JP2001080295A - Transfer sheet and production of decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transfer sheet which has good foil-cutting properties and no foil burr even in transfer to an uneven surface and can prevent powdery transfer and transfer failure, and a method for producing a decorative material. SOLUTION: A transfer sheet S has a transfer layer 4 formed by laminating a peeling layer 2 and a decorative layer 3 on a support sheet 1, and the releasing layer 2 is made a net-shaped crossing fine line pattern. A method for producing a decorative material uses the transfer sheet S, and the transfer layer 4 is transferred to a base material to be transferred by using a solid particle collision pressure from the support sheet 1 side as a transfer pressure for production.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transfer sheet for obtaining a transfer product such as a decorative material used for various purposes such as exterior and interior materials of a house. In particular, the present invention relates to a transfer sheet suitable for an irregular transfer surface and a method of manufacturing a decorative material using the transfer sheet.

[0002]

2. Description of the Related Art Conventionally, various decorative materials have been manufactured by a transfer method. In that case, as the transfer layer of the transfer sheet, to make the peeling force with the support sheet appropriate, or to protect the surface as the outermost surface layer after transfer, etc.
Usually, a release layer is often provided on the support sheet side. And, of course, such a conventional release layer is formed on the entire surface (as a continuous film covering the entire surface).
In addition, if the surface protection function is unnecessary and the release force between the transfer layer and the support sheet can be made appropriate without the release layer,
As the transfer layer, a transfer sheet having a configuration in which a decorative layer is directly formed on a support sheet by printing without a release layer is also used.

On the other hand, Japanese Patent No. 2844424 proposes a method using a solid particle collision pressure as a transfer pressure as a transfer method suitable for a case where the transfer surface of a transfer substrate is an uneven surface. When the transfer sheet is used in such a transfer method, the transfer sheet is required to have unevenness followability that follows the uneven surface.
Therefore, for the support sheet and the transfer layer, a thermoplastic resin is generally used as a material having a concave-convex shape that extends and is formed during transfer.

[0004]

However, in the case of transfer to an uneven surface, in the case of a transfer layer formed on the entire surface, all of the layers are continuously connected as a single layer. As conceptually shown, in the case of the transfer substrate B having the transfer area 6 and the non-transfer area 7, when the support sheet 1 of the transfer sheet S is peeled off, the non-transfer is performed from the boundary between the transfer area and the non-transfer area. The surplus transfer layer extends toward the area,
A so-called “foil burr” 8 may occur, and a phenomenon that “foil breakability” deteriorates may occur. Further, in particular, as a unique problem in the case of the transfer method using solid particle collision pressure, since the release layer is connected over the entire surface, the transfer region portion is transferred to the transfer substrate at the time of transfer as shown in FIG. The air trapped between the sheets cannot be completely removed, but becomes air bubbles G between the substrate B to be transferred and the transfer layer 4, and "transfer floating" occurs in which the transfer layer floats from the substrate to be transferred at the bubble portion. There is also. In the drawing, the transfer is performed after the adhesive layer A is applied on the transfer-receiving base material B.

On the other hand, in the case of a transfer sheet having no release layer, the generation of foil burrs and the transfer floating are improved, but new problems arise. That is, usually, a picture layer formed by printing as a decorative layer of the transfer layer has shading. Therefore,
Depending on the pattern represented by the pattern layer, the low and high adhesion portions of the ink are partially present. For this reason, in particular, when the transfer is performed by the transfer method using the solid particle collision pressure in the transfer pressure pressing means, the transfer can be performed on the uneven surface, but when the transfer layer is fragile, the transfer layer is transferred in a fragmented manner by the collision impact. Transfer failure occurred.
This is because a pattern layer (a pattern pattern layer or a solid layer) formed by printing has a high rigidity and a brittleness due to a large content of a pigment such as a colorant. On the other hand, the release layer is only added with a pigment such as barium sulfate for the printing stability of the pattern layer formed thereon, and the rigidity of the release layer is not so different from that of the resin itself. Instead, it has the flexibility to follow irregularities. Therefore, when there is a release layer, the decorative layer such as the picture layer can follow the unevenness along the release layer. However, without a release layer,
The decorative layer such as the picture layer cannot be followed by the irregularities and is crushed to form a powdery transfer.

Accordingly, an object of the present invention is to ensure sufficient peelability between the support sheet and the transfer layer, and particularly, to obtain a good transfer of the foil to the transfer surface having irregularities, and to remove the transfer by the residual air. The purpose of the present invention is to provide a transfer sheet that can prevent the occurrence of the transfer. Also,
In particular, it is an object of the present invention to provide a method for producing a decorative material in which a decorative surface having irregularities is suitable, and in which transfer defects such as defective foil cutting, defective transfer, and powder transfer do not occur.

[0007]

Means for Solving the Problems In order to solve the above problems,
In the transfer sheet of the present invention, in a transfer sheet having a transfer layer formed by laminating a release layer and a decorative layer on a support sheet in this order, the release layer is formed of a net-like intersecting thin line pattern. In this manner, the release layer is not formed as a continuous layer extending over the entire surface, but as a layer having a net-like intersecting thin line pattern, while ensuring sufficient releasability between the transfer layer and the support sheet, and a foil. The cutting performance is improved, and transfer omission can be prevented. This foil-cutting property is particularly effective in the case of transfer in which the transfer-receiving substrate surface has an uneven surface and a transfer region and a non-transfer region, and transfer prevention is achieved by solid particles on the uneven surface where air tends to remain. This is particularly effective in the case of transfer using collision pressure.

In the method of manufacturing a decorative material according to the present invention, the transfer layer is transferred to a substrate to be transferred by using the transfer sheet and utilizing the solid particle collision pressure from the support sheet side as the transfer pressure. did. As a result, even when the surface to be transferred is an uneven surface, it is possible to manufacture a decorative material without causing transfer defects such as defective foil cutting, defective transfer, and powdery transfer.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a transfer sheet and a method of manufacturing a decorative material according to the present invention will be described with reference to the drawings.

Transfer sheet : First, the transfer sheet will be described.

[Release Layer] FIG. 1 is an explanatory view showing a transfer sheet S of the present invention in one form, and FIG.
FIG. 1B is a plan view of the release layer 2 of the transfer layer 4. As shown in the cross-sectional view of FIG. 1A, the transfer sheet S of the present invention has a transfer sheet 4 having at least a release layer 2 and a decorative layer 3 laminated in this order on a support sheet 1. In this case, as illustrated in the plan view of FIG. 1B, the release layer 2 is formed of a net-like intersecting thin line pattern. In FIG. 1B, a hatched area is a formation area where a release layer is formed, and a white part is an unformed area where no release layer is formed. In the case of FIG. 1B, the thin line pattern is such that a plurality of straight lines parallel to each other at equal intervals are vertically and horizontally perpendicular to each other, and the shape of the area where the release layer is not formed is a fine line pattern over the entire periphery. This is the case of an enclosed square pattern (rectangular lattice pattern).

If the release layer 2 is not formed on the entire surface, the pattern of the release layer formed in a plan view is basically not particularly limited. For example, in FIG. 1B, the relationship of the negative-positive reversal, that is, the square portion of the region drawn in white without hatching is the formation region of the peeling layer, and the dotted pattern or stripe (parallel Line group) pattern, peeling property, foil cutting property,
In addition, good results can be obtained in terms of preventing transfer omission. But,
For the release layer, it is more preferable to adopt a fine line pattern in which fine lines intersect, instead of such a scattered dot or stripe pattern. By adopting a fine line pattern in which fine lines intersect with each other in a plan view shape of the release layer, the foil cutting property is improved and transfer omission can be prevented. This is because, in the fine line pattern, as compared with the dot pattern, the decorative layer in contact with the release layer in that part tends to be formed by the continuous release layer in the fine line, and is formed. Further, in the case of a dot pattern, it is difficult to obtain the effect of connecting the decorative layer two-dimensionally, which is similar to the case where there is no release layer, and the transfer layer cannot be prevented from being shattered and transferred by the impact impact of solid particles. .

There is no particular limitation on the net-like intersecting fine line pattern that the release layer exhibits in plan view. For example, some of the net-like intersecting fine line patterns are illustrated in the plan view of FIG. FIG. 2A is an oblique lattice pattern in which vertical and horizontal straight lines are not in a 90 ° orthogonal relationship, FIG. 2B is a hexagonal hexagonal lattice pattern in which an area where a release layer is not formed, and FIG.
(C) is a triangular lattice pattern in which the unformed region is also triangular. 1 (B) and FIGS. 2 (A) to 2
In the example of (C), the line portions forming the formation region of the peeling layer had a continuous (connected) pattern over the entire surface. However, for example, as shown in FIG. May be used. In the case of FIG. 2 (D), all are discontinuous patterns each having a finite length and independent line segments, and the discontinuous portion is [FIG.
In the case of (B), it is the case of the intersection 5 of the lines. The term "intersect" as used in the present invention also includes the case where the thin lines at the intersection are discontinuous.

2 (A) to 2 (C) or FIG.
The fine line pattern of (D) is a grid-like fine line pattern in which all the regions where the release layer is not formed have the same shape and size and are regularly scattered at equal intervals. A fine line pattern having an irregular shape and size may be used. The thin line may be a curve, a combination of a curve and a straight line, or the like. Further, the thickness of the thin line does not have to be uniform.

The size of the fine line pattern may be appropriately determined depending on the size of the irregularities on the surface to be transferred, the size of the pattern of the decorative layer, the method of applying the transfer pressure, and the like. For example, FIG.
In FIGS. 2 (A) to 2 (D), when the solid particle collision pressure is used as the transfer pressure, the particle size distribution of the solid particles used is usually 0. .4-0.
Since the diameter is about 6 mm, the minimum diameter is preferably about 0.1 mm and the maximum diameter is about 2 mm. If the shape such as the diameter of the unformed region is too large, it becomes difficult to express the original function as the release layer, the release force is increased and the release property is reduced, and the transfer layer is caused by collision impact of solid particles. It tends to shatter and cause poor transfer. The line width of the thin line is, for example, 10
The thickness is preferably about 0 to 200 μm.

As described above, without making the release layer a continuous layer,
If the release layer is connected in a sense (locally at a certain length) as a thin line pattern that intersects in a net-like manner, air will escape from the discontinuous area where the release layer is not formed. The transfer floating, which is a minute gap due to the above, is eliminated. In addition, when a pattern layer composed of a pattern pattern layer and all solid layers is formed by printing as a decorative layer on the release layer,
Although the entire solid layer is a continuous layer, the air tends to escape easily due to the large content of a pigment such as a colorant. On the other hand, since the pattern pattern layer is a discontinuous layer or a layer in which the discontinuous layers overlap (in the case of multicolor printing), air is easily leaked. Therefore, air bubbles can be removed through the transfer layer and between the support sheet and the release layer.

In particular, with respect to the transfer floating, in a transfer method using a solid particle collision pressure capable of forming a larger uneven surface than ever before as a transfer pressure pressing means, there is a specific situation that is advantageous for air bleeding. . This will be described with reference to the conceptual diagram of FIG.
That is, in this transfer method, since the repetitive pressurization in which a large number of solid particles P repeatedly collide with the transfer sheet S, as shown in FIG. After contacting the substrate B to be transferred (FIG. 4 shows a case where the adhesive layer A is provided in advance on the substrate B to be transferred. Of course, the adhesive layer A may be omitted). As shown in FIG. 4B, the support sheet 1 and the transfer layer 4 are separated from each other by the impact of the second collision of the solid particles P to form a gap 9 therebetween, and the transfer layer is formed there. This is because bubbles that have penetrated through 4 may come off.

On the other hand, with respect to foil burrs, if the release layer is formed as a fine line pattern that intersects in a mesh pattern, the release layer is not a continuous layer. The transfer layer is easily cut by the shearing force caused by the transfer pressure, and the foil cutting property is improved.

The thickness of the release layer is preferably thinner in terms of moldability, and is usually about 1 to 5 μm.
In addition, this release layer moves to the transfer-receiving substrate side as a part of the transfer layer at the time of transfer. The migration may be the entire thickness of the release layer, but due to the cohesive failure of the release layer, a part of the thickness of the release layer migrates to the substrate to be transferred, and a part of the thickness becomes integral with the support sheet. It may peel off.

[Support Sheet] The support sheet 1 has releasability from a transfer layer such as a release layer. If the transfer surface (decorative surface) of the substrate to be transferred is uneven, the support sheet 1 may have unevenness. As long as it has a follow-up property, it may be a conventionally known one, and there is no particular limitation. Therefore, when the transfer surface is a flat surface or a two-dimensional uneven surface, paper or the like without stretchability may be used, but in the case of a three-dimensional uneven surface, a support sheet having stretchability is used at least at the time of transfer. . As the stretchable support sheet, for example, polyethylene terephthalate film, thermoplastic polyester film such as polybutylene terephthalate film, polypropylene film, polyethylene film, polymethylpentene film, ethylene-propylene copolymer film, ethylene-propylene -Use a resin film (sheet) such as a polyolefin-based film such as a butene terpolymer film or an olefin-based thermoplastic elastomer film, a vinyl chloride resin film, or a polyamide resin film. In addition, these resin films are preferably low stretched or unstretched in view of stretchability. Further, the support sheet may have a single-layer structure or a multilayer structure composed of different materials. For example, when the surface to be transferred is flat, a support sheet having a structure in which high quality paper is laminated with polypropylene is one of the preferable support sheets in terms of excellent transferability and low cost. The thickness of the support sheet is usually about 20 to 200 μm.

The support sheet may be provided with a release layer as a component of the support sheet on the transfer layer side, if necessary, in order to improve the releasability from the transfer layer. The release layer is removed from the transfer layer as a part of the support sheet when the support sheet is released. As the release layer, for example, a simple substance such as a silicone resin, a melamine resin, a polyamide resin, a urethane resin, a polyolefin resin, a wax, or a mixture containing these is used. For example, it is a support sheet in which polypropylene is laminated on the above-mentioned high quality paper as a release layer.

Further, in the transfer sheet of the present invention, since there is an area where the release layer is not formed, the decorative layer (transfer layer) thereon is partially in contact with the support sheet. Therefore, the releasability (peeling force) between the support sheet and the transfer layer may be optimized only by the release layer, but the support sheet is also preferably adjusted by the wetting index on the side of the transfer layer. If the wettability is low, the peeling force is small, and if the wettability is high, foil burr is less likely to occur. This makes it possible to appropriately adjust printability, foil burr resistance, transferability, and the like when a picture layer or the like is formed by printing on the release layer. For example, the wetting index is preferably 35 or less.

[Transfer Layer] The transfer layer 4 is formed of the release layer 2 described above.
And at least a decorative layer 3 described later. The transfer layer 4 may further include an adhesive layer or the like as appropriate. There are no particular restrictions on the decorative layer, adhesive layer, and the like, which are components of the transfer layer other than the release layer. A decorative layer, an adhesive layer and the like in a conventionally known transfer sheet may be used. Also, release layer, decorative layer,
The transfer layer such as an adhesive layer can be formed by any known forming method such as a conventionally known printing method, coating method, or hand drawing.

However, in the present invention, since the release layer is formed in a pattern to facilitate air bleeding, the transfer layer is formed on the entire surface of the transfer layer, for example, the entire solid layer of the picture layer, the adhesive layer, etc. Is generally not preferable from the viewpoint of achieving the effects of the present invention because it is generally difficult for air to penetrate the transfer layer. However, as described above, all solid layers with a high pigment content are not so,
Preferably, all the solid layers have a high pigment content. Also, it is preferable to provide the adhesive layer containing a large amount of resin on the side of the substrate to be transferred rather than providing the adhesive layer on the transfer layer because air does not hinder the penetration of the transfer layer (air release).

[Decoration Layer] The decoration layer 3 is formed by a conventionally known method such as gravure printing, silk screen printing, offset printing, gravure offset printing, and ink jet printing.
A pattern layer on which a pattern or the like is printed with a material, a metal thin film layer or the like formed partially or entirely of a metal such as aluminum, chromium, gold, and silver by using a known vapor deposition method, etc. . As the pattern, according to the surface unevenness of the base material, wood pattern, stone pattern, cloth pattern, tile pattern,
Use brick-like patterns, squeezed patterns, letters, geometric patterns, solid colors, etc. A layer having a pattern pattern may be referred to as a pattern pattern layer, and an all solid pattern may be referred to as an all solid layer.

The ink for a picture layer, like a general ink, comprises a vehicle such as a binder, a coloring agent such as a pigment or a dye, and various additives appropriately added thereto. The binder resin, acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester resin, cellulose resin,
A simple substance such as urethane resin or a mixture containing these is used. Above all, in terms of being able to balance unevenness followability and adhesion,
Urethane resin is one of the preferred resins. In addition, 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, aluminum foil powder, titanium dioxide-coated mica A brilliant pigment such as foil powder or other dyes is used.

Here, the urethane resin will be further described. As the urethane resin, basically, besides a thermoplastic urethane resin, a two-component curable resin such as a polyol and an isocyanate, and a thermosetting resin or the like can be used. However, the curable resin, in the case of the transfer to the surface to be transferred of the unevenness, the curing is already completed before the transfer sheet is pressed against the base material to be transferred, such as in a state where the thermoplasticity has been lost,
In particular, a solid pattern or the like on the entire surface is not preferable because the unevenness followability of the pattern layer is reduced. Therefore, when the urethane resin is used as the curable resin, even when the curing is progressing, at the time of pressing the transfer sheet against the transfer-receiving substrate, it is semi-cured or uncured to the extent that the desired unevenness followability can be secured. It is preferable to use it in a cured state and to completely cure it after pressing.

Accordingly, as the urethane resin, a thermoplastic urethane resin is preferable from the viewpoint of ease of use. As the thermoplastic urethane resin, a polyester urethane resin, a polyether urethane resin, an acrylic urethane resin, or the like is used alone or in combination. The thermoplastic urethane resin is a urethane resin having no crosslinked structure, and its skeleton structure is usually linear, but may be a branched structure. Further, a "saturated" thermoplastic urethane resin having no isocyanate group is preferable in that it is not cured by moisture or the like and has good stability over time.

When a polyester-based urethane resin is used, the releasability decreases over time, and when the overcoat layer is formed on the pattern layer after transfer by coating with an ionizing radiation-curable resin, etc. In order to prevent the ink from flowing out,
(1) a diamine compound is added to the polyester polyol component to partially urea the urethane skeleton; (2) a phenyl group is introduced into the polyester polyol component;
(3) Good results can be obtained by using a thermoplastic urethane resin produced by adding a diamine compound to a polyester polyol component having a polycarbonate-based alcohol component to convert a part of the urethane skeleton into urea. In particular, in the case of (3), the polyol component has a block copolymer of a urethane portion composed of a polycarbonate diol and isophorone diisocyanate and an acrylic portion having a hydroxyl group at a side chain and a terminal, and has an average molecular weight of not more than that of a transfer region. In order to improve the cutting of the transfer layer at the boundary with the area, a thermoplastic acrylic urethane resin (acrylic) using about 25,000 or less polyol and hydrogenated MDI (hydrogenated diphenylmethane diisocyanate) as an isocyanate component is used. (Which is also a urethane resin). Is preferred.

The thermoplastic urethane resin is obtained, for example, by reacting an active hydrogen compound having an active hydrogen-containing group such as a diisocyanate with a polymer diol and, if necessary, a low molecular diol.

Examples of the diisocyanate include aromatic diisocyanates [eg, 4,4'-diphenylmethane diisocyanate (MDI), 2,4-tolylene diisocyanate, 1,5-naphthalene diisocyanate,
n-isocyanate phenylsulfonyl isocyanate, m- or p-isocyanate phenylsulfonyl isocyanate, etc.), aliphatic diisocyanate (e.g., 1,6-hexamethylene diisocyanate, etc.),
Alicyclic diisocyanates (eg, isophorone diisocyanate, hydrogenated xylylene diisocyanate, hydrogenated diphenylmethane diisocyanate, etc.) may be used alone or in combination of two or more. From the viewpoint of providing good weather resistance, an aliphatic or alicyclic diisocyanate is preferred.

The above-mentioned high molecular diol (herein, the term “high polymer” refers to a low molecular diol and includes a molecular weight of less than 10,000)
, Polyester diols, polyether diols and the like may be used alone or in combination of two or more.

Examples of the polyester diol include a condensed polyester diol obtained by reacting a low molecular diol with a dicarboxylic acid, a polylactone diol obtained by ring-opening polymerization of lactone, and a polycarbonate diol.

The low molecular weight diol includes ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-butanediol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol, or , As low molecular weight diols having a cyclic group, bis (hydroxymethyl)
Cyclohexane, m or p-xylene glycol, bis (hydroxymethyl) benzene, 1,4-bis (2-
Hydroxyethoxy) benzene, 4,4-bis (2-hydroxyethoxy) -diphenylpropane (ethylene oxide adduct of bisphenol A) or the like may be used alone or as a mixture of two or more thereof.

Examples of the dicarboxylic acid include aliphatic dicarboxylic acids such as succinic acid, adipic acid, sebacic acid, glutaric acid, azelaic acid, maleic acid and fumaric acid, and aromatic dicarboxylic acids such as terephthalic acid and isophthalic acid. Used alone or in combination of two or more. In addition, ε-caprolactone or the like is used as the lactone.

Specific examples of the polyester polyol include polyethylene adipate, polybutylene adipate, polyhexamethylene adipate, polyneopentyl adipate, polyethylene butylene adipate, polybutylene hexabutylene adipate, polydiethylene adipate, and poly (polytetramethylene ether). ) Adipate, polyethylene acetate, polyethylene sebacate, polybutylene acetate, polybutylene sebacate,
Polyhexamethylene carbonate diol and the like can be mentioned, and these can be used alone or in combination of two or more.

As the acrylic urethane resin,
For example, a block copolymer of a urethane moiety composed of polycarbonate diol and isophorone diisocyanate and an acrylic moiety having a hydroxyl group at a side chain and at a terminal can be used. Such an acrylic and polyurethane block copolymer, that is, a polyurethane-acrylic block copolymer is, for example, polycarbonate diol and (di)
A polyurethane azo polymer obtained by further adding an azodiol to an isocyanate is used as a radical polymerization initiator, and methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, etc. A) acrylate means acrylate or methacrylate].

Since there is an unformed area in the release layer, a part of the picture layer is exposed as a part of the transfer layer surface after the transfer. For this reason, an extender pigment may be appropriately contained in the design layer, if necessary, for the surface properties of the transfer layer such as surface strength, scratch resistance and suitability for post-coating. As the extender pigment, specifically, a particle diameter of 0.1 to 0.1 of inorganic extender pigment such as barium sulfate, barium carbonate, calcium carbonate, calcium sulfate, magnesium carbonate, silica, alumina (α-alumina and the like), talc, clay and the like. It is preferable to use a powder of about 10 μm. The shape of the powder is spherical, polygonal, irregular, scale-like, or the like. Among them, barium sulfate is preferred from the viewpoint of improving the adhesion (due to the wedge effect) between a coating film such as an overcoat layer formed by post-coating and the picture layer serving as the outermost layer. The extender pigment is used in an amount of 5 to 100 parts by weight based on 100 parts by weight of the resin. If the amount exceeds 100 parts by weight, the transferability (removability and followability of unevenness) is reduced. If the amount is less than 5 parts by weight, the effect of improving the adhesion to the coating film cannot be obtained.

The decorative layer may be a functional layer such as an antibacterial layer, an antifungal layer, or a conductive layer. For example, a known antibacterial agent such as zeolite powder carrying silver ions is used for the antibacterial layer as the picture layer, and 1
A known antifungal agent such as 0,10-oxybisphenoxyarsine may be contained in the binder resin, and a known conductive agent formed of a powder or foil powder of graphite or silver may be contained in the binder resin for the conductive layer. Alternatively, the conductive layer may be a metal thin film layer or the like as a picture layer. These decorative layers may also be used as decorative layers for design expression.

[Adhesive Layer] When an adhesive layer is provided as the transfer layer 4, the resin or the like described in the above-mentioned picture layer may be used. The adhesive layer may be formed by a conventionally known forming method such as a coating method such as roll coating and a printing method such as screen printing.

Transfer Method of Transfer Sheet When transferring using the transfer sheet of the present invention, the transfer method used is not particularly limited. Depending on the application, for example, the following known transfer method may be adopted.

Transfer method using elastic roller: This method is suitable for a substrate to be transferred having relatively small or uneven surface. The elastic roller is disclosed in, for example,
An elastic roller used in a conventionally known roller transfer method, such as described in Japanese Patent Application Laid-Open No. 9550 and Japanese Patent Application Laid-Open No. 8-286599, may be used.

Vacuum forming transfer method: Japanese Patent Publication No. 56-457
No. 68 (overlay method), Japanese Patent Publication No. 60-5801
As described in Japanese Patent Publication No. 4 (vacuum press method) or the like, a transfer sheet is opposed to or placed on a three-dimensionally-transferred base material, and at least a pressure difference caused by vacuum suction from the base material is used. A transfer method utilizing a so-called vacuum forming and laminating method for transferring the transfer layer of (1) to the substrate to be transferred.

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 then heated and melted, and the resin in a fluid state is placed in the mold. A method for transferring a transfer layer from a transfer sheet to the surface of a substrate to be transferred at the same time as molding a resin molded product as a substrate to be transferred.

Wrapping transfer method: JP-B-61-58
No. 95, JP-A-5-330013, etc., a plurality of rollers having different directions while feeding a transfer sheet in the long axis direction of a columnar transfer substrate such as a cylinder or a polygon. A transfer method by a so-called lapping method, in which a transfer sheet is transferred by successively pressing and bonding a transfer sheet to a plurality of side surfaces constituting a transfer-receiving substrate.

Transfer method using solid particle collision pressure: Japanese Patent No. 2844424, Japanese Patent Application Laid-Open No. 10-193893
This is a novel transfer method disclosed in Japanese Unexamined Patent Application Publication No. 2000-125, etc. That is, as shown in the conceptual diagram of FIG. 5, the transfer layer side of the transfer sheet S composed of the support sheet and the transfer layer is opposed to the transfer surface (front surface) side of the transfer base material B, and A large number of solid particles P collide against the support sheet side, and the pressure of the collision is used to press the transfer sheet against the transfer surface of the transfer substrate. Then, after the transfer layer is adhered to the substrate to be transferred, the support sheet of the transfer sheet is peeled off to complete the transfer.
The arrow added to the solid particles P indicates a velocity vector of the solid particles.

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 onto a substrate to be transferred which already has a shape.
This is a method of transferring simultaneously with the development of the shape of the substrate to be transferred as a resin molded product. Further, in the above method, after pre-molding the transfer sheet with a resin mold, or another mold,
There is also a method of injection molding a resin and transferring the resin 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 preformed.

Method for Producing a Cosmetic Material: In the method for producing a cosmetic material according to the present invention, the transfer sheet using the above-described transfer sheet according to the present invention and the transfer method using the solid particle collision pressure as the above transfer pressure are used. Then, the transfer layer is transferred. The transfer method using the solid particle collision pressure is a very excellent method that can transfer even a three-dimensional uneven shape that cannot be obtained by other conventional transfer methods such as a roller transfer method. If necessary, a pretreatment step of the base material to be transferred, such as formation of an undercoat layer, or a posttreatment step, such as formation of an overcoat layer on the surface of the transfer layer after transfer, may be performed as a pretreatment step.

Hereinafter, the method for producing the decorative material of the present invention will be further described.

[Substrate to be Transferred] The substrate B to be transferred is not particularly limited. For example, as a material, an inorganic nonmetal-based, metal-based, wood-based, or plastic-based base material can be used.
Specifically, non-porcelain ceramics such as calcium silicate, hollow extruded cement, slag cement, ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), pulp cement, asbestos cement, wood chip cement, gypsum, gypsum slag, etc. Materials, wood materials such as cedar, cypress, oak, lauan, teak and other various wood species, wood plywood, particle board, glued wood, woody materials such as wood medium density fiberboard (MDF), iron, aluminum, copper Metal materials, such as
Inorganic materials such as ceramics such as earthenware, pottery, porcelain, setware, glass, and enamel, and resin materials such as polypropylene, ABS resin, and phenol resin.

The shape of the substrate to be transferred is arbitrary, such as a flat plate, a bent plate, a columnar object, and a three-dimensional object such as a molded product, as long as the transfer layer can be transferred to the decorative surface. For example, the base material to be transferred may be a flat plate material (having an envelope shape) as a whole, or a base material having two-dimensional irregularities whose cross section is convex or concave in an arc shape and curved in one direction. Even in the case of transfer formation, as a decorative surface, in addition to a flat surface, an uneven surface may be used as long as the transfer sheet and the transfer method to be employed have an irregularity following (shape following). This is especially true when the solid particle collision pressure described below is used for the transfer method. Surface irregularities are optional, but for example, joints when arranging multiple tiles or bricks on a plane, cleaved surfaces of granite, irregularities on stone surfaces such as sand, wood paneling such as wood paneling, floating grain, etc. The surface unevenness of the siding board without the surface, the unevenness of the spray-painted surface such as ricin or stucco, etc.

[Undercoat layer] The decorative surface of the substrate to be transferred may be provided with an undercoat layer (base coat layer) as necessary. The undercoat layer prevents the elution of alkali components from the base material to be transferred (alkali base material such as cement) (so-called sealer) or fills in the unevenness of the surface of the base material to be transferred (inorganic base material or the like). It is provided for the purpose of smoothing the surface, improving the transferability and the like, and imparting surface properties suitable for transfer of the transfer layer (so-called sealing). Also, the undercoat layer is made opaque by coloring so as to have a concealing property, and is also used for the purpose of preventing the color or pattern of the transferred substrate itself from adversely affecting the pattern of the decorative layer such as a picture layer (so-called undercoating). it can. In these cases, the function of the undercoat layer can also be provided by the adhesive layer alone while also serving as the adhesive layer. The undercoat layer is used in one layer or in multiple layers depending on the application. The undercoat layer may be formed by applying a conventionally known coating liquid composed of a resin or the like according to the material and surface state of the substrate to be transferred and the purpose thereof. For example, as the resin, a two-component curable urethane resin, a one-component moisture-curable urethane resin, an acrylic resin, a vinyl acetate resin, an epoxy resin, a polyester resin, or the like is used.
In particular, when the substrate is an alkaline substrate such as cement,
A resin having excellent alkali resistance is preferable. As a resin having excellent alkali resistance, for example, acrylic urethane resin,
Acrylic resin, epoxy resin and the like are preferable. The method for forming the undercoat layer is appropriately selected from conventionally known forming methods such as a coating method such as spray coating and flow coating, and a printing method such as screen printing, depending on the surface unevenness of the substrate to be transferred.

[Adhesive applied to substrate to be transferred] In the present invention,
Since the release layer of the transfer sheet is formed in a pattern, it is effective to apply the adhesive not to the transfer sheet but to the substrate to be transferred in order to utilize the air bleeding performance. Such an adhesive is not particularly limited and may be appropriately selected from known adhesives according to the application. For example, conventionally known heat-sensitive adhesives made of thermoplastic resins such as vinyl acetate resin, acrylic resin, thermoplastic polyester resin, and thermoplastic urethane resin, two-component curable urethane resin adhesives, and urethane-based moisture-curable adhesives Or a rubber-based adhesive. The adhesive may be any of an organic solvent type, a water type, a hot melt type and the like. In order to form an adhesive layer on the transferred substrate by applying an adhesive on the transferred substrate, spray coating, a coating method such as flow coating, a conventionally known forming method such as a printing method such as screen printing, etc. An appropriate one may be selected from among them according to the surface irregularities of the substrate to be transferred.

[Solid Particle Collision Pressure] The solid particle collision pressure can be obtained by colliding a large number of solid particles with the transfer sheet, as described with reference to the conceptual diagram of FIG. The solid particles are ejected from an ejector and collide with the transfer sheet.

As the solid particles P, ceramic beads,
Use non-metallic inorganic particles such as glass beads, metal particles such as zinc and iron, organic particles such as resin beads such as nylon beads and crosslinked rubber beads, or inorganic / resin composite particles composed of inorganic particles such as metal and resin. I do. The particle shape is preferably spherical, but other shapes can also be used. The particle size is usually about 10 to 1000 μm. The solid particles are ejected from the ejector toward the transfer sheet, and the collision pressure that collides with the transfer sheet 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.

FIGS. 6 and 7 are conceptual diagrams showing an example of the ejector using the 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. 7). 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 having a hollow inside and the same rotation axis as the rotation axis of the impeller 812 is provided as a sprayer 818 (see FIG. 7). 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. Impeller 81
The dimensions of 2 are usually about 5 to 60 cm in diameter, and the width of the blade is 5
Approximately 20 cm, the length of the impeller is approximately the diameter of the impeller, and the rotation speed of the impeller is approximately 500-5000 [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 about 10 to 150 [kg / m ² ].

Next, FIG. 8 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.

If 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.In a chamber that separates the space to be transferred from the surrounding space,
It is preferable that the solid particles collide with the transfer sheet. The peeling of the support sheet may be performed outside the chamber.

Preferably, the transfer sheet composed of a support sheet of a thermoplastic resin is previously softened by heating with an infrared radiation heater or the like to impart stretchability. If the transfer substrate has a large heat capacity, it is preheated in advance. The layers (such as an adhesive layer and a pattern layer) in the case where the initial bonding is thermally fused are such that the solid particles collide with the transfer sheet in a state of being activated by heating. The timing of heating when activating and thermally fusing a layer to be heat-fused may be before application of collision pressure, during application of collision pressure, or before and during application of collision pressure. On the other hand, when the transfer sheet has a concave-convex surface, the transfer sheet follows the surface shape and is formed. When the transfer layer is sufficiently in contact with the transfer substrate, a layer heat-sealed by cooling means such as cold air. Cooling may be promoted. The cool air is blown from, for example, the transfer sheet side or the transfer substrate side.

[Overcoat Layer] The surface of the decorative material after the transfer of the transfer layer may be further coated with an overcoat layer such as a transparent protective layer in order to impart durability, a sense of design, and the like. In particular, in the present invention, since the release layer serving as the outermost surface layer after transfer is formed not in the entire surface but in a pattern, it is difficult to leave the function of a surface protective layer after transfer to the release layer itself. In this respect, the formation of the overcoat layer is effective for improving the surface properties and the like. What is necessary is just to form a thing according to a use and required physical property in an overcoat layer. For example, polyfluoroethylene, a fluororesin such as polyvinylidene fluoride, an acrylic resin such as polymethyl methacrylate, a silicone resin, one or more of urethane resins and the like as a binder, if necessary, benzotriazole, UV absorbers such as ultrafine cerium oxide, light stabilizers such as hindered amine radical scavengers, lubricating agents consisting of particles such as silica, spherical α-alumina, flaky α-alumina, coloring pigments, extender pigments, lubricants, etc. Is applied using a paint to which is added. The coating may be performed by a known coating method such as spray coating, curtain coating, roll coating using a soft rubber roller or a sponge roller. The thickness of the overcoat layer is about 1 to 100 μm.

Use of Transfer Product There is no particular limitation on the use of a transfer product such as a cosmetic material obtained by the transfer sheet of the present invention or a cosmetic material obtained by the method for producing a cosmetic material of the present invention. For example, transfer products are used as decorative materials, such as exterior walls such as siding, fences, roofs, gates, exteriors such as gable boards, wall interiors, ceilings, floors and other building interiors, window frames, doors,
In various fields such as surface decoration of fittings such as handrails, sills, Kamoi, furniture such as wardrobes, surface decoration of cabinets for light electric and OA equipment such as television receivers, and vehicle interior materials such as automobiles, trains, aircraft, ships, etc. Can be used. The shape of a transfer product such as a cosmetic material may be a curved plate, a rod, a three-dimensional object, or the like, in addition to a flat plate. In a flat plate or a curved plate, the decorative material is used as a decorative plate. In particular, in the present invention, the use of an uneven transfer surface is preferable because the transferability can be prevented because the foil is easily cut off.

[0063]

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

EXAMPLE As shown in the perspective view of FIG. 9A, a decorative material was manufactured as follows using a transfer-receiving base material B having an uneven transfer-receiving surface. The transfer-receiving substrate B has a vertical joint 11 having a width of 8 mm (at the bottom surface) and a depth of 3 mm, and a width of 6 m (at the bottom surface).
m, having a groove-shaped joint with a horizontal joint 12 having a depth of 3 mm,
Extruded cement with a thickness of 18 mm having an uneven surface having a large number of mountain-like projections distributed in a height of 0.1 to 2 mm on a top surface (convex portion) partitioned by the vertical joints 11 and the horizontal joints 12. It is a board. The top surface is arranged in a brickwork pattern. Further, as shown in the cross-sectional view of FIG. 9B, the side surfaces of the vertical joints 11 and the horizontal joints 12 are slopes whose width becomes smaller toward the bottom at about 30 °. The transfer area was the top surface, and the non-transfer area was vertical joints and horizontal joints.

Then, a sealer layer for sealing (spray-coating a sealer made of an acrylic water-based emulsion) as an undercoat layer on the transfer-receiving surface of the transfer-receiving base material in advance, and a base layer for adjusting the base color. A coat layer (spray coating of an acrylic water-based emulsion paint colored with titanium white) was formed.

Then, in order to adhere the transfer layer, a two-pack curable urethane resin-based adhesive comprising a main component of an acrylic urethane-based polyol and a 1,6-hexamethylene diisocyanate-based curing agent is applied onto the transfer-receiving substrate. After applying the applied amount by spray coating so that the solid content becomes 5 g / m ² ,
The volatile component is dried by heating in a hot air drying oven (nozzle jet dryer) at 50 ° C. for 60 seconds, and an adhesive layer (to be applied to the substrate to be transferred) (to be applied to the substrate to be transferred) is placed on the substrate to be transferred. Formed.

On the other hand, the transfer sheet is a transfer sheet S as shown in the cross-sectional view of FIG. 1 (A), a surface-untreated ethylene-propylene copolymer film having a thickness of 80 μm (ethylene ratio 3% by weight, wetness index 32 or less). Gravure printing of a release layer ink composed of a thermoplastic urethane resin as a release layer 2 on one side of a support sheet 1 composed of
Thickness of a square lattice thin line pattern as shown in the plan view
A μm release layer was printed. The line width is 100 μm, and the line interval (the length of one side of the square which is an unformed area) is 150 μm.
And

Next, on the release layer 2, as a pattern layer to be the decorative layer 3, a binder resin is a thermoplastic urethane resin, and a coloring agent is an inorganic pigment such as quinacridone, isoindonoline, phthalocyanine blue, and carbon black. Gravure multicolor printing using a colored ink consisting of a mixed solvent of methyl ethyl ketone, toluene and isopropyl alcohol at a 5: 3: 2 weight ratio as a diluting solvent, and a marble-like stone pattern pattern Layer and the binder resin is a thermoplastic urethane resin and a color ink using titanium white as a colorant to form a solid white layer with all white solid layers,
The transfer sheet of the present invention was obtained.

Then, the transfer-receiving base material (adhesive layer) on which the adhesive layer has been formed is heated in a hot-air drying furnace to 100 g.
After pre-heating to a temperature of 0 ° C., the transfer sheet is placed so that the transfer layer side faces the transfer substrate side, and the transfer sheet and the transfer substrate are transported at a substrate speed of 15 m / min. The transfer was performed by colliding a large number of solid particles on the side. The direction in which the base material to be transferred is transferred and transferred is a direction indicated by an arrow “transfer direction” in FIG. 9 and is a direction parallel to the vertical joint 11. Further, as the solid particles, spherical zinc spheres heated to 50 ° C. and having a particle size distribution in the range of 0.4 mm to 0.6 mm were formed at a speed of 40 m / sec by an impeller as shown in FIGS. It accelerated to the speed and collided with the transfer sheet. Two ejectors were used in series in the transport direction of the substrate to be transferred, and the projection amount was 700 kg / min. And 25
After cooling with cold air at ℃, the support sheet was peeled off after the transfer layer was in close contact with the substrate to be transferred.

Further, as an overcoat layer, a 30 g / m ² (solid basis) spray coating of an overcoat paint (top coat agent) made of an acrylic water-based emulsion was applied on the transfer layer after the transfer, followed by hot air drying at 150 ° C. To form a transparent overcoat layer by heating and drying for 45 seconds to form a transparent overcoat layer, and completely cure the adhesive layer applied to the transfer-receiving substrate to obtain a decorative plate with an overcoat layer as an exterior siding as a decorative material. Was.

As a result, foil burrs did not occur, the foil cutting property was good, and the transfer layer was not lifted by residual air, and transfer omission was prevented. In addition, although it was in a pattern form, the transfer layer was not transferred in powder form due to collision impact due to the presence of the release layer.

Comparative Example 1 In the example, the release layer was a solid layer having a thickness of 2 μm on the entire surface. Except for this, in the same manner as in the example, a transfer sheet was prepared, and then a decorative material was prepared.
As a result, foil burrs occurred at the joints in the vertical and horizontal directions. In addition, the transfer layer did not adhere to the concave portion at the mountain-like protrusion on the top surface, and transfer omission occurred. However, no powder transfer occurred.

[Comparative Example 2] In the example, the release layer was omitted. Except for this, in the same manner as in the example, a transfer sheet was prepared, and then a decorative material was prepared. As a result, no foil burrs and no transfer omission occurred. However, the transferred transfer layer (picture layer) was finely crushed by cracks, and was in a powder form.

[0074]

According to the transfer sheet of the present invention, while maintaining the releasability of the transfer layer and the support sheet, the foil cutting property is improved, and powder transfer and transfer omission can be prevented. . This foil cutting property is particularly effective in the case of transfer having a transfer area and a non-transfer area in which the surface of the substrate to be transferred has an uneven surface. It is especially effective in cases. In addition, the effects of preventing transfer omission and powdery transfer are particularly effective in the case of a transfer method using solid particle collision pressure. According to the method for producing a decorative material of the present invention, when the decorative surface is particularly uneven, the effects of the above-described transfer sheet of the present invention, such as good foil cutting properties, transfer omission prevention, and powdery transfer prevention effects, are obtained. Obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view (A) and a plan view (B) illustrating an embodiment of a transfer sheet of the present invention.

FIG. 2 is a plan view illustrating some of the pattern shapes of a release layer.

FIG. 3 is a sectional view conceptually illustrating a foil burr.

FIG. 4 is a sectional view conceptually illustrating transfer floating.

FIG. 5 is a conceptual diagram illustrating a transfer method using a solid particle collision pressure in the method of manufacturing a decorative material according to the present invention.

FIG. 6 is a perspective view conceptually illustrating an example of an ejector using an impeller.

FIG. 7 is a conceptual diagram illustrating the inside of the impeller of FIG. 6;

FIG. 8 is a cross-sectional view conceptually illustrating an example of an ejector using an ejection nozzle.

9A and 9B are a perspective view and a cross-sectional view illustrating a shape of a transfer-receiving surface of a transfer-receiving base material.

FIG. 10 is a sectional view conceptually illustrating transfer floating.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 support sheet 2 release layer 3 picture layer 4 transfer layer 5 intersection 6 transfer area 7 non-transfer area 8 foil burr 9 void 11 vertical joint 12 horizontal joint 812 impeller 813 blade 814 side plate 815 hollow portion 816 direction controller 817 Opening 818 Sprayer 819 Rotating shaft 820 Bearing 840 Ejector using blowing nozzle 841 Induction chamber 842 Internal nozzle 843 Nozzle opening 844 Nozzle A Adhesive layer B Transfer substrate F Fluid G Bubbles P Solid particles S Transfer sheet

Claims (2)

[Claims] 1. A transfer sheet having a transfer layer in which a release layer and a decorative layer are laminated on a support sheet in this order, wherein the release layer comprises a net-like pattern of intersecting fine lines. 2. A method for producing a decorative material, comprising using the transfer sheet according to claim 1 to transfer a transfer layer to a substrate to be transferred by utilizing a solid particle collision pressure from a support sheet side as a transfer pressure.