JP2002370280A - Method and apparatus for manufacturing decorated sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for manufacturing a decorated sheet capable of efficiently heating and dehydrating the decorated sheet by being not liable to close fine garbage or the like therein in the case of obtaining the decorated sheet having a transfer layer having at least a design layer between a base sheet and a cover coating sheet and having excellent steric workability. SOLUTION: The method for manufacturing the decorated sheet comprises the steps of obtaining the decorative sheet without winding the base sheet even at once by a series of steps including a step of obtaining a laminate by feeding and supplying the base sheet having the excellent steric workability from a roll, and laminating a carrier sheet having excellent dimensional stability and a transfer foil having the transfer layer including at least the design layer on the base sheet, a step of releasing the carrier sheet of the transfer foil from the laminate, and a step of laminating the cover coating sheet having the excellent workability on the surface of the transfer layer in which the carrier sheet is released; and then discharging the decorated sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative sheet used for decorating a pattern of a plurality of colors, such as an automobile interior display part, on the surface of a three-dimensional molded product.

[0002]

2. Description of the Related Art Conventionally, decorative sheets have been used to decorate molded articles having a three-dimensional shape. That is, the decorative sheet provided with the pattern is three-dimensionally processed by a method such as vacuum molding, the three-dimensionally processed decorative sheet is set in a mold for injection molding, the mold is closed, and the molding resin is injected into the cavity. By solidifying the molding resin, it is possible to form a three-dimensionally shaped resin molded article, and at the same time, integrally bond a decorative sheet to the surface of the resin molded article to decorate the three-dimensionally shaped molded article. In addition, the decorative sheet can be three-dimensionally processed and attached on the surface of a molded product having a three-dimensional shape.

[0003] A decorative sheet for decorating a plurality of color pattern patterns, such as automobile interior display parts, is required to have three-dimensional workability and register accuracy of the pattern patterns. However, in the method of manufacturing a decorative sheet having excellent three-dimensional processability, when forming a pattern layer by a printing method, dimensional changes are likely to occur due to printing pressure, tension, drying heat, etc. applied to the base sheet, In other words, because the dimensional stability is poor,
There is a problem that it can be applied only to a pattern pattern such as a wood grain pattern, which requires less register accuracy.

As a means for solving this problem, a method that does not use a printing method for forming a design layer has been devised. Specifically, after forming a design layer on a carrier sheet excellent in dimensional stability, a base sheet excellent in three-dimensional processability is laminated on the design layer side, and the carrier sheet is peeled off.

[0005] Further, after the carrier sheet is peeled off and the base sheet on which the transfer layer is formed is once wound around a roll, it is excellent in three-dimensional workability for the purpose of protection on the design layer side of the base sheet in another apparatus. In some cases, a cover coat sheet is further laminated to form a decorative sheet.

[0006]

However, when obtaining a decorative sheet having a transfer layer having at least a design layer formed between a base sheet having excellent three-dimensional workability and a cover coat having excellent three-dimensional workability, In the prior art, since a laminate of a transfer foil and a base sheet is obtained and the carrier sheet is peeled off and removed, the base sheet on which the transfer layer is formed is once wound around a roll, so that the base sheet is charged at each winding. Fine particles and the like are adsorbed on the surface of the transfer layer after the carrier sheet is peeled off by the charged base sheet, and then the fine particles and the like are confined in the decorative sheet by covering with the cover coat sheet. Was significantly impaired.

Further, in this conventional technique, when the step of bonding the transfer foil and the cover coat sheet is performed by means involving heating such as dry lamination, the carrier sheet may be bonded to the base sheet while heating. After peeling and removing the base sheet, the base sheet on which the transfer layer is formed is once wound around a roll and placed in an atmosphere of normal temperature and normal humidity, so that the temperature of the base sheet on which the transfer layer is formed drops to around normal temperature. Therefore, when the cover coat sheet is subsequently bonded, it must be heated from around normal temperature again, and a large amount of heat is required in the entire manufacturing process.

In the above-described vacuum forming, if the decorative sheet to be used holds a large amount of water, the water is vaporized in the sheet by heating during the vacuum forming to generate air bubbles. The appearance of the product may be significantly impaired. In addition, since the decorative sheet is stretched along the inner surface of the mold during vacuum forming, the generated bubbles are also stretched, and the presence of the bubbles is more conspicuous. Therefore, at the stage of manufacturing the decorative sheet, it is necessary to remove as much moisture in the decorative sheet as possible. However, in the prior art, after the carrier sheet is peeled and removed, the substrate sheet once dehydrated by heating in the process up to that point is once wound up on a roll and placed in an atmosphere of normal temperature and normal humidity. Water was absorbed from the atmosphere, and the additional amount of water had to be dehydrated by heating when bonding the cover coat sheet thereafter.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned problems, and a transfer having at least a design layer between a base sheet having excellent three-dimensional workability and a cover coat sheet having excellent three-dimensional workability. When obtaining a decorative sheet having a layer formed thereon, the above-mentioned fine dust and the like are hardly trapped in the decorative sheet, and a decorative sheet manufacturing method and a decorative sheet manufacturing apparatus capable of efficiently heating and dewatering. Is to provide.

[0010]

Means for Solving the Problems The present invention has the following configuration to achieve the above object.

That is, the method for producing a decorative sheet according to the present invention is characterized in that a base sheet excellent in three-dimensional workability is fed out from a roll and supplied, and while the base sheet is conveyed, a carrier sheet excellent in dimensional stability and at least a design are provided. Bonding a transfer layer side of a transfer foil comprising a transfer layer having a layer to a base sheet to obtain a laminate of the transfer foil and the base sheet, removing a carrier sheet of the transfer foil from the laminate, A series of steps including at least a step of attaching a cover coat sheet having excellent three-dimensional workability to the peeled transfer layer surface. After the sheet was obtained, the decorative sheet was discharged.

Further, in the above configuration, the step of bonding the transfer foil and the cover coat sheet is performed by dry lamination.

[0013] In the above-mentioned configuration using dry lamination, the series of steps for obtaining the decorative sheet is performed between the step of obtaining a laminate of the transfer foil and the base sheet and the step of peeling the carrier sheet. The method includes a step of cooling the laminate of the transfer foil and the base sheet within a range in which part of the heat applied in the step of obtaining the laminate of the base sheet is left.

Further, the decorative sheet manufacturing apparatus of the present invention comprises a base sheet supply section for feeding a base sheet excellent in three-dimensional processability from a roll into one apparatus, and a dimensional stable sheet for the base sheet. A transfer foil supply unit for supplying a transfer foil comprising a carrier sheet having excellent performance and a transfer layer having at least a design layer, and laminating the transfer foil and the base sheet by bonding the transfer layer side of the transfer foil to the base sheet Transfer section for obtaining a product, a carrier sheet peeling and removing section for peeling a transfer foil carrier sheet from the laminate, and a cover for supplying a cover coat sheet having excellent three-dimensional workability to the laminate from which the carrier sheet has been peeled. A coat sheet supply unit,
A laminating unit for bonding the cover coat sheet to the surface of the base sheet on which the transfer layer is provided, and a decorative sheet discharging unit for discharging a decorative sheet having a transfer layer between the base sheet and the cover coat sheet. It was configured to have.

[0015] In the above-described apparatus, a cooling unit capable of cooling before the carrier sheet is peeled off by the carrier sheet peeling / removing unit after the laminate of the transfer foil and the base sheet is obtained at the transfer unit. I did it.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail with reference to the drawings. FIG. 1 is a diagram illustrating an embodiment of an apparatus used in the method for manufacturing a decorative sheet according to the present invention, and FIG. 2 is a diagram illustrating an embodiment of a transfer unit of the apparatus used in the method for manufacturing a decorative sheet according to the present invention. FIG. 3 is a view showing one embodiment of a decorative sheet discharging unit of the apparatus used in the method for manufacturing a decorative sheet according to the present invention. FIG. 4 is a cooling unit of the apparatus used in the method for manufacturing a decorative sheet according to the present invention. FIG. 3 is a diagram showing one embodiment of the present invention. In the figure,
1 is a base sheet supply unit, 2 is a transfer foil supply unit, 3 is a transfer unit, 3a is a heating roll, 3b is a backup roll, 3
c is a drive roll, 3d is a drive belt, 3e is a holding roll, 4 is a carrier sheet peeling and removing section, 5 is a cover coat sheet supply section, 6 is a laminating section, 6a is a heating roll, 6b is a backup roll, and 7 is a decoration roll. A sheet discharge unit, 8 is a base sheet, 9 is a transfer foil, 9a is a carrier sheet, 9b is a transfer layer, 10 is a cover coat sheet, 11 is a decorative sheet, 12 is a cooling unit, 12a is a cooling roll, 13
Indicates a cutting blade.

In the method for producing a decorative sheet according to the present invention, at least a transfer layer having a design layer is formed between a base sheet having excellent three-dimensional workability and a cover coat sheet having excellent three-dimensional workability. When a decorative sheet that can be easily subjected to three-dimensional processing in molding or the like is obtained, the above-described fine dust and the like are hardly trapped in the decorative sheet, and heating and dewatering can be performed efficiently.

The decorative sheet 11 to be obtained by the method for manufacturing a decorative sheet according to the present invention is excellent in three-dimensional workability. For example, at an environmental temperature of 110 ° C., a test piece of a decorative sheet having a width of 10 mm is fixed at a distance between a pair of chucks of 30 mm, and one end of the test piece is set at 100 mm /
It can be defined as having a property such that the tensile elongation at break is 130% or more when a tensile test is performed by applying a load at a constant speed for one minute. Here, the reason that the environmental temperature, that is, the temperature of the atmosphere in which the test piece is actually tested is 110 ° C. is that 110 to 180 ° C. is suitable for three-dimensional processing, and the lowest value is adopted. It is. Also,
The reason why the speed at which the test piece is pulled is set to 100 mm / min is to adopt the lowest value of the speed at which the decorative sheet is stretched in three-dimensional processing. The test piece was 10 mm in width and the distance between the chucks was 30 mm. The dimensions of the decorative sheet required to obtain each decorative molded product were 80 mm × 250 mm for an air conditioner heater panel, and a speedometer / fuel display. 160 mm x 450 m for panels
m, 250mm x 800mm for front grill,
The ratio of these width to length (10: 3
0). In addition, the three-dimensional processability of the decorative sheet manufactured in the present invention can be appropriately set in accordance with the shape of the molded product, other than the example defined by the above numerical values.

As described above, when the decorative sheet 11 is obtained, the fine dust and the like are hardly trapped in the decorative sheet, and the heating and dewatering can be efficiently performed. The method for manufacturing a decorative sheet according to
The base sheet 8 having excellent three-dimensional workability is fed out from a roll and supplied, and while the base sheet 8 is being conveyed, the transfer foil 9 including the carrier sheet 9a having excellent dimensional stability and the transfer layer 9b having at least a design layer is formed. A step of laminating the transfer layer 9b side to the base sheet to obtain a laminate of the transfer foil 9 and the base sheet 8, and a carrier sheet 9a of the transfer foil 9 from the laminate.
And a cover coat sheet 10 having excellent three-dimensional workability on the surface of the transfer layer 9b from which the carrier sheet 9a has been peeled.
After obtaining the decorative sheet 11 having excellent three-dimensional workability and high register accuracy of the pattern pattern without winding up the base sheet 8 by a series of steps including at least the step of attaching the decorative sheet 11, the decorative sheet 11 is discharged. I do.

The apparatus for manufacturing a decorative sheet according to the present invention basically includes, in one apparatus, a base sheet supply section 1 for feeding a base sheet 8 excellent in three-dimensional workability from a roll and supplying the same. A transfer foil supply unit 2 for supplying a transfer foil 9 including a carrier sheet 9a having excellent dimensional stability to the base sheet 8 and a transfer layer 9b having at least a design layer;
A transfer section 3 for bonding the transfer layer 9b side of the transfer foil 9 to the base sheet 8 to obtain a laminate of the transfer foil 9 and the base sheet 8, and a carrier for peeling the carrier sheet 9a of the transfer foil 9 from the laminate A sheet peeling / removing unit 4; a cover coat sheet supplying unit 5 for supplying a cover coat sheet 10 having excellent three-dimensional workability to the laminate from which the carrier sheet 9a has been peeled; Laminating section 6 to be bonded to the side on which transfer layer 9b is provided, base sheet 8 and cover coat sheet 1
The decorative sheet discharging section 7 discharges the decorative sheet 11 having the transfer layer 9b between the two positions. FIG. 1 shows an embodiment of an apparatus having such components.

In the base sheet supply section 1, a roll-shaped base sheet 8 is supported at its center by a shaft and pulled out by rotation of a roll or a belt of the transfer section 3. The running base sheet 8 needs stable tension of an appropriate strength so as not to sag, and thus the tension is adjusted by means such as back tension and winding tension.

As the material of the base sheet 8, for example,
The tensile elongation at break when the above tensile test was performed was 13
In the case of a decorative sheet having 0% or more, use a polyvinyl chloride film, an acrylic film, a polycarbonate film, a polypropylene film, a polyester film, a polybutylene terephthalate film, a polystyrene film, an acrylonitrile butadiene styrene film, a nylon film, or the like. Can be. These sheets may be transparent or translucent, or may be colored. In order to improve the strength of the base sheet 8, a filler such as glass, silica, mica, and talc may be added. In addition, other commonly used additives that can improve the performance of the sheet, for example, an antistatic agent for improving the antistatic performance, a wear-resistant agent made of a metal oxide such as alumina to increase abrasion resistance, A slip agent (wax, spherical particles) or the like for preventing wrinkles can be added. The base sheet 8 may be stretched, but in consideration of the three-dimensional workability of the obtained decorative sheet 11, a non-stretched sheet that is not intentionally stretched is more preferable. The base sheet 8 may have a thickness of 0.016 to 1.00 mm.

In the transfer foil supply section 2, a roll-shaped transfer foil 9
Is supported at the center by a shaft, and is pulled out by rotation of a roll or a belt of the transfer unit 3 or the like. In addition, since the transfer foil 9 during running needs stable tension of appropriate strength so as not to sag, the tension is adjusted by means such as back tension and winding tension.

The transfer foil 9 used is a sheet in which a transfer layer 9b having at least a design layer is provided on a carrier sheet 9a having excellent dimensional stability. Since the carrier sheet 9a has excellent dimensional stability, the transfer foil 9 is formed with high printing register accuracy of the symbol layer.

The carrier sheet 9a is, for example, 90 ° C.
A sheet having a dimensional change rate of 0.6% or less under the environmental temperature of can be used. Here, the reason why the environmental temperature is set to 90 ° C. is that the ambient temperature in the drying device installed in a normal multicolor printing machine is 60 to 90 ° C., and the highest value of 90 ° C. is adopted. Things. Set the dimensional change rate to 0.
The reason for setting it within 6% is that the dimensions of the decorative sheet necessary to obtain actual decorative molded products are 80 mm x 250 mm for an air conditioner heater panel and 160 mm x 450 mm for a speedometer / fuel display panel. In the case of the front grille, which is about 250 mm × 800 mm, the printing registration accuracy of ± 80 mm, which is the shortest of these required dimensions, does not have a sense of incongruity with the printing registration misregistration at least by the naked eye. It is necessary to be within 0.5 mm and 0.5 / 80, that is, within 0.6%. Examples of the material of such a carrier sheet 9a include a biaxially oriented polyester film, a biaxially oriented polypropylene film, a polyethylene naphthalate film,
Examples include a polyimide film, a polyetherketone film, and a polysulfone film. Carrier sheet 9a
Is preferably peeled off in the manufacturing process of the decorative sheet 11, and it is preferable to use an inexpensive biaxially stretched polyester film or a biaxially stretched polypropylene film. The dimensional stability of the carrier sheet 9a used in the present invention can be appropriately set according to the application, the design pattern, and the like, in addition to the example defined by the above numerical values.

The thickness of the carrier sheet 9a is 5 to 3
A range of 00 μm is preferred. When the thickness is less than 5 μm, the carrier sheet 9a may be easily cut due to the tension of the printing press.
It is difficult to install the carrier sheet 9a in a rotary printing press used for manufacturing the transfer foil 9 by forming the transfer layer 9b thereon, and the productivity is reduced. Particularly, 15 to 50 μm
Carrier sheet 9a has good workability for bonding and peeling, and is more preferable.

In the case where the transfer layer has good releasability, the transfer layer 9b may be provided directly on the carrier sheet 9a. In order to improve the releasability of the transfer layer 9b from the carrier sheet 9a, a release layer may be formed on the entire surface before providing the transfer layer 9b on the carrier sheet 9a.
When the carrier sheet 9a is peeled off after the transfer, the release layer is released from the transfer layer 9b together with the carrier sheet 9a. As the material of the release layer, a melamine resin-based release agent, a silicone resin-based release agent, a fluororesin-based release agent, a cellulose derivative-based release agent, a urea resin-based release agent, a polyolefin resin-based release agent, Paraffin-based release agents, composite release agents thereof, and the like can be used. Examples of the method for forming the release layer include a coating method such as a roll coating method and a spray coating method, and a printing method such as a gravure printing method and a screen printing method.

The transfer layer 9b is a layer having at least a design layer, and usually has a release layer between the design layer and the carrier sheet 9a, and an adhesive layer on the side opposite to the carrier sheet 9a.

The release layer is formed entirely or partially on the carrier sheet 9a or the release layer. When the carrier sheet 9a is peeled off after the transfer, the release layer is a layer that is peeled off from the carrier sheet 9a or the release layer and becomes the outermost surface. Examples of the material of the release layer include polyacrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin, polyurethane resin, polyvinyl acetate resin, and vinyl chloride-vinyl acetate copolymer. It is preferable to use a copolymer such as a system resin or an ethylene-vinyl acetate copolymer system resin. The release layer may be colored or uncolored. Examples of the method for forming the release layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure coating method and a screen printing method.

The design layer is formed on the release layer, usually as a printing layer. As the material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, a polyacryl resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method may be used. In particular, an offset printing method or a gravure printing method is suitable for performing multicolor printing and gradation expression. The printing layer may be provided entirely or partially depending on the design to be expressed.

The design layer may be composed of a combination of a printing layer and a metal thin film layer. The metal thin film layer is for expressing a metallic luster as a design layer, and includes a vacuum deposition method, a sputtering method, an ion plating method,
It is formed by plating or the like. In this case, aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead,
Metals such as zinc, their alloys or compounds are used.
When the metal thin film layer is provided, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion between another transfer layer and the metal thin film layer. As the material of the front anchor layer and the rear anchor layer, two-component cured urethane resin, thermosetting urethane resin, melamine resin, cellulose ester resin, chlorine-containing rubber resin, chlorine-containing vinyl resin, polyacrylic resin, It is preferable to use an epoxy resin, a vinyl copolymer resin resin, or the like. Examples of a method for forming the front anchor layer and the rear anchor layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure coating method and a screen printing method.

The adhesive layer is for bonding each of the above layers to the base sheet 8. The adhesive layer is formed on a portion to be bonded. That is, if the portion to be formed with the adhesive layer is entirely, the adhesive layer is entirely formed on the pattern layer. If the portion to be formed with the adhesive layer is partially formed, the adhesive layer is partially formed on the design layer. As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the base sheet 8 is appropriately used. For example, when the material of the base sheet 8 is a polystyrene-based resin or a polycarbonate-based resin, a polyacryl-based resin, a polystyrene-based resin, a polyamide-based resin, or the like that has an affinity for these resins may be used. Further, the base sheet 8
When the material is polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. Examples of the method for forming the adhesive layer include a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure coating method and a screen printing method.

The configuration of the transfer layer 9b is not limited to the above-described embodiment. For example, when the pattern layer is made of a material having excellent adhesion to the base sheet 8,
When the adhesive is coated after the transfer foil 9 is pulled out from the roll, the adhesive layer can be omitted. Also,
When a material having excellent releasability from the carrier sheet 9a is used as the material of the design layer, the release layer can be omitted.

In the transfer section 3, the transfer layer 9a of the transfer foil 9 is used.
The side is bonded to the base sheet 8 to obtain a laminate of the transfer foil 9 and the base sheet 8. As a bonding method, for example, an adhesive is coated on the base sheet 8 or the transfer foil 9 and the solvent is evaporated by drying.
Dry lamination in which the transfer layer 9a side is overlapped with and pressurized and heated and adhered can be used. In the case of bonding by dry lamination, if an adhesive layer is formed in advance as the outermost layer of the transfer layer 9b, it is not necessary to coat and dry the adhesive in the transfer section 3. Pressing and heating in the dry lamination may be a point contact method using a heated heating roll 3a and a backup roll 3b as shown in FIG. 1, or a driving roll 3c and a heated drive belt as shown in FIG. A surface contact method using 3d and a pressing roll 3e may be used. In the transfer unit 3 in the point contact method, the heating roll 3a and the backup roll 3b are made of heat-resistant rubber such as silicon or SBR, metal, or ceramics. A roll internal heating method such as a heating method, an electromagnetic induction heating method, and a high-temperature fluid circulation heating method can be used. The transfer unit 3 in the surface contact method includes a drive belt 3d, a drive roll 3
c and the pressing roll 3e are made of heat-resistant rubber such as silicon or SBR, metal, or ceramics. As a heating method of the transfer unit 3, the drive belt 3d is a ceramic heater,
An external heating method in which heating is performed by a high-temperature air circulation method or the like, or a method in which the drive roll 3c and the presser roll 3e are heated by an electromagnetic induction heating method, a high-temperature fluid circulation heating method, or the like and are conducted to the drive belt 3d can be used. FIG. 1 shows an example in which an adhesive layer is formed in advance as the outermost layer of the transfer layer 9b.
In the above, the coating and drying of the adhesive may be performed. In that case, the transfer foil 9 may be coated with an adhesive, or the base sheet 8 may be coated with an adhesive. Although FIG. 1 shows an example in which the heating roll 3a is arranged so as to heat from the transfer foil 9 side, the positions of the heating roll 3a and the backup roll 3b are interchanged so that the heating is performed from the base sheet 8 side. Or both rolls may be heating rolls 3a. The base sheet 8 and / or the transfer foil 9 may be heated before the base sheet 8 and the transfer foil 9 are overlaid between rolls or belts. Further, for laminating the base sheet 8 and the transfer foil 9 according to the present invention, dry lamination is most preferable in that the selectivity of the substrate to be used is wide, but other laminating methods can be used.

In the carrier sheet peeling / removing section 4, the carrier sheet 9a of the transfer foil 9 is peeled off from the laminate, leaving only the transfer layer 9b of the transfer foil 9 on the base sheet 8 side. The peeling of the carrier sheet 9a may be started immediately after obtaining the laminate of the transfer foil 9 and the base sheet 8 as shown in FIG. 1, or after being transported for a while in the state of the laminate as shown in FIG. May be started. The carrier sheet 9a, which has been peeled and removed, is usually wound up in a roll shape. The winding method is a center driving method in which a winding shaft is turned, or a winding by friction on a rotating winding roller. There is a surface drive method to take.

In the cover coat sheet supply section 5, the roll-shaped cover coat sheet 10 is supported at its center by a shaft, and is pulled out by the rotation of the roll or belt of the laminating section 6. The running cover coat sheet 10 is
Since a stable tension of an appropriate strength is required so as not to sag, the tension is adjusted by means such as back tension and winding tension.

As the material and film thickness of the cover coat sheet 10 to be used, the same materials as those of the base sheet 8 having excellent three-dimensional workability can be used.

In the laminating section 6, the side of the base sheet 8 on which the transfer layer 9 b is provided and the cover coat sheet 10
To obtain a decorative sheet 11 having excellent three-dimensional workability and high register accuracy of a pattern. As a bonding method, for example, the base sheet 8 provided with the transfer layer 9b is provided.
Alternatively, after the cover coat sheet 10 is coated with the adhesive 6c and dried (pass through the drying zone 6d in FIG. 1) to evaporate the solvent, the surface of the base sheet 8 on which the transfer layer 9b is provided and the cover coat sheet 10 And press
Dry lamination for heat bonding can be used (see FIG. 1). Pressing and heating in the dry lamination is performed by using a heated heating roll 6 as shown in FIG.
a and the backup roll 6b may be used,
The transfer unit 3 may use a drive roll, a heated drive belt, and a press roll in the same manner as shown in FIG. The materials of the rolls and the belt and the heating method thereof are the same as those described for the rolls and the belt of the transfer unit 3. The adhesive 6c is dried by hot air drying or the like. Although FIG. 1 shows an example in which the adhesive 6c is coated on the cover coat sheet 10, the adhesive 6c is applied to the base sheet 8 provided with the transfer layer 9b.
May be coated. If the outermost layer of the transfer layer 9b on the side of the cover coat sheet 10 and the cover coat sheet 10 are the same resin, there is no need to coat and dry the adhesive. FIG. 1 shows an example in which the adhesive is coated and dried in the laminating section 6. However, if the cover coat sheet 10 supplied from a roll has an adhesive layer in advance, the transfer section shown in FIG. As in the case of No. 3, there is no need to coat and dry the adhesive. FIG. 1 shows an example in which the heating roll 6a is arranged so as to heat from the cover coat sheet 10 side. However, the heating roll 6a and the backup roll 6b are interchanged in position to heat from the base sheet 8 side. Or both rolls may be heating rolls 6a. Furthermore, dry lamination with a wide range of selectivity of the base material to be used is most preferable for bonding the cover coat sheet 10 and the base sheet 8 according to the present invention, but other bonding methods can be used.

In the bonding step of the cover coat sheet 10, embossing may be performed on at least one of the cover sheet 10 side and the base sheet 8 side of the decorative sheet 11 simultaneously with the adhesion. As an apparatus, for example, in the laminating unit 6 using the heating roll 6a and the backup roll 6b, the heating roll 6a and / or the backup roll 6b may be embossed rolls having irregularities.

Decorative sheet 1 in decorative sheet discharge section 7
As the discharging method of No. 1, the carrier sheet peeling and removing unit 4
It is also possible to wind the sheet into a roll in the same manner as described above (see FIG. 1), or to cut it into a single sheet with the cutting blade 13 or the like without winding (see FIG. 3).

As described above, the method for producing a decorative sheet of the present invention comprises the steps of obtaining a laminate of the transfer foil 9 and the base sheet 8;
Since the step of peeling the carrier sheet 9a of the transfer foil 9 from the laminate and the step of bonding the cover coat sheet 10 proceed as a series of steps, there is no winding to a roll after the carrier sheet 9a is peeled and removed. The sheet 8 is hardly charged. Therefore, the fine dust and the like can be prevented from being trapped in the decorative sheet 11 by the covering of the cover coat sheet 10.

Further, a step of obtaining a laminate of the transfer foil 9 and the base sheet 8, and the carrier sheet 9a of the transfer foil 9 is obtained from the laminate.
And the step of bonding the cover coat sheet 10 proceed as a series of steps, and the carrier sheet 9a
In the present invention, in which the transfer foil 9 and the cover coat sheet 10 are bonded by a means involving heating such as dry lamination in the present invention in which there is no winding on a roll after the peeling and removal of the transfer foil 9 and the base sheet 8, Since the bonding step of the cover coat sheet 10 can be performed while part or all of the heat applied in the step of obtaining the laminate is left, the amount of heat required in the entire manufacturing process can be reduced. In other words, in addition to reducing manufacturing costs,
Since the heating time is short, the overall line speed is increased.

Further, a step of obtaining a laminate of the transfer foil 9 and the base sheet 8, and the carrier sheet 9 a of the transfer foil 9 is obtained from the laminate.
And the step of bonding the cover coat sheet 10 proceed as a series of steps, and the carrier sheet 9a
In the present invention in which there is no winding on a roll after peeling and removing the base sheet, if the moisture in the decorative sheet 11 is removed by heating in the decorative sheet manufacturing stage, the base sheet is attached before the step of bonding the cover coat sheet 10. 8 can be prevented from absorbing moisture from the atmosphere, and the additional moisture does not need to be dehydrated.

The present invention is not limited to the decorative sheet manufacturing method and the decorative sheet manufacturing apparatus including only the above-described steps.

For example, in the method for manufacturing a decorative sheet according to the present invention, a series of steps for obtaining the decorative sheet 11 are performed after the step of bonding the cover coat sheet 10 to the cover coat sheet of the decorative sheet 11 obtained. A step of embossing at least one of the 10 side and the base sheet 8 side may be included. As an apparatus, for example, a heating zone and an embossed portion including at least one between rolls having irregularities are provided between the laminating section 6 and the decorative sheet discharging section 7, and after the decorative sheet 11 is heated, the embossing section is formed between the rolls. Through. In the case where the lamination process of the cover coat sheet 10 is performed by dry lamination and the embossing is performed while the decorative sheet 11 is still sufficiently hot, it is not necessary to perform heating in the embossing process.

In the method for producing a decorative sheet according to the present invention, when the step of bonding the transfer foil 9 is by dry lamination, a series of steps for obtaining the decorative sheet 11 are performed by the transfer foil 9 and the base sheet. A step of cooling the laminate of the transfer foil 9 and the base sheet 8 may be included between the step of obtaining the laminate of No. 8 and the step of peeling off the carrier sheet 9a. When the transfer foil 9 is cooled, there is no stickiness due to the softening of the transfer layer, and the transfer foil 9 can be easily peeled off at the interface with the carrier sheet 9a. However, when the laminating process of both the transfer foil 9 and the cover coat sheet 10 is performed by dry lamination, the cooling is performed within a range where a part of the heat applied in the process of obtaining the laminate is left. This involves performing the bonding step of the cover coat sheet 10 with a part of the heat applied in the step of obtaining the laminated body of the transfer foil 9 and the base sheet 8, thereby reducing the amount of heat required in the entire manufacturing process. That's why. As an apparatus, for example, a cooling roll 12a (see FIG. 4) or a cooling section 12 having the above-mentioned temperature range including a cooling zone is provided between the transfer section 3 and the carrier sheet peeling and removing section 4, and the transfer foil 9 and the base sheet are provided. After the laminate of No. 8 has passed through the cooling unit 12, the carrier sheet 9a is peeled and removed.

In the method for manufacturing a decorative sheet according to the present invention, when the bonding step of the cover coat sheet 10 is performed by dry lamination or when the embossing is performed after the decorative sheet 11 is obtained, A series of steps for obtaining the decorative sheet 11 may include a cooling step immediately before the step of discharging the decorative sheet 11. By doing so, when the discharged decorative sheets 11 overlap, it is possible to prevent the back surface and the front surface having heat from coming into close contact with each other, thereby preventing the occurrence of blocking or a change in surface properties. Further, when the decorative sheet discharging unit 7 is to wind up the decorative sheet 11, it is possible to prevent the generation of wrinkles (steps) during winding by cooling the decorative sheet 11. Easy to take. If the decorative sheet 11 is kept heated (softened) without cooling, wrinkles (steps) are likely to occur when the decorative sheet 11 bends due to winding tension and bends. The wrinkles (steps) cause tight winding due to winding, making winding difficult. Further, in a state where the adhesive for bonding is softened, the cover coat sheet 10 and the base sheet 8 are likely to be displaced. However, this problem can be solved by performing a cooling step. As the apparatus, a cooling unit including a cooling roll or a cooling zone is provided immediately before the decorative sheet discharge unit 7.

[0048]

EXAMPLE In this example, first, a substrate sheet made of an ABS film having a thickness of 350 μm is unwound from a roll in a substrate sheet supply section and supplied to a transfer section.

At this time, also in the transfer foil supply section, a PET film having a thickness of 25 μm, a release layer made of an acrylic resin, and black, brown, indigo, red, and yellow acrylic-vinyl copolymer resin colored inks were used. A transfer foil comprising a pattern layer formed by the above and a transfer layer having an adhesive layer made of a vinyl chloride resin is fed out from a roll and supplied to a transfer portion.

Next, in the transfer section, the transfer layer side of the transfer foil is superimposed on the conveyed base sheet and heated and pressurized by using a heating roll heated to 170 ° C. and a backup roll. A laminate of the transfer foil and the base sheet is obtained. Thereafter, the carrier sheet of the transfer foil is peeled off from the laminate and wound up in the carrier sheet peeling / removing section, and the base sheet having the remaining transfer layer is conveyed to the laminating section. I do.

At this time, also in the cover coat sheet supply section, a cover coat sheet made of an acrylic resin film having a thickness of 125 μm is unwound from a roll and supplied to the laminating section.

Next, in the laminating section, the cover sheet is superimposed on the surface of the transfer layer as it is, and the base sheet and the cover coat are heated and pressurized using a heating roll and a backup roll heated to 150 ° C. And a decorative sheet having a transfer layer having a design layer formed between them.

Finally, the decorative sheet is conveyed to a decorative sheet discharging section, where the base sheet is wound up for the first time.

[0054]

Since the decorative sheet manufacturing method and the decorative sheet manufacturing apparatus of the present invention have the above-described configuration, they have the following excellent effects.

That is, the method for producing a decorative sheet according to the present invention includes a step of obtaining a laminate of a transfer foil and a base sheet, a step of peeling a carrier sheet of the transfer foil from the laminate, and a step of laminating a cover coat sheet. The process proceeds as a series of steps, and the base sheet on which the transfer layer is formed is not wound around a roll after the carrier sheet is peeled off, so that the base sheet is hardly charged. Therefore, it is possible to prevent the fine dust and the like from being trapped in the decorative sheet due to the covering with the cover coat sheet.

The step of obtaining a laminate of the transfer foil and the base sheet, the step of peeling the carrier sheet of the transfer foil from the laminate, and the step of bonding the cover coat sheet proceed as a series of steps. In the present invention in which the transfer foil and the cover coat sheet are not bonded to a roll after the removal, if the step of bonding the transfer foil and the cover coat sheet is performed by a means involving heating such as dry lamination, the step of obtaining a laminate of the transfer foil and the base sheet is performed. The cover coat sheet bonding step can be performed while part or all of the applied heat is left, and the amount of heat required in the entire manufacturing process can be reduced.

Further, a step of obtaining a laminate of the transfer foil and the base sheet, a step of peeling the carrier sheet of the transfer foil from the laminate, and a step of laminating the cover coat sheet proceed as a series of steps. In the present invention in which there is no winding into a roll after the removal, in the case of removing the moisture in the decorative sheet by heating in the decorative sheet manufacturing stage, the base sheet is removed from the air before the step of bonding the cover coat sheet. Water can be prevented from being absorbed, and the additional water does not need to be dehydrated.

Further, in the decorative sheet manufacturing apparatus of the present invention, a transfer section for obtaining a laminate of a transfer foil and a base sheet and a carrier sheet peeling apparatus for peeling a carrier sheet of the transfer foil from the laminate are provided in one apparatus. A step of obtaining a laminate of the transfer foil and the base sheet since the removing section and a laminating section for bonding the cover coat sheet to the surface of the base sheet on which the transfer layer is provided; , And the step of attaching the cover coat sheet can be easily performed as a series of steps.

[Brief description of the drawings]

FIG. 1 is a view showing one embodiment of an apparatus used in a method for manufacturing a decorative sheet according to the present invention.

FIG. 2 is a view showing one embodiment of a transfer unit of an apparatus used for a method for manufacturing a decorative sheet according to the present invention.

FIG. 3 is a view showing one embodiment of a decorative sheet discharging unit of the apparatus used in the method for manufacturing a decorative sheet according to the present invention.

FIG. 4 is a view showing one embodiment of a cooling unit of an apparatus used for a method for manufacturing a decorative sheet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Substrate sheet supply part 2 Transfer foil supply part 3 Transfer part 3a Heating roll 3b Backup roll 3c Driving roll 3d Drive belt 3e Holding roll 4 Carrier sheet peeling removal part 5 Cover coat sheet supply part 6 Laminating part 6a Heating roll 6b Backup roll 6c Adhesive 6d Drying zone 7 Decorative sheet discharge unit 8 Base sheet 9 Transfer foil 9a Carrier sheet 10 Cover coat sheet 11 Decorative sheet 12 Cooling unit 12a Cooling roll 13 Cutting blade

Claims (5)

[Claims] 1. A transfer foil comprising a carrier sheet having excellent dimensional stability and a transfer layer having at least a design layer while feeding a base sheet having excellent three-dimensional processability from a roll and feeding the base sheet. Bonding the transfer layer side to the base sheet to obtain a laminate of the transfer foil and the base sheet, removing the carrier sheet of the transfer foil from the laminate, and having excellent three-dimensional workability on the transfer layer surface from which the carrier sheet has been removed. After obtaining a decorative sheet having excellent three-dimensional workability and high register accuracy of the pattern pattern without winding the base sheet by a series of steps including at least a step of bonding the cover coat sheet, A method for manufacturing a decorative sheet, comprising discharging the sheet. 2. The method for producing a decorative sheet according to claim 1, wherein the step of bonding the transfer foil and the cover coat sheet is by dry lamination. 3. A series of steps for obtaining the decorative sheet, wherein the step of obtaining a laminate of the transfer foil and the base sheet is between the step of obtaining a laminate of the transfer foil and the base sheet and the step of removing the carrier sheet. 3. The method for producing a decorative sheet according to claim 2, further comprising a step of cooling the laminate of the transfer foil and the base sheet within a range in which a part of the heat applied remains. 4. An apparatus used in the method for manufacturing a decorative sheet according to claim 1 or 2, wherein one apparatus comprises:
A base sheet supply unit that feeds a base sheet excellent in three-dimensional processability from a roll and supplies a transfer foil including a carrier sheet excellent in dimensional stability to the base sheet and a transfer layer having at least a design layer on the base sheet A transfer foil supplying section, a transfer section for bonding a transfer layer side of the transfer foil to the base sheet to obtain a laminate of the transfer foil and the base sheet, and a carrier sheet for peeling a transfer foil carrier sheet from the laminate. A peel-off unit, a cover coat sheet supply unit for supplying a cover coat sheet excellent in three-dimensional processability to the laminate from which the carrier sheet was peeled, and a transfer layer of the base sheet with the cover coat sheet were provided. A laminating unit to be bonded to the surface side, and a decorative sheet discharging unit for discharging a decorative sheet having a transfer layer between the base sheet and the cover coat sheet. Decorative sheet manufacturing apparatus characterized by having. 5. A cooling unit which can cool the carrier sheet after the laminate of the transfer foil and the base sheet is obtained at the transfer unit and before the carrier sheet is peeled at the carrier sheet peeling and removing unit.
The decorative sheet manufacturing apparatus according to the above.