the transfer method of the present invention includes a transfer method (transfer method using a roller) and a transfer method using a transfer pressure by an elastic roller.
Is a transfer method in which transfer is performed at a transfer pressure due to solid particle collision pressure. The elastic roller is suitable in that it can be easily transferred even if it has some surface irregularities. This is preferable in that it can be easily transferred to surface irregularities.

Transfer method using an elastic roller (roller transfer method): Japanese Patent Publication No. 60-59876,
As described in JP-A-270199 and JP-A-5-139097, the transfer sheet is pressed with an elastic roller from the support sheet side with the transfer layer facing the transfer object side, and the transfer layer is covered. A so-called roller transfer method in which the support sheet is peeled off after bonding to the transfer body.

Vacuum forming transfer method: JP-B-56-457
No. 68 (overlay method), Japanese Patent Publication No. 60-5801
As described in Japanese Patent Publication No. 4 (vacuum pressing method) or the like, a transfer sheet is opposed or placed on a three-dimensionally-transferred object, and at least a transfer layer of the transfer sheet is generated by a pressure difference caused by vacuum suction from the object. A transfer method using a so-called vacuum forming and laminating method for transferring the material onto a transfer object.

Injection molding simultaneous painting transfer method: JP-A-6
As described in JP-A-315950, the transfer sheet is placed between the male and female molds for injection molding so that the transfer layer side faces the injection resin side, and the resin in a fluid state is molded by heating and melting. A transfer method in which a transfer layer is transferred from a transfer sheet to the surface of a transfer-receiving body at the same time as molding of a resin-molded article as a transfer-receiving body by injection-filling the inside.

Wrapping transfer method: JP-B-61-58
No. 95, Japanese Unexamined Patent Publication No. 5-330013, etc., while supplying a transfer sheet in the long axis direction of a columnar transfer object such as a cylinder or a polygonal column, a plurality of rollers having different directions are used. A transfer method using a so-called lapping method in which a transfer sheet is successively transferred to a plurality of side surfaces constituting a transfer object by pressure bonding to transfer a transfer layer.

Transfer method using solid particle impact pressure: The transfer pressure pressing means disclosed in Japanese Patent No. 2844424 and Japanese Patent Application Laid-Open No. 10-193893 is a novel transfer method. FIG. 2 is a conceptual diagram conceptually showing this transfer method. In this transfer method, as shown in FIG. 2, the transfer layer side of a transfer sheet S composed of a support sheet and a transfer layer is opposed to the transfer surface (front surface) of the transfer object B, and the support sheet of the transfer sheet is A large number of solid particles P collide against the transfer side, and the pressure of the collision is used to press the transfer sheet against the transfer surface of the transfer object.
Then, after the transfer layer is adhered to the transfer object, the support sheet of the transfer sheet is peeled off and removed, whereby the transfer to the transfer object by the transfer layer is completed. The arrow attached to the solid particles P is
Represents the velocity vector of a solid particle.

In addition, BMC (Bulk Molding Compoun
d) Molding method, SMC (Sheet Molding Compound) molding method,
FRP (Fiber Reinforced
Plastics) or RIM (React
ion injection molding), a transfer method performed simultaneously with molding such as a matched mold molding method, and the like.

The above-mentioned and the above-mentioned methods are for transferring to an already-formed transfer object, and the above-mentioned methods are for simultaneously transferring the shape of the transfer object as a resin molded product. In addition, in the above method, there is also a method in which after a transfer sheet is preformed by using a resin mold or another mold, the resin is injection-molded and transferred at the same time as molding. Similarly, in the methods listed above, the transfer sheet may be formed simultaneously with resin molding, or may be preformed before resin molding. In the hand lay-up method, the transfer sheet is formed by preliminary forming.

Next, a transfer method using an elastic roller and a transfer method using a transfer pressure of a solid particle collision pressure, which are particularly adopted in the present invention, will be further described.

[Transfer Method Using Elastic Roller] This transfer method (that is, the roller transfer method) is preferable in that it can be easily transferred to a transfer target having relatively small or uneven surface. FIG. 3 is a conceptual diagram conceptually illustrating the roller transfer method. The transfer sheet S is moved from the support sheet side to the elastic roller R with the transfer layer facing the transfer object B side.
Press to apply the transfer pressure, and after the transfer layer adheres to the transfer receiving body,
The support sheet is peeled off. As the elastic roller R to be used, usually, an elastic member R2 is formed around a rigid shaft center R1 such as iron.
Is used. As the elastic body R2, silicone rubber, fluorine rubber, viton rubber, butadiene rubber, natural rubber, or the like is used. The rubber hardness of the elastic roller is
In order for the transfer sheet to follow the concave and convex portions on the surface of the transfer object, the rubber hardness is preferably set to 65 ° or less. The diameter of the roller is usually about 5 to 20 cm. In addition, the elastic roller is usually heated by a heating source such as an internal electric heater or an external infrared radiation heater and used as a heating roller.

[Transfer Method Using Solid Particle Impact Pressure] In this transfer method, a transfer pressure pressing means using the solid particle impact pressure as the transfer pressure is large, which is impossible with a conventional transfer method such as a roller transfer method. It becomes possible to transfer to uneven surfaces. Therefore, as in the transfer sheet for molding of the present invention, problems to be solved such as compatibility between moldability and releasability come out. In particular, this transfer method is one of the transfer methods that can make use of the above-mentioned characteristics of the transfer sheet for molding of the present invention, which can be transferred to an uneven surface by its moldability.

The solid particles P include non-metallic inorganic particles such as ceramic beads and glass beads, metal particles such as zinc and iron, organic particles such as resin beads such as nylon beads and crosslinked rubber beads, and inorganic particles such as metals. Inorganic / resin composite particles composed of particles and resin are used. The particle shape is preferably spherical, but other shapes can also be used. For example, metal zinc spheres are suitable solid particles in that the substrate is less likely to break due to impact on the substrate. The particle size is usually 10
About 1000 μm.

The solid particles are ejected from the ejector toward the transfer sheet for molding, and the collision pressure that collides with the transfer sheet for molding becomes the transfer pressure. Typically, an impeller or a blowing nozzle is used for the ejector. The impeller accelerates the solid particles by its rotation, and the blowing nozzle accelerates the solid particles with a high-speed fluid flow. Sandblasting, shot blasting, shot peening and the like used in the blasting field can be used for the impeller and the blowing nozzle. For example, a centrifugal blast device is used for the impeller, and a pressurized or suction blast device, a wet blast device, or the like is used for the blowing nozzle. The centrifugal blast device accelerates and ejects solid particles by the rotational force of the impeller. A pressurized blasting device ejects solid particles together with air while being mixed with compressed air. The suction-type blast device sucks solid particles into a negative pressure portion generated by a high-speed flow of compressed air, and ejects the solid particles together with the air. The wet blast device mixes and ejects solid particles with a liquid. Among these, the impeller is one of the efficient and preferable ejectors in that the ejection amount of solid particles is large.

FIG. 4 and FIG. 5 are conceptual diagrams showing an example of an ejector using an impeller. The impeller 812 includes a plurality of impellers 8.
13 is fixed on both sides by two side plates 814, and the center of rotation is a hollow portion 815 without the blade 813. Further, a direction controller 816 is provided inside the hollow portion 815 (see FIG. 5). The direction controller 816 has an opening 817 that is partially open in the circumferential direction, has a hollow cylindrical shape, and has the same rotation axis as the rotation axis of the impeller 812, and rotates independently of the impeller. It is free. When using the impeller, the opening of the direction controller is fixed so as to face an appropriate direction, and the ejection direction of the solid particles is adjusted. Further, inside the directional controller, another impeller, which is hollow inside and has the same rotation axis as the rotation axis of the impeller 812, is provided as a sprayer 818 (see FIG. 5). The spreader 818 rotates with the outer impeller 812. A rotation shaft 819 is fixed to the center of rotation of the side plate 814, and the rotation shaft 819 has a bearing 820.
A rotary power source such as an electric motor that is rotatably supported by a motor (not shown)
, And the impeller 812 rotates. The rotating shaft 819 does not penetrate between the two side plates 814 having the blades 813 therebetween, and forms a space without a shaft. Then, the solid particles P are supplied into the sprayer 818 from a hopper or the like through a transport pipe. Usually, the solid particles are supplied from above (directly above or obliquely above) the impeller. The solid particles supplied into the sprayer are scattered outward by the impeller of the sprayer. The scattered solid particles are emitted only in the direction allowed by the opening 817 of the direction controller 816 and supplied between the blades 813 of the outer impeller 812. Then, it collides with the blade 813 and the impeller 812
It is accelerated by the rotational force of the gas and squirts from the impeller.

The size of the impeller 812 is usually 5 to 60 in diameter.
cm, the width of the blade is about 5 to 20 cm, the length of the blade is almost the diameter of the impeller, and the rotation speed of the impeller is 500 to
It is about 5000 [rpm]. The ejection speed of the solid particles is about 10 to 50 [m / s], and the projection density (total weight of the solid particles to be collided per unit area of the base material) is 10 to 150.
[Kg / m ² ].

Next, FIG. 6 is a conceptual diagram showing an example of an ejector using an ejection nozzle. An ejector 840 shown in the figure is an example of an ejector in which a gas such as air is used as a solid particle accelerating fluid, and the gas and the solid particles are mixed and ejected when ejecting the solid particles. The ejector 840 includes an induction chamber 841 that mixes the solid particles P and the fluid F, an internal nozzle 842 that ejects the fluid into the induction chamber, and an ejection nozzle unit 844 that ejects the solid particles and the fluid from the nozzle opening 843. A fluid F in a pressurized state from a compressor or the like is ejected from an internal nozzle 842, passes through an induction chamber 841 and passes through a nozzle opening 84 of a nozzle 844.
3, a negative pressure is created by the action of a fluid flow flowing at a high speed in the guide chamber 841 in the ejector, and the negative pressure guides and mixes the solid particles into the fluid flow, thereby forming the solid particles in the fluid flow. It accelerates, conveys, and jets out together with the fluid flow from the nozzle opening 843 of the nozzle 844. In addition, there is a blowing nozzle or the like that uses a liquid as a solid particle acceleration fluid. The fluid pressure is usually about 0.1 to 10 kg / cm ^{2 in} spray pressure. The flow velocity of the fluid flow is usually about 1 to 20 m / sec for the liquid flow, and is usually about 5 to 80 m / sec for the air flow.

In the case where the pressure area cannot be formed into a desired shape and size by using only one jetting device, a plurality of jetting devices are used. Further, when actually transferring using solid particles, it is preferable that the solid particles are not scattered in the surrounding atmosphere and circulated and reused. May be caused to collide with the transfer sheet for molding. The peeling of the support sheet may be performed outside the chamber.

Preferably, the transfer sheet for molding is preliminarily heated and softened with an infrared radiation heater or the like to impart stretchability. When the transfer object has a large heat capacity, it is preheated in advance, and a heat-sealing adhesive is used. The layer acting as a layer (depending on the case, a picture layer, an adhesive layer, etc.) is made to collide solid particles with the transfer sheet for molding in a state of being heat-activated. When transferring by thermal fusion, the timing of heating to activate and thermally fuse a layer to be thermally fused, such as an adhesive layer, is before applying the collision pressure, during the application of the collision pressure, or before applying the collision pressure. And during application. On the other hand, if the transfer sheet for molding follows the surface shape of the transferred object and is formed, and the transfer layer is sufficiently in contact with the transferred object, cooling of the heat-sealed layer by cooling means such as cold air is promoted. Is also good. The cool air is blown from, for example, the molding transfer sheet side or the transfer receiving body side.

[Transfer object] The transfer object B is not particularly limited. However, in order to form and transfer the sheet by making use of the moldability of the transfer sheet for molding, the transfer surface must be formed. The surface becomes uneven. For example, the material of the transfer object is an inorganic nonmetal-based, metal-based, wood-based, plastic-based, or the like.
Specifically, in the case of inorganic nonmetals, for example, papermaking cement, extruded cement, slag cement, ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), pulp cement, wood chip cement, asbestos cement,
Non-ceramic ceramic materials such as calcium silicate, gypsum and gypsum slag; and inorganic materials such as ceramics such as earthenware, pottery, porcelain, tableware, glass, and enamel. Further, in the metal system, for example, there are metal materials such as iron, aluminum, and copper. In the wood system, for example, cedar, cypress, oak, lauan,
There are veneers made of teak, etc., plywood, particle board, fiber board, laminated wood and the like. In the case of plastics, for example, there are resin materials such as polypropylene, ABS resin, and phenol resin.

The shape of the object to be transferred may be any shape, such as a flat plate, a bent plate, a column, a three-dimensional object such as a molded product, etc., as long as it can be transferred to the surface to be transferred. For example, the object to be transferred may be a flat plate material (envelope surface shape) as a whole, or a material having two-dimensional unevenness whose cross section is convex or concave in an arc shape and curved in one direction.

The concavo-convex shape of the surface to be transferred of the object to be transferred may be any shape as long as it can be transferred by the molding transfer sheet to be used and the transfer method to be used. The uneven shape is, for example, a joint when a plurality of tiles and bricks are arranged on a plane,
Cleavage surface of granite, unevenness of stone surface such as grain, uneven surface of wood panel such as wood paneling, floating grain, surface unevenness of siding siding, shining, stucco, etc. is there.

On the surface of the object to be transferred, if necessary, an easy-adhesion primer for assisting adhesion to an adhesive, or an alkaline component when the object to be transferred is an alkaline substrate, as a base treatment. A sealant agent for preventing oozing of the surface, or a sealing agent for sealing and sealing fine irregularities and porosity on the surface may be formed by a coating method. In addition, the undercoating (base coat) for adjusting the base (transfer) color is used for the base treatment.
And so on. A resin such as an isocyanate, a two-part curable urethane resin, an epoxy resin, an acrylic resin, or a vinyl acetate resin is applied and formed as an easy-adhesion primer, a sealer, a sealant, or an undercoat. These may be used in a single layer or a multilayer depending on the purpose.

[Uses of Transfer Products] The transfer products such as decorative materials obtained by the transfer sheet for molding of the present invention or the transfer method of the present invention can be used for transferring decorative surfaces having irregularities, particularly three-dimensional shapes. Such an article having an uneven surface is suitable and can be used for various applications. For example, as a cosmetic material,
Exterior such as siding, exterior walls such as fences, roofs, gates, gable boards, interiors of buildings such as walls, ceilings, floors, window frames, doors, handrails, thresholds, surface decorations for fittings such as sluices, chests, etc. It can be used in various fields such as surface decoration of cabinets for light electric and OA equipment such as furniture and television receivers, and interior materials for vehicles such as automobiles, trains, aircraft, and ships. The decorative material is used as a decorative board or the like. In addition, the shape of the transfer product including the cosmetic material is arbitrary such as a flat plate, a curved plate, a rod-shaped body, and a three-dimensional object.

[Post-processing] The surface of a transferred product such as a cosmetic material after the transfer is further coated with a conventionally known overcoat such as a transparent protective layer, if necessary, in order to impart durability, design feeling, and the like. The layer may be formed by a coating method or the like.

[0054]

Next, the present invention will be further described with reference to Examples and Comparative Examples.

Example 1 As shown in FIG. 1A, a transfer sheet S for molding was prepared as follows using a support sheet having a three-layered ethylene-propylene random copolymer layer. First, as the support sheet 10, the ethylene content of the ethylene-propylene random copolymer used for each layer was determined. The center layer 11 had an ethylene content of 5% by weight, the outer layer 12 had an ethylene content of 3% by weight, and the back outer layer had an ethylene content of 3% by weight. 13 also has an ethylene content of 3% by weight.
Layered simultaneously with film formation by layer co-extrusion method, thickness 64μ
m, center layer 11, 8 μm thick outer layer 12, 8 μm thick
Of the back outer layer 13 having a total thickness of 80 μm.

The outer layer 1 of the support sheet 10
On the surface of No. 2 (the conaro discharge treatment was not performed on this surface in order to impart the releasability of the transfer layer), a transfer layer 20 composed of a release layer and a picture layer was formed in this order to form a transfer sheet for molding. Produced. As the release layer, a transparent coating solution composed of a thermoplastic acrylic urethane resin was gravure-coated to form a coating film (application amount 1 g / m ^{2 based} on solid content). Also, as the pattern layer, the binder resin is a thermoplastic acrylic urethane resin, and the coloring agent is a red iron oxide pattern, titanium white, carbon black,
A gravure tricolor printing of a coloring ink using quinacridone, isoindolinone and phthalocyanine blue was used to form a wood-grain pattern layer (coating amount based on solid content: 2 g / m ² ).

Example 2 As shown in FIG. 1B, a transfer sheet S for molding was prepared as follows using a support sheet having a two-layered ethylene-propylene random copolymer layer. First, as the support sheet 10A, the ethylene content of the ethylene-propylene random copolymer used for each layer was set to 3% by weight for the surface layer 14 and 5% by weight for the back layer 15 and the ethylene content was adjusted to 2%. Layer T
Lamination was performed simultaneously with film formation by a two-layer coextrusion method using a die to prepare a laminate having a total thickness of 80 μm including a surface layer 14 having a thickness of 72 μm and a back layer 15 having a thickness of 8 μm.

Using the above-mentioned support sheet, a transfer layer 20 composed of a release layer and a picture layer was formed on the surface of the surface layer 14 in the same manner as in Example 1 to prepare a transfer sheet for molding.

Comparative Example 1 As a support sheet, a single-layer 80 μm-thick sheet made of an ethylene-propylene random copolymer having an ethylene content of 3% by weight was prepared. To form a transfer sheet for molding.

Comparative Example 2 As a support sheet, a single-layer 80 μm-thick sheet made of an ethylene-propylene random copolymer having an ethylene content of 5% by weight was prepared. To form a transfer sheet for molding.

COMPARATIVE EXAMPLE 3 In Example 1, the resin constituting the central layer, the outer layer and the outer layer of the support sheet was composed of a resin, and the central layer was an ethylene-propylene random copolymer having an ethylene content of 5% by weight. In the same manner as in Example 1 except that both the outer layer and the outer layer were changed to homo-isotactic polypropylene, a central layer having a thickness of 64 μm,
A laminate having a total thickness of 80 μm, comprising a front outer layer having a thickness of 8 μm and a rear outer layer having a thickness of 8 μm, was used as a support sheet. Otherwise, a transfer layer was formed in the same manner as in Example 1 to prepare a transfer sheet for molding.

[Evaluation of Formability by Vacuum Forming Transfer Method] An MDF (medium density fiberboard) having a cross-sectional shape as shown in FIG. 7 was prepared as an object to be transferred. The performance of the transfer sheet was evaluated. The shape of the transfer target B is a rectangular parallelepiped plate material having a thickness of 20 mm, a length of 250 mm, and a width of 150 mm.
Side). The upper surface and the side surface and the adjacent side surface and the ridge line (edge) of the side surface are chamfered so that the cross section is a circle having a radius of curvature of 3 mm. Then, in the vacuum forming transfer, the aqueous urethane-based adhesive is spray-applied to the transfer-receiving surface of the transfer-receiving body (wet coating amount: 100 g / m ² ), and then heated at 60 ° C. for 2 minutes. Transcribed. Further, after the support sheet was peeled off and transferred, the surface of the transferred transfer layer was post-coated with a two-component curable urethane resin paint to prepare a decorative material D as shown in the sectional view of FIG. Incidentally, the decorative material D has a configuration in which the transfer layer 20 is laminated on the transfer object B via the adhesive layer 41, and the overcoat layer 42 is further laminated thereon.

When the moldability of the transfer sheet for molding was evaluated, the results were as shown in Table 2. The evaluation criteria for the moldability are as follows: the transfer sheet for molding follows the entire side surface of the transfer object with a thickness of 20 mm is “especially good”, and the transfer sheet for molding follows the entire side surface with a thickness of 20 mm, but is partially dot-shaped. In the case where the transfer omission occurred, "good" was given.

[0064]

[Table 2]

As shown in Table 2, the moldability of each of Examples 1, 2 and Comparative Example 2 was particularly good.
It stopped somewhat well, and Comparative Example 3 was poor.

[Evaluation of Releasability Performance] The releasability of each transfer sheet for molding is basically shown in Table 3 without depending on the transfer method. That is, in Examples 1 and 2, and Comparative Examples 1 and 3, the peel strength was an appropriate value, and after leaving to stand at 40 ° C. for 2 weeks, there was no significant difference from immediately after production, and no remarkable time-dependent change was observed. It is good. However, in Comparative Example 2, 40 ° C.2
After leaving for a week, the peel strength greatly increases (approximately three times), the transferability is greatly reduced, and a part of the transfer layer is peeled off together with the support sheet when the support sheet is peeled, resulting in transfer omission and failure. It became.

[0067]

[Table 3]

The evaluation of the peel strength, including the stability over time, as the peelability was performed by leaving each transfer sheet for molding in a constant-temperature bath at 40 ° C. for 2 weeks and then conceptually referring to the explanatory view of FIG. The peeling test of the peeling at the peeling angle θ = 90 degrees as shown in FIG.
The transfer sheet S for molding is formed on the support sheet 10 (or 1
0A) 3 m thick with double-sided adhesive tape (not shown)
m on a support 31 made of iron plate, and a width 2
A 5 mm cellophane adhesive tape 32 [Nichiban Co., Ltd., "Cellotape" (registered trademark)] was attached, and the slightly peeled end was pulled vertically to the surface of the support base 31 with a tensile tester to measure the peel strength. Was evaluated.

[Evaluation of Formability by Transfer Method Using Impact Pressure of Solid Particles] Formability was evaluated by transferring to a transfer target as described below. That is, the transferred object B as shown in the perspective view of FIG.
A cement base material having a thickness of 15 mm, the surface to be transferred has a concave-convex shape having a linear groove-shaped concave portion, and the frontage Lw of the groove-shaped concave portion and the depth Ld thereof are different from each other as shown in Table 1. (No. 1 to No. 6) were transferred to the substrate and evaluated. In addition, the inclination angles of the slopes were all set to 45 degrees.

In the transfer, the above-mentioned object to be transferred is previously coated with a base coat layer of an acrylic emulsion type enamel paint,
On top of that, an acrylic polyol (glass transition temperature-
(20 ° C.) An adhesive layer of a two-part curable urethane resin consisting of 100 parts by weight and 5 parts by weight of 1,6-hexamethylene diisocyanate was spray-coated. Then, the base coat layer and the adhesive layer of the transfer object are heated and dried (the two-component curable urethane resin of the adhesive layer is not completely cured), and the transfer sheet for molding is placed on the transfer object. The transfer layer side is placed so as to face the transfer object side, and in a state where the transfer object surface temperature is heated to 100 ° C., solid particles collide against the back surface side of the support sheet to give the collision pressure as the transfer pressure. An attempt was made to press the transfer sheet for molding against the transfer-receiving member and to follow the uneven surface. Note that, as the solid particles, spherical zinc spheres having an average particle diameter of 0.4 mm preheated to 50 ° C. were used, and as the ejector, an ejector using an impeller as shown in FIGS. 4 and 5 was used. The ejection speed of the solid particles was 35 m / s. Then, after the collision of the solid particles, the solid particles are cooled with cold air at 25 ° C.
After the transfer sheet for molding is adhered to the transfer object by heat fusion, the support sheet is peeled off at a peeling angle (however, an angle measured from the top surface portion 51 of the transfer object) θ = 80 °, and only the transfer layer is formed. Was transferred to the transfer object side to complete the transfer.

As a result, the moldability was evaluated as shown in Table 4. In Table 4, “○” indicates that the transfer layer was transferred to the inside of the groove or the like and was good, “△” indicates that the transfer float occurred at the groove angle, but was slightly good, and “×” indicates the bottom of the groove. This indicates that transfer floating has occurred and is defective.

[0072]

[Table 4]

[Evaluation of Formability by Transfer Method Using Elastic Roller] The transfer object used for the evaluation was the same as that used in the evaluation by the transfer method based on the solid particle collision pressure described above. The evaluation was limited to 6 transfer media. The base treatment of the transfer object is the same as in the case of the transfer method using solid particle collision pressure. For the elastic roller, the periphery of the iron core is covered with silicone rubber, and the hardness of the surface is set to a rubber hardness of 3 defined by JIS.
A pressure roller with a diameter of 10 cm and a surface temperature of 100
What was heated to ° C was used. The transfer direction was made to coincide with the running direction of the groove of the transfer object. As a result, the moldability is
Comparative Example 1 was slightly better, but other Examples 1 and 2 and Comparative Examples 1 and 3 were all good. The moldability evaluation criteria are the same as in the case of the above-described transfer method using solid particle collision pressure.

[Evaluation Summary] From the above results, it can be seen that only the transfer sheets for molding of Examples 1 and 2 are compatible with both moldability and releasability.

[0075]

According to the transfer sheet for molding of the present invention, both moldability and peelability are compatible. In addition, when the support sheet has a three-layer structure, it has excellent blocking resistance, and is manufactured, stored,
Curling can be prevented during use. In the transfer method of the present invention, when the transfer pressure by the solid particle collision pressure is used, the transfer is reliably and easily performed without transfer defects such as transfer omission even on a deep uneven surface that is impossible with the transfer method using the elastic roller. it can. As a result, it is possible to easily manufacture a transfer product such as a high-design decorative material. In the transfer method of the present invention, when the transfer pressure by the elastic roller is used, the transfer can be easily performed on a relatively flat uneven surface.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a transfer sheet for molding of the present invention.

FIG. 2 is a conceptual diagram illustrating a transfer method for transferring a solid particle collision pressure by a transfer pressure.

FIG. 3 is a conceptual diagram illustrating a transfer method for performing transfer with a transfer pressure by an elastic roller.

FIG. 4 is a perspective view conceptually illustrating an example of an ejector using an impeller for ejecting solid particles.

FIG. 5 is a conceptual diagram illustrating the inside of the impeller of FIG. 4;

FIG. 6 is a cross-sectional view conceptually illustrating an example of an ejector using an ejection nozzle.

FIG. 7 is a cross-sectional view showing a concave-convex shape of a transferred body used for evaluation of formability by a vacuum forming transfer method.

FIG. 8 is a perspective view showing a concave-convex shape of a transfer-receiving body used for evaluation of formability in a transfer method using solid particle collision pressure.

FIG. 9 is an explanatory view conceptually illustrating a method of measuring peel strength.

FIG. 10 is a sectional view showing a decorative material obtained by a vacuum forming transfer method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Support sheet 11 Central layer 12 Outer layer 13 Outer layer 14 Outer layer 15 Back layer 20 Transfer layer 31 Support base 32 Cellophane adhesive tape 41 Adhesive layer 42 Overcoat layer 51 Top surface part of transferred object 812 Impeller 813 Blade 814 Side plate 815 Hollow part 816 Direction controller 817 Opening part 818 Sprayer 819 Rotating shaft 820 Bearing 840 Ejector using blowing nozzle 841 Induction chamber 842 Internal nozzle 843 Nozzle opening part 844 Nozzle B Transfer object D Transfer product (facing board etc.) F fluid Lw frontage Ld depth P solid particles S transfer sheet for molding

 ──────────────────────────────────────────────────続 き Continued on the front page F-term (reference) 3B005 EA06 EB01 EB05 FE03 FE04 FE17 FG01X GA17 GA18 4F100 AK25J AK51J AK64A AK64C AK64D AL01 AR00B AT00A BA02 BA04 BA05 BA07 BA10A BA10B BA13 CA13 EC04B GB07 GB01 GB04

Claims (4)

[Claims] 1. A transfer sheet for molding having a transfer layer on a support sheet, wherein the support sheet comprises three ethylene-propylene random copolymer layers of a central layer, an outer layer and an outer layer, and The ethylene content of the ethylene-propylene random copolymer in each layer is larger in the center layer than in the outer and outer layers.
Transfer sheet for molding. 2. A transfer sheet for molding having a transfer layer on a support sheet, wherein the support sheet has two layers: a surface layer on a side facing the transfer layer and a back layer on a side not facing the transfer layer. A transfer sheet for molding, comprising an ethylene-propylene random copolymer layer, wherein the ethylene content of the ethylene-propylene random copolymer in both layers is smaller in the surface layer than in the back layer. 3. A transfer method using the transfer sheet for molding according to claim 1 or 2, wherein the transfer is performed at a transfer pressure due to a solid particle collision pressure. 4. A transfer method using the transfer sheet for molding according to claim 1 or 2, wherein transfer is performed by transfer pressure using an elastic roller.