JP2001205991A - Transfer sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transfer sheet for preventing a powder-like transfer or a transfer omission without foil burr with good foil tearableness even in the case of transferring to an rugged surface. SOLUTION: The transfer sheet S comprises a transfer layer 4 obtained by laminating a release layer 2 and a decorative layer 3 on a support sheet 1. The layer 2 is formed in a halftone dot assembly pattern. A method for manufacturing a decorative material comprises the steps of transferring the transfer layer to a base material to be transferred, by utilizing a solid particle collision pressure from the side of the support sheet as a transfer pressure and manufacturing the decorative material. Releasability of the layer 4 and the sheet 1 is held, foil tearableness is upgraded, and the powder-like transfer and the transfer omission can be prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention belongs to a technical field for obtaining a transfer product such as a decorative material used for various uses such as exterior and interior of a house, and more particularly, to a transfer sheet suitable for an uneven transfer surface. Things.

[0002]

2. Description of the Related Art Conventionally, various decorative materials have been manufactured by a transfer method. In this case, the transfer layer of the transfer sheet is usually peeled to the support sheet side in order to make the peeling force with the support sheet appropriate or to protect the surface as the outermost surface layer after transfer. Layers are often provided. And, of course, such a conventional release layer is formed on the entire surface (as a continuous film covering the entire surface). Also, if the surface protection function is not required and the peeling force between the transfer layer and the support sheet can be made appropriate without the release layer, the transfer layer is printed and formed directly on the support sheet without the release layer. A transfer sheet having a configuration formed by performing such operations is also used.

On the other hand, as a transfer method suitable for a case where the surface to be transferred of a substrate to be transferred is an uneven surface, a method utilizing a solid particle collision pressure as a transfer pressure has been proposed in Japanese Patent No. 2,844,524. When such a transfer method is used, 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 is extended and formed at the time of transfer.

[0004]

However, in the case of transfer to an uneven surface, in the case of a release layer formed on the entire surface, all the layers are continuously connected as a single layer. As shown in the drawing, if the transfer substrate 6 has the transfer region 6 and the non-transfer region 7, when the support sheet 1 of the transfer sheet S is peeled off, the boundary E between the transfer region 6 and the non-transfer region 7 is removed. A surplus transfer layer 4 extends and remains toward the non-transfer area 7 to cause a so-called foil burr 8, which may cause a phenomenon that the foil cutting property deteriorates.

Another problem inherent in the transfer method utilizing the collision pressure of solid particles is that the release layer is connected over the entire surface, so that, as shown in FIG.
The air trapped between the transfer substrate B and the transfer sheet during the transfer is not completely removed, and the air bubbles G between the transfer substrate B and the transfer layer 4 are not removed.
As a result, a so-called transfer floating in which the transfer layer 4 floats at the bubble portion from the transfer-receiving substrate B may occur. Note that FIG.
In the drawing, the case where the transfer is performed after the adhesive layer A is applied on the substrate B to be transferred is illustrated.

On the other hand, when a transfer sheet having no release layer is used, a new problem arises instead of improving the generation of foil burrs and the transfer floating. That is, 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 is broken up by the collision impact, resulting in poor transfer. There was something. This is because the pattern layer (pattern pattern layer or all solid layer) formed by printing has a high rigidity and a brittleness due to a large content of a pigment such as a coloring agent. On the other hand, the release layer has only a small amount of a pigment such as barium sulfate added for printing stability of a pattern layer formed thereon, and the rigidity of the release layer is not so much as that of the resin itself. It has the flexibility to follow irregularities without change. Therefore, when a transfer sheet having a release layer is used, a decorative layer such as a picture layer can be tied to the release layer, and can follow the unevenness by the release layer. However, in a transfer sheet without a release layer at all, even if a decorative layer such as a picture layer is cracked due to an impressive transfer pressure, the crack cannot be retained, and as a result, the decorative layer cannot follow irregularities. It is crushed into a powdery transfer.

An object of the present invention is to ensure sufficient peelability between a support sheet and a transfer layer, and at the same time, it has good foil-cutting properties, particularly on a transfer surface having irregularities, and can prevent transfer omission due to residual air. The purpose is to provide a transfer sheet.

[0008]

Means for Solving the Problems In order to solve the above problems,
According to the present invention, in 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, the release layer is formed of an aggregate pattern of halftone dots.

As described above, the release layer is not formed as a continuous layer over the entire surface, but as a layer having an aggregate pattern of halftone dots, thereby ensuring sufficient release properties between the transfer layer and the support sheet. At the same time, the foil breakage becomes good and the 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 area and a non-transfer area. This is particularly effective in the case of transfer using pressure. In addition, since the decorative layer is tied to a large number of adjacent portions by the flexible peeling layer, even if only partially, the decorative layer has an effect of preventing powdery transfer when solid particle collision pressure is used.

Further, in the transfer sheet of the present invention,
By forming the decorative layer and the support sheet in direct contact with each other in the area between the halftone dots of the release layer, the halftone area (because the support sheet and the release layer are in direct contact, The coexistence of the peel strength of the layer from the support sheet and the inter-dot area (the peel strength of the transfer layer is high because the support sheet and the decorative layer are in direct contact with each other) makes the transfer sheet support sheet coexist. Peeling strength can be kept at an appropriate value.

[0011]

Embodiments of the present invention will be described below in detail with reference to the drawings. First, the transfer sheet will be described.

FIG. 1 shows the transfer sheet of the present invention in one form, in which FIG. 1A is a sectional view and FIG. 1B is a plan view of a release layer of the transfer layer.

As shown in FIG. 1A, the transfer sheet S
Has a transfer layer 4 formed by laminating a release layer 2 and a decorative layer 3 on a support sheet 1 in this order, and as shown in FIG. It consists of an aggregate pattern. In FIG. 1B, a hatched area is a formation area where the release layer 2 is formed, and a white part is a non-formation area 5 where the release layer 2 is not formed.
In the halftone dot pattern shown in FIG. 1B, the release layer 2 has a square shape, and a large number of the squares are arranged vertically and horizontally (two-dimensionally) periodically through a region where the release layer 2 is not formed. This is the case of a pattern (rectangular lattice pattern) that is formed.

The aggregate pattern of the halftone dots that the release layer exhibits in plan view is not particularly limited as shown in FIG. In FIG. 2A, the vertical and horizontal sides of the release layer 2 are formed at 90 °.
FIG. 2B shows an instep lattice pattern in which the release layer 2 is formed in a hexagonal shape, and FIG.
(C) is a triangular lattice pattern in which the formation region of the release layer 2 is triangular.

In the aggregate pattern of halftone dots shown in FIGS. 2A to 2C, all the formation regions of the peeling layer have the same shape and size, and are regularly scattered at equal intervals. Although it is a pattern, it may be an aggregate pattern of halftone dots in which the shape and size of the formation area are not uniform. Also, the aggregate pattern of the halftone dots may be a combination of a plurality of halftone dots having different shapes.

The size of the halftone dot pattern may be appropriately determined in accordance with the size of the irregularities on the surface to be transferred, the size of the pattern of the decorative layer, the method of giving the transfer pressure, and the like. For example, in the aggregate pattern of halftone dots shown in FIGS. 1B and 2A to 2C, when the solid particle collision pressure is used as the transfer pressure as the size of the formation region of the release layer 2 Since the particle size distribution of the solid particles used is usually about 0.4 to 0.6 mm, the minimum size (evaluated by diameter, diagonal length, or length of one side) is about 0.1 mm, and the maximum is About 2 mm is preferable. The distance (interval) between halftone dots is preferably about 0.01 to 1 mm. If the shape of the formation region is too small, or if the shape of the non-formation region is too large, it becomes difficult to exhibit the original function as the release layer, the release force increases, the release property decreases, and the transfer layer is reduced. Tends to be broken by collision impact of solid particles to cause poor transfer.

As described above, since the release layer is not formed as a continuous layer but is formed as an aggregate pattern of halftone dots, air escapes from the discontinuous portion where the release layer is not formed. Transfer floating, which is a minute gap caused by air, is eliminated.

When a pattern layer composed of a pattern pattern layer and a solid layer is printed as a decorative layer on the release layer, the solid layer may be formed as a continuous layer. Since the content of the pigment such as an agent is high, air tends to escape, and the effect of the dot-like release layer is not hindered. On the other hand, the pattern pattern layer is a discontinuous layer or a layer in which the discontinuous layers overlap (in the case of multicolor printing). In addition, since the pattern pattern layer is printed as halftone dots, air is more likely to escape than all solid layers. Therefore, air bubbles can be removed between the support sheet and the release layer by penetrating the transfer layer.

In particular, with respect to this transfer floating, in a transfer method using solid particle collision pressure, which can transfer to a larger uneven surface than ever before, as a transfer pressure pressing means, there is a unique situation that is advantageous for air release. is there. This will be described with reference to the conceptual diagram of FIG. That is, since this transfer method is a repetitive pressurization in which a large number of solid particles P repeatedly collide with the transfer sheet S, the transfer layer 4 is formed at the first collision of the solid particles P as shown in FIG. After contacting the transfer-receiving substrate B, FIG.
As shown in (2), the support sheet 1 and the transfer layer 4 are separated from each other by the impact at the time of the second collision of the solid particles P to form a gap 9 therebetween, and the transfer sheet 4 penetrates there. This is because air bubbles may come off. Although FIG. 3 shows a case in which the adhesive layer A is provided in advance on the substrate to be transferred B,
The adhesive layer A may be omitted.

On the other hand, with respect to foil burrs, if the release layer is an aggregate pattern of halftone dots, the release layer is not a continuous layer.
In a non-transfer portion such as a joint portion, the transfer layer is easily cut by a shearing force due to a transfer pressure such as a solid particle collision 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.

The release layer moves as a part of the transfer layer on the transfer-receiving substrate side during transfer. The release layer to be migrated may be the entire thickness, but by causing the release layer to undergo cohesive failure, a part of the thickness of the release layer is transferred to the transfer-receiving substrate side,
A part of the thickness may be peeled off integrally with the support sheet.

The support sheet has releasability from a transfer layer such as a release layer, and the transfer surface (decorative surface) of the substrate to be transferred.
In the case where is irregularities, any conventionally known ones may be used as long as they can follow the irregularities, 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 having no stretchability may be used. However, when the three-dimensional uneven surface is used, a stretchable support sheet 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.
The support sheet may have a single-layer structure or a plurality of structures formed 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, or a wax, or a mixture containing these is used. For example, it is a support sheet obtained by laminating polypropylene as a release layer on the high-quality paper described above.

Further, in the transfer sheet of the present invention, since there is a non-formation area 5 of the release layer 2 between the halftone dots, the release layer 2 is sequentially formed on the support sheet 1 as a method of manufacturing the transfer sheet.
When the decorative layer 3 is formed, the decorative layer 3 (transfer layer) on the non-formation area 5 partially directly contacts the support sheet 1 as shown in FIG. Therefore, the releasability (peeling force) between the support sheet and the transfer layer may be optimized only by the release layer, but also for the interface between the support sheet and the decorative layer, a combination of both materials is appropriately selected. It is preferable to adjust the wetting index on the side of the transfer layer of the support sheet. If the wettability is high, the peeling force becomes large and foil burrs hardly occur, but peeling (transfer) becomes difficult. If the wettability is low, peeling (transfer) is easy, but foil burr tends to occur. In addition to this, the peeling force of the transfer layer is optimized by adjusting the area ratio between the area where the release layer is formed (dots) and the area where the release layer is not formed (between the dots). Can be. As a method of manufacturing a transfer sheet, when a decorative layer is formed first, and then a release layer and a support sheet are sequentially laminated thereon, as shown in FIG. The support sheet 1 and the decorative layer 3 may be kept in non-contact in the transfer layer non-formation region 5 between them. In this case, a decorative layer having poor peelability from the support sheet 1 (peeling force is too large) can be employed.

The transfer layer has at least the release layer described above and a decorative layer described later. The transfer layer may further include an adhesive layer or the like as appropriate. There is no particular limitation on the decorative layer, adhesive layer, and the like, which are components of the transfer layer other than the above-described release layer. A decorative layer, an adhesive layer, or the like in a conventionally known transfer sheet may be used. The transfer layer such as a release layer, a decoration layer, and an adhesive layer can be formed by a conventionally known printing method, coating method, or any other means such as hand-drawing.

However, in the present invention, since a 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 difficult for air to penetrate the transfer layer,
Originally, it is not preferable from the viewpoint of expressing the effects of the present invention. However, as described above, this is not the case with all solid layers having a high pigment content, so that preferably all 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). FIG. 1 shows that the decorative sheet is in direct contact with the support sheet between the halftone dots.
In the case of (A), it is a matter of course that the decorative layer which comes into direct contact with the support sheet is selected from those which can be practically separated from the support sheet.

The decorative layer may be formed by a conventionally known method such as gravure printing, silk screen printing, offset printing, gravure offset printing, ink jet printing, a pattern layer obtained by printing a pattern with a material, aluminum, chromium, gold, silver, etc. A metal thin film layer or the like in which a metal is partially or entirely formed by using a known vapor deposition method or the like, and a material suitable for the intended use is used. As the pattern, according to the surface unevenness of the base material, wood pattern, stone pattern, cloth pattern, tile pattern, brick pattern,
A leather pattern, a character, a geometric pattern, a solid pattern, etc. are used. 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 the 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.

Since the release layer has a non-formed area, a part of the picture layer is exposed as a part of the surface of the transfer layer after the transfer. For this reason, an extender pigment may be appropriately contained in the pattern 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,
It has a scaly shape. Among them, barium sulfate is preferred from the viewpoint of improving the adhesion (due to the wedge effect) between a paint film such as a top coat layer formed by post-coating and a 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.

When an adhesive layer is provided as a transfer layer, 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 a roll coat or a printing method such as a screen printing.

When transferring using the above-described transfer sheet of the present invention, the transfer method used is not particularly limited.
Depending on the use, for example, the following known transfer method may be employed.

(1) Transfer Method Using an Elastic Roller: This method is suitable for a substrate to be transferred having relatively small or flat surface irregularities. The elastic roller is disclosed in, for example,
An elastic roller used in a conventionally known roller transfer method as described in JP-A-99550 and JP-A-8-286599 may be used.

(2) Vacuum forming transfer method: This method is described in Japanese Patent Publication No. 56-45768 (overlay method) and Japanese Patent Publication No. 60-58014 (vacuum press method). A so-called vacuum forming and laminating method is used in which a transfer sheet is opposed or placed on a transfer substrate, and a transfer layer of the transfer sheet is transferred to the transfer substrate by a pressure difference caused by vacuum suction from at least the transfer substrate side. This is a transfer method.

(3) Injection Molding Simultaneous Painting Transfer Method: In this method, as described in JP-A-6-315950, the transfer sheet is formed such that the transfer layer side faces the injection resin side. After being placed between the male and female molds, the resin is heated and melted, and the resin in the fluid state is injected and filled into the mold. This is a transfer method for transferring a layer.

(4) Wrapping transfer method: This method
JP-B-61-5895, JP-A-5-330013
As described in Japanese Unexamined Patent Application Publication No. H10-207, a transfer substrate is formed by a plurality of inorganic different rollers while supplying a transfer sheet in the long axis direction of a columnar transfer substrate such as a cylinder and a polygonal column. This is a transfer method based on a so-called lapping method in which a transfer sheet is transferred by successively applying pressure to a plurality of side surfaces to transfer a transfer layer.

(5) Transfer Method Utilizing Solid Particle Impact Pressure: This method is a novel transfer method disclosed in Japanese Patent No. 2844424, Japanese Patent Application Laid-Open No. 10-193893, and the like. That is, as shown in the conceptual diagram of FIG. 5, the transfer layer side of the transfer sheet S including the support sheet and the transfer layer is opposed to the transfer surface (front surface) side of the transfer base material B. A large number of solid particles P are made to collide with the support sheet side, and the collision pressure is used to press the transfer sheet S against the transfer surface of the transfer substrate B. Then, after the transfer layer is adhered to the base material B to be transferred, the support sheet of the transfer sheet S is peeled off to complete the transfer. The arrow added to the solid particles P indicates a velocity vector of the solid particles.

(6) In addition, BMC (Bulk Molding Comp
sound) molding method, SMC (Sheet Molding Compound) molding method, hand lay-up molding method and other FRP (Fiber Reinfor
ced Plastics) or RIM (R
eaction Injection Molding), a transfer method performed simultaneously with molding such as a match molding method, and the like.

The above (1), (2), (4) and (5) are methods for transferring to an already-formed transfer substrate, and (3) and (6) are methods for forming a resin molded product. This is a method of transferring simultaneously with the development of the shape of the substrate to be transferred. In the method (3), there is a method in which a transfer sheet is preformed by a resin molding die or another die, and then the resin is injection-molded and transferred at the same time as molding. Similarly, in the methods listed in (6), the transfer sheet may be molded simultaneously with the resin molding, or may be preformed before the resin molding.
In the hand lay-up method, the transfer sheet is formed by preliminary forming.

The transfer method using the solid particle collision pressure of the above (5) is a very excellent method which can transfer even to a three-dimensional uneven shape which cannot be achieved by other conventional transfer methods such as a roller transfer method. . Note that, as necessary, a pretreatment step of the base material to be transferred, such as formation of an undercoat layer, or a post-treatment step, such as formation of an overcoat layer on the surface of the transfer layer after transfer, may be performed as necessary. Hereinafter, a method of manufacturing a decorative material by this transfer method will be described.

The material of the substrate to be transferred is not particularly limited. For example, an inorganic nonmetal-based, metal-based, wood-based, or plastic-based substrate can be used. Specifically, 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.
Wood materials such as wood veneer, wood plywood, particle board, laminated wood, medium-density fiberboard (MDF) made of various tree species such as cypress, oak, lauan, teak, etc., and metal materials such as iron, aluminum and copper, 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 column, a three-dimensional object such as a molded product, etc., 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 (envelope shape) as a whole, or a base material having two-dimensional unevenness 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 irregular surface may be used as long as the transfer sheet and the transfer method to be employed have irregularity conformability (shape conformability). This is especially true when a solid particle collision pressure described later 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. This is the surface unevenness of the siding, lysine-like, stucco-like, etc. of the spray-coated surface without siding.

Incidentally, an undercoat layer (base coat layer) may be appropriately provided on the decorative surface of the substrate to be transferred, if 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). In addition, the undercoat layer is colored and opaque to provide concealing properties, and is also used for the purpose of preventing the color or pattern of the transfer-receiving substrate itself from adversely affecting the pattern of a decorative layer such as a picture layer (so-called undercoating). it can. In these cases, the function of the undercoat layer can also be satisfied 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 condition of the substrate to be transferred and the purpose thereof. For example, as the resin, 2
Liquid-curable urethane resin, one-component moisture-curable urethane resin,
Acrylic resin, vinyl acetate resin, epoxy resin, polyester resin and the like are used. In particular, when the substrate is an alkaline substrate such as cement, a resin having excellent alkali resistance is preferable. As the 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 may be selected from coating methods such as spray coating and flow coating, printing methods such as screen printing, and the like, depending on the surface unevenness of the substrate to be transferred. select.

In the present invention, since the release layer of the transfer sheet is formed in a pattern, the adhesive is applied not to the transfer sheet but to the substrate to be transferred in order to utilize the air release performance. Is effective. Such an adhesive is not particularly limited, and may be appropriately selected from known adhesives according to applications. 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 Curable adhesive or 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. What is necessary is just to select suitably from among them according to the surface unevenness shape of a to-be-transferred base material.

The solid particle collision pressure can be obtained by colliding a large number of solid particles with the transfer sheet, as described in the conceptual diagram of FIG. The solid particles are ejected from an ejector and collide with the transfer sheet.

The solid particles 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 metal and resin. And inorganic / resin composite particles composed of the following. 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, and the like are 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 10 includes a plurality of blades 11.
Are solidified on both sides by two side plates 12, and the center of rotation is a hollow portion 13 having no blade 11. Further, a direction controller 14 is provided inside the hollow portion 13 (see FIG. 7). The direction controller 14 has a hollow cylindrical shape having an opening 15 in which a part of the outer periphery is opened in the circumferential direction, and has the same rotation axis as the rotation axis of the impeller 10 and is independent of the impeller. It is freely rotatable. When using the impeller, fix the opening 15 of the direction controller 14 so as to face an appropriate direction,
The ejection direction of the solid particles P is adjusted. Further, inside the directional controller 14, another impeller having a hollow inside and the same rotation axis as the rotation axis of the impeller 10 is provided as a sprayer 16 (see FIG. 7). The spreader 16 rotates with the outer impeller 10. A rotating shaft 17 is fixed to the center of rotation of the side plate 12, and the rotating shaft 17 is rotatably supported by a bearing 18. The rotating shaft 17 is driven and rotated by a rotating power source (not shown) such as an electric motor. The car 10 rotates. Also,
The rotating shaft 17 is composed of two side plates 12 having the blades 11 therebetween.
It does not penetrate between them, forming a space without a shaft.

Then, the solid particles P are supplied into the sprayer 16 from a hopper or the like through a transport pipe. Usually, the solid particles P are supplied from above (directly above or obliquely above) the impeller 10. The solid particles P supplied into the sprayer 16 are dispersed in the sprayer 1.
Splash outside with the impeller # 6. Scattered solid particles P
Are discharged only in the direction allowed by the opening 15 of the direction controller 14 and the blades 11 and 1 of the outer impeller 10
1 is supplied. Then, it collides with the impeller 11, is accelerated by the rotational force of the impeller 10, and is ejected from the impeller 10.

The size of the impeller 10 is usually 5 to 60 c in diameter.
m, the width of the blade 11 is about 5 to 20 cm, the length of the blade 11 is about the diameter of the impeller 10, and the rotation speed of the impeller 10 is about 500 to 5000 [rpm]. Solid particles P
Has a jet velocity of about 10 to 50 [m / s], and a projection density (total weight of solid particles to be collided per unit area of the base material) of 1
It is about 0 to 150 [kg / m ² ].

Next, FIG. 8 is a conceptual diagram showing an example of an ejector using an ejection nozzle. The ejector 20 of FIG. 1 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 to the solid particle ejector. The ejector 20 includes an induction chamber 21 for mixing the solid particles P and the fluid F, an internal nozzle 22 for ejecting the fluid F into the induction chamber 21, and an ejection nozzle for ejecting the solid particles P and the fluid F from the nozzle opening 23. It consists of a part 24. When the fluid F in a pressurized state from a compressor or the like is ejected from the internal nozzle 22 and is ejected from the nozzle opening 23 of the nozzle 24 through the induction chamber 21, the fluid F flows at high speed in the induction chamber 21 in the ejector. A negative pressure is created by the action of the fluid flow, the solid particles P are introduced into the fluid flow by the negative pressure and mixed, and the solid particles P are accelerated and conveyed by the fluid flow, and are ejected together with the fluid flow from the nozzle opening 23 of the nozzle 24. Is what you do. In addition, there is a blowing nozzle using a liquid as the solid particle acceleration fluid. Fluid pressure is the spray pressure, usually 0.1.
It is about 1 to 10 kg / cm ² . The flow velocity of the fluid flow is usually about 1 to 20 m / sec for the liquid flow, and is usually 5 to 80 m for the air flow.
m / sec.

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.In a chamber that separates the space to be transferred from the surrounding space,
The solid particles may collide with the transfer sheet. Peeling of the support sheet may be outside the chamber.

Preferably, the transfer sheet whose support sheet is made of a thermoplastic resin is preliminarily heated and softened with an infrared radiation heater or the like to impart stretchability. The layers (such as an adhesive layer and a pattern layer) in the case where the initial bonding is heat-sealed are such that the solid particles collide with the transfer sheet in a state of being heat-activated. When the layer to be heat-sealed is activated and heat-sealed, the heating may be performed before the collision pressure is applied, during the application of the collision pressure, or before and during the application of the 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-receiving substrate side.

The surface of the decorative material after the transfer of the transfer layer may be post-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 protecting the surface after transfer to the release layer itself. The formation of an overcoat layer is effective for improving the surface properties and the like.

The overcoat layer may be formed according to the intended use and required physical properties. For example, polyfluoroethylene, fluororesin such as polyvinylidene polyfluoride, acrylic resin such as polymethyl methacrylate, silicone resin, one or more of urethane resin and the like as a binder, if necessary, benzotriazole, UV absorbers such as ultrafine cerium oxide, light stabilizers such as hindered amine radical scavengers, silica, spherical α-alumina, lubricating agents comprising particles such as flaky α-alumina, coloring pigments, extender pigments,
Apply using a paint to which a lubricant or the like has been 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.

There are no particular restrictions on the use of a transfer product such as a decorative material obtained with the transfer sheet of the present invention. For example, transfer products are used as cosmetics, such as exterior walls such as siding, fences, roofs, gates, exteriors such as gable boards, wall surfaces, ceilings, interiors of buildings such as floors, window frames, doors, handrails, sills, and Kamoi. It can be used in various fields such as surface decoration of fittings, furniture such as a chest of drawers, surface decoration of cabinets of light electric / OA equipment such as television receivers, and interior materials of vehicles such as automobiles, trains, aircraft, and ships. In addition,
The shape of transfer products such as cosmetics is not limited to flat
A rod-shaped plate, a three-dimensional object, or the like may be used. 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.

[0060]

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

EXAMPLE As shown in the perspective view of FIG. 9 (A), a decorative material was manufactured as follows using a transfer-receiving substrate B having an uneven transfer surface. The transferred substrate B is (on the bottom surface)
A vertical joint 31 having a width of 8 mm and a depth of 3 mm, and a width 6 (at the bottom).
mm, a grooved joint with a horizontal joint 32 having a depth of 3 mm, and a height of 0.1 to 2 mm on a top surface (convex portion) defined by the vertical joint 31 and the horizontal joint 32. It is an extruded cement board having a thickness of 18 mm, having an uneven surface having a large number of distributed mountain-shaped projections. 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 31 and the horizontal joints 32 have an angle of about 30 with the normal.
The slope becomes narrower as it goes to the bottom in degrees. The transfer area was the top surface, and the non-transfer area was vertical joints and horizontal joints.

Then, on the transfer-receiving surface of the transfer-receiving substrate B,
The undercoat layer is spray-coated with a sealer layer for sealing (spray coating with a sealer made of an acrylic aqueous emulsion) and a base coat layer for adjusting the base color (titanium white colored acrylic aqueous emulsion paint) ) And formed.

Further, in order to adhere the transfer layer, a two-part 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 provided on the transfer-receiving substrate. Is applied by spray coating so that the solid content is 5 g / m ^2, and then heated in a hot air drying oven (nozzle jet dryer) at 150 ° C. for 60 seconds to dry volatile components. An adhesive layer (cured) was formed on the transferred substrate.

On the other hand, a transfer sheet S as shown in FIG. 1 was prepared. Specifically, a thickness of 80 μm
A support sheet 1 made of a surface-untreated ethylene-propylene copolymer-based film (ethylene ratio 3% by weight, wetness index 32 or less) has an acrylic resin and vinyl chloride
A release layer ink composed of a resin of a mixture of 8: 2 by weight with a vinyl acetate copolymer is gravure-printed, and a thickness composed of an aggregate pattern of square lattice halftone dots as shown in the plan view of FIG. A release layer 2 having a thickness of 2 μm was printed. The line width of the separation layer non-formation area between the halftone dots was 70 μm, and the length of one side of the square of the halftone dot (release layer formation area) was 100 μm.

Next, the decorative layer 3 is further formed on the release layer 2.
As a picture layer, a binder resin is a mixed resin of an acrylic resin and a vinyl chloride-vinyl acetate copolymer, and a coloring agent comprising a quinacridone, isoindolinone, phthalocyanine blue and a carbon black inorganic pigment is used as a coloring agent, The pattern layer of a marble-like stone pattern and the binder resin are formed by gravure multicolor printing using a coloring ink using a mixed solvent of methyl ethyl ketone, toluene and isopropyl alcohol in a weight ratio of 5: 3: 2 as a diluting solvent. The whole solid layer of white solid is formed with the same resin as in the case of using a coloring ink using titanium white as a coloring agent, and the decorative layer 3 is formed on the support sheet 1 in the absence of the peeling layer between the halftone dots. The transfer sheet S as shown in FIG. 1A was obtained.

Then, after preliminarily heating the transfer-receiving substrate on which the adhesive layer has been formed to 100 ° C. in a hot-air drying oven, the transfer sheet is placed so that the transfer layer side faces the transfer-substrate side,
While transferring the transfer sheet and the substrate to be transferred at a substrate speed of 15 m / min, transfer was performed by colliding a large number of solid particles against the support sheet side of the transfer sheet.

The direction in which the substrate to be transferred is transferred and transferred is the direction indicated by the arrow “transfer direction” in FIG. 9, that is, the direction parallel to the vertical joint 31. Also, as solid particles,
A spherical zinc sphere having a particle size distribution in the range of 0.4 to 0.6 mm was used, heated to 50 ° C., and accelerated to a speed of 40 m / sec by an impeller as shown in FIGS. 6 and 7. The transfer sheet was hit. Two ejectors were used in series in the transport direction of the substrate to be transferred, and the projection amount was 700 kg / min. Then, the substrate was cooled with cold air at 25 ° C., and after the transfer layer was in close contact with the substrate to be transferred, the support sheet was peeled off.

Further, as a top coat layer, a top coat paint (top coat agent) made of an acrylic water-based emulsion was spray-coated on the transfer layer after transfer at 30 g / m ² (solid content basis), and then dried with hot air at 150 ° C. A transparent overcoat layer is formed by heating and drying in a furnace for 45 seconds to solidify, and the adhesive layer applied to the transfer-receiving substrate is completely cured, and as a decorative material, with a topcoat layer used for exterior siding. A decorative plate was obtained.

As a result, foil burrs did not occur, the foil was cut easily, and the transfer layer was not lifted by the residual air, and the transfer omission was prevented. Further, although it was a pattern, the transfer layer was not transferred in powder form due to a collision impact because of the release layer.

Comparative Example 1 In the example, the release layer was a solid (continuous film) layer having a thickness of 2 μm over the entire surface. Otherwise, after a transfer sheet was prepared in the same manner as in the example, a decorative material was similarly prepared using the transfer sheet. As a result, foil burrs occurred at the joints in the vertical and horizontal directions. In addition, the transfer layer does not adhere to the concave portion in the mountain-shaped protrusion on the top surface,
Transfer omission occurred. However, no powder transfer occurred.

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

[0072]

According to the transfer sheet of the present invention, while maintaining the releasability between the transfer layer and the support sheet, the foil breakability is improved, and powder transfer and transfer omission can be prevented.
This foil cutting property is particularly effective in the case of transfer in which the substrate surface to be transferred has a transfer area and a non-transfer area with 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.

[Brief description of the drawings]

FIG. 1 shows a transfer sheet of the present invention in one form, in which FIG. 1 (A) is a cross-sectional view and FIG. 1 (B) is a plan view of a release layer of a transfer layer.

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

FIG. 3 is a cross-sectional view for explaining transfer floating when a solid particle collision pressure is used.

FIG. 4 is a cross-sectional view illustrating another form of the transfer sheet.

FIG. 5 is a conceptual diagram for explaining a transfer method using a solid particle collision method.

FIG. 6 is a perspective view for explaining an example of an ejector using an impeller.

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

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

FIG. 9 is a perspective view (A) and a cross-sectional view (B) for explaining the shape of a transfer-receiving surface of a transfer-receiving substrate used in Examples.

FIG. 10 is a sectional view conceptually illustrating a foil burr.

FIG. 11 is a cross-sectional view for conceptually explaining transfer floating.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Support sheet 2 Release layer 3 Decorative layer 4 Transfer layer 5 Non-formation area 6 Transfer area 7 Non-transfer area 8 Foil burr 9 Void 10 Impeller 11 Blade 12 Side plate 13 Hollow part 14 Direction controller 15 Opening part 16 Sprayer Reference Signs List 17 rotating shaft 18 bearing 20 ejector using blow nozzle 21 guide chamber 22 internal nozzle 23 nozzle opening 24 nozzle 31 vertical joint 32 horizontal joint A adhesive layer B transfer substrate E boundary F fluid G bubble P solid particle 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 an aggregate pattern of halftone dots. 2. The transfer sheet according to claim 1, wherein the decorative layer and the support sheet are in direct contact with each other in a region between the halftone dots of the release layer.