JP2010018012A - Embossed sheet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an embossed sheet capable of enhancing design and abrasion resistance by performing transfer printing processing only to the recess of embossed cloth. <P>SOLUTION: The method for manufacturing the embossed sheet includes steps of superposing an adhesive layer of a transfer sheet having a support layer (support film 12) and an adhesive layer 4 and cloth 18, heating and pressurizing the transfer sheet and the cloth by means of a recess 17 of an embossed mold 15 from the transfer sheet side, and forming a recess 19 in the cloth with a part of the adhesive layer 4 adhered only to the recess 19. The adhesive layer is preferably composed of a hot-melt adhesive. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an embossed sheet and a method for producing the same, and more particularly to an embossed sheet capable of improving design and friction resistance by subjecting only a concave portion of an embossed fabric to a transfer printing process and a method for producing the same.

  Conventionally, an embossed sheet has been used as an interior material in a vehicle such as an automobile. As a method for producing this type of embossed sheet, for example, as shown in FIG. 13, a dough 103 is passed between a roll-shaped embossing die 101 and a blanket roll 102 provided opposite thereto, It is known to form a recess 104 on the surface side of the fabric 103 by embossing the fabric 103 with the convex portion of the embossing mold 101.

  In recent years, a transfer printing process is sometimes applied to the sheet in order to improve the design of the sheet. As a method for manufacturing this type of sheet, for example, as shown in FIG. 14, a fabric 108 and a foil transfer sheet 109 are passed between a heating roll 106 and an impression cylinder 107 provided facing the heating roll 106. Things are known. Here, the foil transfer sheet 109 has a two-layer structure of the support film 110 and the foil 111. Further, an adhesive resin 112 is printed in advance on the surface of the fabric 108 with a stencil or intaglio. As a result, the fabric heated and pressed by the heating roll 106 is melted by the adhesive resin 112 and is pressed onto the foil 111 of the foil transfer sheet 109. When the foil transfer sheet 109 is peeled off from the fabric 108, the foil 111 is adhered and stuck to the portion where the adhesive resin 112 was present, and the foil 111 remains on the foil transfer sheet 109 side in other portions.

  However, in the embossed sheet 100 described above, an uneven design is only formed on the surface of the embossed fabric 103, and no color is added. In addition, it is conceivable to add color to the fabric 103 in advance and emboss only that portion, but it is difficult to perform alignment and the like at the time of embossing.

  Moreover, in the sheet | seat 105 which performed the transfer printing process mentioned above, the site | part to which foil 111 was transcribe | transferd is restricted to a flat part or a convex part, and its design property is low. In addition, it is conceivable to transfer the foil only to the recesses formed in advance on the fabric 103, but it is difficult to apply the adhesive resin 112 to the recesses and to align the foil 111 to the recesses. . Further, since the portion to which the foil 111 is transferred is a flat portion or a convex portion, it is easily peeled off by friction from the outside after the foil transfer. For this reason, for example, it is unsuitable for use in a place where friction is large, such as an interior product in an automobile interior.

  As another embossed sheet manufacturing method, there is known a method of embossing the transferred transfer layer and adhesive layer at the same time as transferring the transfer layer of the transfer sheet to a flat transfer target substrate. (For example, refer to Patent Document 1). However, this conventional manufacturing method aims to obtain an embossed sheet having recesses in the transfer layer and adhesive layer transferred to the substrate to be transferred (fabric), and the recesses in the substrate to be transferred (fabric) itself. It is not intended to obtain an embossed sheet having Therefore, in the embossed sheet obtained by this conventional manufacturing method, the transfer layer is adhered to the entire surface of the substrate to be transferred, and the transfer layer is also transferred to the portion where the substrate to be transferred is exposed without adding color. The design is low. Further, since the transfer layer is transferred to the flat portion or the convex portion in addition to the concave portion, it is easily peeled off by the external friction after the transfer.

JP 2001-150884 A

  The present invention has been made in view of the above-described situation, and provides an embossed sheet that can be subjected to transfer print processing only on a concave portion of an embossed fabric to enhance designability and friction resistance, and a method for manufacturing the same. For the purpose.

The present invention is as follows.
1. The adhesive layer and the fabric of the transfer sheet having the support layer and the adhesive layer are overlapped, and the transfer sheet and the fabric are heated and pressed from the transfer sheet side by an embossed convex portion to form a recess in the fabric. A method for producing an embossed sheet, wherein a part of the adhesive layer is adhered only to the recess.
2. The adhesive layer is made of a hot melt adhesive. The manufacturing method of the embossed sheet of description.
3. The transfer sheet further includes a foil layer interposed between the support layer and the adhesive layer, and the adhesive layer and the foil layer are formed only in the concave portion when heated and pressed by the convex portion of the emboss type. 1. Adhering a part Or 2. The manufacturing method of the embossed sheet as described in 2.
4). A heating part for bonding is provided on a part of the front surface side of the embossed convex part, and the concave part is formed in the fabric by the embossed convex part at the time of heating and pressing by the embossed convex part. At the same time, the adhesive layer is melted by the adhesive heating section to adhere the adhesive layer having substantially the same shape as the adhesive heating section to a part of the bottom surface of the recess. To 3. The manufacturing method of the embossed sheet as described in any one of these.
5). 1. Only the embossed convex portion is brought into contact with the transfer sheet at the time of heating and pressing by the embossed convex portion. To 4. The manufacturing method of the embossed sheet as described in any one of these.
6). An embossed sheet having a recess in the fabric,
An embossed sheet, wherein a part of the adhesive layer transferred from a transfer sheet having a support layer and an adhesive layer is adhered only to the concave portion.
7). 5. The adhesive layer is bonded to a part of the bottom surface of the recess. The embossed sheet described.

According to the embossed sheet manufacturing method of the present invention, the concave portion of the transfer sheet is formed only by forming the concave portion in the fabric and heating the embossed convex portion by pressing the embossed convex portion. Only the transfer printing process can be performed. As a result, the design can be improved and the sheet life can be extended by improving the friction resistance as compared with the sheet having the transfer printing process applied to the flat portion or the convex portion of the cloth as in the prior art. it can.
Moreover, when the said adhesive layer consists of a hot-melt-adhesive agent, an adhesive layer can be fuse | melted by the heat press of an embossing type convex part, and an adhesive layer can be more reliably adhere | attached only on the recessed part of cloth | dough. In particular, when an adhesive layer made of a hot melt adhesive is formed on a transfer sheet in a pre-process different from embossing, blocking during winding of the transfer sheet on which the adhesive layer is formed can be suppressed.
In addition, when the transfer sheet further includes a foil layer interposed between the support layer and the adhesive layer, the adhesive layer of the transfer sheet and only the concave portion when heated and pressed by the embossed convex portion A part of the foil layer can be adhered. Therefore, foil transfer printing can be performed only on the concave portion of the fabric.
In addition, when a bonding heating part is provided on a part of the tip surface side of the embossed convex part, a concave part is formed in the fabric with the embossed convex part, and an adhesive layer is formed by the bonding heating part. It is possible to melt and bond an adhesive layer having substantially the same shape as the bonding heating section to a part of the bottom surface of the recess. Therefore, the adhesive layer bonded to the recess can be an adhesive layer having a smaller planar area than the bottom surface of the recess, and the design can be further improved. In particular, when the adhesive layer bonded to the concave portion is an outer peripheral shape adhesive layer different from the outer peripheral shape of the bottom surface of the concave portion, the design property can be extremely enhanced.
Furthermore, when only the embossed convex part is brought into contact with the transfer sheet during the heating and pressing by the embossed convex part, the portions other than the embossed convex part do not come into contact with the transfer sheet. The heat of the embossed convex portion is hardly transmitted to the outer peripheral side, and the adhesive layer can be more reliably prevented from being transferred to a portion other than the concave portion.

According to the embossed sheet of the present invention, since a part of the adhesive layer transferred from the transfer sheet is adhered only to the concave portion, compared with a sheet in which transfer printing processing is applied to the flat portion or convex portion of the cloth as in the past. Thus, the design can be improved, and the friction resistance can be improved to extend the life of the sheet.
Further, when the adhesive layer is bonded to a part of the bottom surface of the concave portion, the adhesive layer bonded to the concave portion can be an adhesive layer having a smaller planar area than the bottom surface of the concave portion, It can be further increased. In particular, when the adhesive layer to be bonded to the concave portion is an adhesive layer having an outer peripheral shape different from the outer peripheral shape of the bottom surface of the concave portion, the design property can be extremely enhanced.

1. Embossed sheet manufacturing method Embodiment 1 The embossed sheet manufacturing method according to the present invention includes superposing the adhesive layer and the fabric of a transfer sheet having a support layer and an adhesive layer, and heating and pressing the transfer sheet and the fabric from the transfer sheet side by an embossed convex portion. In addition, a concave portion is formed in the fabric, and a part of the adhesive layer is adhered only to the concave portion.

  The “transfer sheet” is not particularly limited in its structure, size, shape, material, and the like as long as it can be deformed by heating and pressing the embossed convex portions during embossing. As this transfer sheet, for example, (1) a form having a support layer 12 and an adhesive layer 4 and a foil layer 13 interposed between these layers 12 and 4 (see FIG. 3), (2) a support layer 42 and an adhesive layer 34, and a foil layer is not interposed between these layers 42 and 34 (see FIG. 7).

  The structure, size, shape, material, quantity, etc. of the support layer constituting the transfer sheet of the above (1) form are not particularly limited as long as the support layer supports the foil layer and the adhesive layer. This support layer is usually formed in a film shape. This support layer includes polyethylene terephthalate, polybutylene terephthalate, ethylene-terephthalate-isophthalate copolymer, thermoplastic polyester resin such as polyester-based thermoplastic elastomer, polypropylene, polyethylene, polymethylpentene, ethylene-propylene copolymer, Resins such as ethylene-propylene-butene terpolymers, polyolefin resins such as olefinic thermoplastic elastomers, vinyl chloride resins, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, acrylic resins, polyamide resins, etc. A single layer or laminated body made of film (sheet), coated paper obtained by laminating a release layer of polyolefin resin or silicon resin on fine paper, thin paper, etc., paper such as glassine paper, sulfuric acid paper, or the like is used. The thickness of this support layer can be, for example, 5 to 100 μm (preferably 10 to 50 μm).

  In order to improve the peelability from the foil layer on the foil layer side, a release layer may be provided as a constituent element of the support layer, if necessary, in the support layer constituting the transfer sheet of the above (1) form. As this release layer, for example, a simple substance such as a silicon resin, a melamine resin, a polyamide resin, a urethane resin, a polyolefin resin, a wax, or a mixture containing these is used. Specifically, for example, those obtained by adding p-toluenesulfonic acid to a mixed resin of a polyester resin and a melamine resin are preferable. Moreover, you may perform a corona discharge process, an ozone process, etc. to the surface at the side of the foil layer of a support layer for adjustment of peelability.

The structure, size, shape, material, quantity, etc. of the adhesive layer constituting the transfer sheet of the form (1) are not particularly limited as long as it adheres to the cloth. The adhesive layer can be made of, for example, a hot melt adhesive that melts by heat. As the hot melt adhesive, a curable resin can be used as long as it exhibits thermoplasticity before curing, but a thermoplastic resin is usually used. Examples of the thermoplastic resin include polyamide resin (nylon, etc.), polyester resin, vinyl resin (hydrophobized polyvinyl alcohol resin, etc., particularly vinylon), polyolefin resin (polyethylene resin, polypropylene resin, polybutadiene resin, etc.) and the like. These may use only 1 type and may use 2 or more types together. The basis weight of this hot melt adhesive can be, for example, 1 to 10 g / m ² (preferably 1 to 5 g / m ² ). The thickness of the hot melt adhesive can be, for example, 1 to 50 μm (preferably 1 to 25 μm). Examples of the method for applying the adhesive layer include roll coating, spray coating, curtain flow coating, gravure coating, comma coating, silk screen printing, and the like.
In addition, the said adhesive layer can be used as the layer which contains colorants, such as a pigment, dye, and metal powder, in a resin, or can be made into a colorless and transparent layer, without containing a colorant in resin.

  The structure, size, shape, material, quantity, etc. of the foil layer constituting the transfer sheet in the form (1) are not particularly limited as long as the fabric is colored. This foil layer can have, for example, a colored layer and a metal layer. This colored layer is on the support layer side, for example, a layer containing a colorant such as a pigment, dye or metal powder in the resin, or a colorless and transparent layer without containing a colorant in the resin. be able to. As this metal layer, for example, a metal thin film layer formed of a metal such as aluminum, chromium, gold, silver or the like using a known vapor deposition method can be exemplified. The thickness of this foil can be, for example, 0.05 to 3 μm (preferably 0.06 to 2 μm).

  If necessary, the foil layer can be provided with a release layer in contact with the support layer. This release layer is used to adjust the peelability between the support layer and the foil layer, and to protect the surface of the foil layer after transfer, so that the surface protection layer is coated on the foil layer after transfer. Provided for improvement. For the release layer, for example, an acrylic resin, a vinyl chloride-vinyl acetate copolymer, a polyester resin, a cellulose resin, a urethane resin, or the like, or a mixture containing these is used. This release layer is formed by a conventionally known printing method or a coating method such as roll coating. In addition, this peeling layer is one component of the foil layer, and is transferred to the fabric side as a part of the foil layer at the time of transfer to cover the surface of the foil layer.

  In addition, when using the transfer sheet of the form (1), the adhesive layer 4 and the foil layer that are not heated and pressed by the embossed convex portions together with the support layer 12 by peeling the support layer 12 from the fabric 18 after embossing. A part of 13 is peeled off from the cloth 18, and the embossed sheet 1 in which a part of the adhesive layer 4 and the foil layer 13 of the transfer sheet is transferred only to the concave part 19 is obtained (see FIG. 5).

  The structure, size, shape, material, quantity, etc. of the support layer constituting the transfer sheet of the form (2) are not particularly limited as long as it supports the adhesive layer. As this support layer, for example, a layer to which the structure of the support layer of the transfer sheet of the above (1) form is applied can be mentioned. If necessary, this support layer may be provided with a release layer as a component of the support layer in order to improve the peelability from the adhesive layer on the adhesive layer side. Examples of the release layer include those to which the configuration of the release layer described in the above (1) mode is applied.

  The structure, size, shape, material, quantity, etc. of the adhesive layer constituting the transfer sheet in the form (2) are not particularly limited as long as it adheres to the cloth. As this adhesive layer, for example, a layer to which the configuration of the adhesive layer of the transfer sheet of the above (1) form is applied can be mentioned.

  When the transfer sheet having the form (2) is used, a part of the adhesive layer 34 that is not heated and pressed by the embossed convex portions together with the support layer 42 by peeling the support layer 42 from the fabric 18 after embossing. Is peeled off from the fabric 18, and the embossed sheet 31 having the adhesive layer 34 of the transfer sheet 33 transferred only to the recess 19 is obtained (see FIG. 9).

  The “fabric” is not particularly limited in its structure, size, shape, material, and the like as long as the concave portion is formed by heating and pressing the embossed convex portion. This fabric may be a non-flexible sheet, but is usually a flexible sheet. As this flexible sheet, for example, various sheet materials such as non-woven fabric such as polyethylene terephthalate, woven fabric, knitted fabric, urethane sheet, adhesive laminate, leather and the like can be applied regardless of the presence or absence of raising. The thickness of the fabric can be, for example, 0.5 to 15 mm (preferably 1 to 3 mm). Although it does not specifically limit as a use of this fabric, For example, it can utilize for a chair, a ceiling, a sun visor, an instrument panel etc. as a vehicle interior material.

  The “embossing type” is not particularly limited in its structure, size, shape, material, quantity, etc., as long as it heats and presses the transfer sheet and the fabric. Examples of the embossing type include a roll type and a flat type. The embossed convex part is heated by a heating part such as an internal or external heater. The heating temperature is appropriately selected depending on the material and thickness of the adhesive layer, the thickness of the transfer sheet, the depth of the concave portion of the cloth, and the like, but can be 120 to 220 ° C. (preferably 150 to 210 ° C.). .

  Here, for example, an adhesive heating portion can be provided on a part of the embossed convex portion on the tip surface side (see FIGS. 10 and 11). Thereby, at the time of heat-pressing by the embossing type convex part, the concave part is formed on the cloth on the entire front end surface of the embossing type convex part, and the adhesive layer is partially melted by the heating part for bonding, and the bottom surface of the concave part is formed. An adhesive layer having substantially the same planar shape as the bonding heating section can be bonded to a part. In this case, on the tip surface side of the embossed convex part, an adhesive heating part may be provided at a part thereof, and an insulating part such as a heat insulating material or a cooling water passage may be provided so as to surround the adhesive heating part. Preferred (see FIGS. 10 and 11). This is because the heat transfer of the adhesion heating unit to the outer peripheral side of the bottom surface of the recess can be more reliably suppressed.

  Here, for example, at the time of heating and pressing by the embossed convex portion, only the embossed convex portion can be brought into contact with the transfer sheet, and portions other than the embossed convex portion can be prevented from coming into contact with the transfer sheet. Thereby, it is difficult for embossed heat to be transmitted to the outer peripheral side of the concave portion of the fabric, and it is possible to more reliably prevent the adhesive layer from being transferred to a portion other than the concave portion. In this case, the height H of the embossed convex portion is usually larger than the sum of the gap S between the root end of the convex portion and the surface of the fabric during embossing and the depth D of the concave portion of the fabric. The value is set (see FIG. 5). The height H of this convex part can be 0.5 mm or more (preferably 1 mm or more), for example. The gap S can be, for example, 0.1 mm or more (preferably 0.2 mm or more). The depth D of this recessed part can be 0.4 mm or more (preferably 0.8 mm or more), for example.

  The first embodiment. In the embossed sheet manufacturing method, since the adhesive layer and / or the foil layer is adhered only to the concave portion of the fabric during embossing, the adhesive layer and / or the foil layer is adhered to the concave portion and flat portion of the fabric during embossing. Compared with the method of scraping the adhesive layer and / or the foil layer of the flat portion of the fabric by sanding or the like, the number of steps can be reduced and the productivity can be increased.

2. Embossed sheet Embodiment 2 The embossed sheet according to the present invention is an embossed sheet having a concave portion in the cloth, and a part of the adhesive layer transferred from the transfer sheet having the support layer and the adhesive layer is adhered only to the concave portion.
Here, for example, an adhesive layer may be bonded to a part of the bottom surface of the recess.

  In the second embodiment. As the configuration of each component of the embossed sheet, for example, the above-described embodiment 1. The configuration of each component described in the method for manufacturing an embossed sheet can be applied. Further, in the second embodiment. The embossed sheet is, for example, the above-described embodiment 1. It can be manufactured by the method for manufacturing an embossed sheet.

  Hereinafter, the present invention will be described in detail with reference to the first and second embodiments with reference to the drawings.

Example 1
(1) Embossed sheet manufacturing method In the embossed sheet manufacturing method according to the first embodiment, as shown in FIG. 1, first, the gravure coating apparatus 2 is used to form the adhesive layer 4 on the foil transfer sheet 3. The gravure coating apparatus 2 includes a supply roll 5 for supplying a foil transfer sheet 3, a gravure roll 6 (intaglio roll), a pressing roll 7 facing the roll, and a hot melt adhesive in which a part of the gravure roll 6 is immersed. 4a (hereinafter simply abbreviated as "adhesive 4a"), a doctor 9 for scraping off the adhesive 4a of the gravure roll 6, a drying chamber 10, and a take-up roll 11 are provided. The adhesive 4a is made of polyester resin or nylon resin.

As shown in FIG. 2, the foil transfer sheet 3 is made of polyester and has a support film 12 having a thickness of about 20 μm (exemplified as a “support layer” according to the present invention), a release layer 12a made of silicon, And a foil layer 13 having a thickness of about 1 μm composed of a colored layer 13a and an aluminum vapor-deposited layer 13b. The foil transfer sheet 3 supplied from the supply roll 5 passes between the rolls 6 and 7 with the foil layer 13 side being the gravure roll 6 side. At that time, an adhesive 4a having a basis weight of about 1.5 g / m ² is applied to the foil layer 13 side of the foil transfer sheet 3 by the gravure roll 6. Next, the foil transfer sheet 3 is conveyed to the drying chamber 10, and the adhesive 4a is dried and solidified. Therefore, the adhesive layer 4 with a thickness of about 2.5 μm is formed on the foil layer 13 side of the foil transfer sheet 3 (see FIG. 3). Next, the foil transfer sheet 3 is taken up by the take-up roll 11.
In addition, the “transfer sheet” according to the present invention is constituted by a sheet formed by forming the adhesive layer 4 on the foil transfer sheet 3 of the above embodiment.

  Next, as shown in FIG. 4, an embossing machine 14 is used to emboss a fabric 18 having a thickness of about 1.5 mm made of a polyethylene terephthalate nonwoven fabric to be processed. The embossing machine 14 includes a roll-shaped embossing die 15 and a bottom roller 16 facing the embossing die 15. In this embossing die 15, at least the entire tip surface side of the convex portion 17 is heated to about 200 ° C. As shown in FIG. 5, the height H of the convex portion 17 is about 1.2 mm. Further, the depth D of the concave portion 19 of the fabric 18 is about 1 mm. Further, the gap S between the root end of the convex portion 17 and the surface of the fabric 18 during embossing is about 0.2 mm. Therefore, at the time of heating and pressing by the convex portion 17 of the embossing die 15, only the convex portion 17 is in contact with the foil transfer sheet 3, and portions other than the convex portion 17 are not in contact with the foil transfer sheet 3.

  Then, the adhesive layer 4 side of the foil transfer sheet 3 and the cloth 18 are overlapped and passed between the rollers 15 and 16. Thereby, the foil transfer sheet 3 and the cloth 18 are heated and pressed from the side of the foil transfer sheet 3 by the convex portion 17 of the embossing die 15. As a result, a recess 19 is formed in the fabric 18 and a part of the adhesive layer 4 located on the bottom surface of the recess 19 is melted so that only part of the adhesive layer 4 and the foil layer 13 remains in the recess 19. Bonded (see FIG. 5).

  Thereafter, when the foil transfer sheet 3 that has passed between the rollers 15 and 16 is peeled off from the fabric 18, the adhesive layer 4 adhered to the bottom surface of the concave portion 19 and the adhesive layer 4 other than the foil layer 13 as shown in FIG. And the foil layer 13 will be in the state which remained in the foil transfer sheet 3, and the embossed sheet 1 with which the adhesive layer 4 and the foil layer 13 were adhere | attached only on the bottom face of the recessed part 19 will be obtained.

(2) Effect of Example According to the method for manufacturing the embossed sheet 1 of the present example, the concave portion 19 is formed in the fabric 18 by the heat pressing of the convex portion 17 of the embossing mold 15 and the adhesive layer 4 is partially formed. Since a part of the adhesive layer 4 and the foil layer 13 is bonded only to the concave portion 19 by melting, the foil transfer printing process can be performed only on the concave portion 19 of the fabric 18. As a result, it is possible to improve the design and improve the life of the embossed sheet 1 as compared with conventional embossed sheets that have been subjected to foil transfer printing on the flat and convex portions of the fabric. Can be achieved.

  In this embodiment, since the adhesive layer 4 is formed from the hot melt adhesive 4a, the adhesive layer 4 is partially melted by heating and pressing the convex portion 17 of the embossing die 15 and adhered only to the concave portion 19 of the fabric 18. The layer 4 and the foil layer 13 can be adhered more reliably. In particular, when the adhesive layer 4 made of the hot melt adhesive 4a is formed on the foil transfer sheet 3 in a pre-process different from the embossing as in this embodiment, the foil transfer sheet 3 on which the adhesive layer 4 is formed is formed. Blocking during winding can be suppressed.

  Furthermore, in this embodiment, only the convex portion 17 of the embossing die 15 is brought into contact with the foil transfer sheet 3 at the time of heating and pressing by the convex portion 17 of the embossing die 15. Is not in contact with the foil transfer sheet 3, and the heat of the convex portion 17 of the embossing mold 15 is not easily transmitted to the outer peripheral side of the concave portion 19 of the fabric 18, and the adhesive layer 4 and the foil layer 13 are transferred to a portion other than the concave portion 19. This can be prevented more reliably.

(Example 2)
(1) Embossed sheet manufacturing method In the embossed sheet manufacturing method according to the second embodiment, a transfer sheet 33 shown in FIG. 7 is used. The transfer sheet 33 is made of polyester and has a support film 42 having a thickness of about 25 μm (exemplified as a “support layer” according to the present invention), a release layer 42 a made of silicon, and an adhesive layer having a thickness of about 50 μm. 34 are laminated. The adhesive layer 34 is made of a hot melt adhesive made of polyester resin or nylon resin containing a colorant such as a pigment.

  Next, as shown in FIG. 8, the adhesive layer 34 side of the transfer sheet 33 and the cloth 18 are passed through between the rollers 15 and 16 of the embossing machine 14 described in the first embodiment. Thereby, the transfer sheet 33 and the fabric 18 are heated and pressed from the transfer sheet 33 side by the convex portion 17 of the embossing die 15. Then, a concave portion 19 is formed in the cloth 18, and a portion of the adhesive layer 34 located on the bottom surface of the concave portion 19 is melted and bonded so that only a portion of the adhesive layer 34 remains in the concave portion 19 ( (See FIG. 9).

  Thereafter, when the transfer sheet 33 that has passed between the rollers 15 and 16 is peeled off from the fabric 18, the adhesive layer 34 other than the adhesive layer 34 adhered to the bottom surface of the recess 19 is applied to the transfer sheet 33 as shown in FIG. 9. The embossed sheet 31 with the adhesive layer 34 bonded to only the bottom surface of the recess 19 is obtained.

(2) Effects of the Example According to the method for manufacturing the embossed sheet 31 of the present example, in addition to the effects and effects substantially the same as those of the method for manufacturing the embossed sheet 1 of Example 1, the convexity of the embossed mold 15 is achieved. Since the concave portion 19 is formed in the fabric 18 by the heat pressing of the portion 17 and the adhesive layer 34 is partially melted so that the adhesive layer 34 containing a colorant such as a pigment is adhered only to the concave portion 19. Only 18 recesses 19 can be transferred and printed. As a result, it is possible to improve the design and improve the life of the embossed sheet 31 as compared with the embossed sheet that has been subjected to foil transfer printing on the flat and convex portions of the fabric as in the past. Can be achieved.

  In the present invention, the present invention is not limited to the first and second embodiments, and various modifications can be made within the scope of the present invention depending on the purpose and application. That is, in the first and second embodiments, the entire front end surface side of the convex portion 17 of the embossing mold 15 is heated to transfer the adhesive layer 4 and the foil layer 13 (adhesive layer 34) to the entire bottom surface of the concave portion 19. However, the present invention is not limited to this. For example, as shown in FIG. 10 or FIG. 11, the adhesive layer 4 (adhesive layer 34) is heated at a higher temperature than the other part at a part of the tip surface side of the embossed convex portion 17. You may make it provide the heating part 20 for adhesion | attachment, such as a heater which can be fuse | melted. Thereby, the adhesive layer 4 and the foil layer 13 (adhesive layer 34) adhered to the concave portion 19 of the fabric 18 are used as the adhesive layer 4 and the foil layer 13 (adhesive layer 34) having a planar area smaller than the bottom surface of the concave portion 19. Can be further improved in design. In this case, as shown in FIG. 12 (a), the outer peripheral shape of the adhesive layer 4 ′ and the foil layer 13 ′ (adhesive layer 34 ′) are different from the outer peripheral shape of the bottom surface of the recess 19, or as shown in FIG. 12 (b). Thus, the adhesive layer 4 ″ and the foil layer 13 ″ (adhesive layer 43 ″) having substantially the same outer peripheral shape as the outer peripheral shape of the bottom surface of the recess 19 can be obtained.

  In the case of the above-described embodiment, as shown in FIG. 10 or FIG. 11, the bonding heating unit 20 is provided on a part of the tip surface side of the convex portion 17 of the embossing mold 15, and the bonding heating unit 20 is provided. It is preferable to provide a heat insulating portion 22 such as a heat insulating material or a cooling water passage so as to surround the space. This is because heat transfer of the adhesion heating unit 20 to the outer peripheral side of the bottom surface of the recess 19 of the dough 18 can be more reliably suppressed. FIG. 10 shows a convex portion 17 in which the bonding heating portion 20 protrudes from another portion, and FIG. 11 shows a convex portion in which the bonding heating portion 20 is at the same height level as the other portion. 17 is shown.

  Moreover, in the said Example 1, although the process which forms the contact bonding layer 4 in the foil transfer sheet 3 as a pre-process different from embossing was illustrated, it is not limited to this, For example, foil transfer sheet is the same process as embossing. 3, the adhesive layer 4 may be formed. For example, the adhesive layer 4 may be formed by applying the adhesive 4a to the foil transfer sheet 3 before being supplied between the rolls 15 and 16 by the embossing machine 14 and drying and solidifying it.

  In the first and second embodiments, the bottom shape of the concave portion 19 of the fabric 18 (that is, the tip shape of the convex portion 17 of the embossing die 15) is exemplified as a circular shape, but is not limited thereto. The bottom surface shape of the recess 19 may be an ellipse, a polygon, an irregular shape, or the like.

  Moreover, in the said Example 1, although the adhesive agent 4 is apply | coated to the foil transfer sheet 3 using the gravure coating apparatus 2, it is not limited to this, Another method may be sufficient.

  Moreover, in the said Example 1 and 2, although the embossing type | mold 15 is made into the roller shape, it is not limited to this, For example, a plate-like embossing type may be sufficient.

  Further, in Examples 1 and 2, the support film 12 is peeled off during embossing. However, the present invention is not limited to this. For example, an intermediate product that is left without peeling off the support film 12 is intermediate. You may make it handle as a product and peel the support body film 12 at the time of use of this intermediate product.

  Furthermore, in Example 2 described above, a layer containing a colorant such as a pigment is exemplified as the adhesive layer 34 adhered to the concave portion of the fabric. However, the layer is not limited to this, and for example, it contains no colorant such as a pigment and is colorless. A transparent adhesive layer 34 may be used. In this case, the design is enhanced by the difference in texture between the colorless and transparent adhesive layer 34 bonded to the recess 19 of the fabric 18 and the flat portion of the fabric 18.

  It is widely used as a technique related to an embossed sheet in which transfer printing is performed only on the concave portion. In particular, it is suitably used as a technique related to an embossed sheet for vehicle interior materials such as automobiles.

It is the schematic which shows the process of forming an adhesive layer in the foil transfer sheet which concerns on the present Example 1. FIG. It is a longitudinal cross-sectional view which shows the foil transfer sheet before formation of an adhesive layer. It is a longitudinal cross-sectional view which shows the foil transfer sheet after formation of an contact bonding layer. It is the schematic which shows the process of manufacturing the embossed sheet which concerns on the present Example 1. FIG. It is a principal part enlarged view of FIG. It is an enlarged view of the VI arrow part of FIG. FIG. 6 is a schematic diagram illustrating a transfer sheet according to the second embodiment. It is the schematic which shows the process of manufacturing the embossed sheet which concerns on the present Example 2. FIG. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating another emboss type convex part. It is explanatory drawing for demonstrating another emboss type convex part. It is explanatory drawing for demonstrating another transfer form, (a) shows the outer periphery shape adhesive layer and / or foil layer which are different from the outer periphery shape of the bottom face of a recessed part, (b) is the outer periphery shape of the bottom face of a recessed part. The adhesion layer and / or foil layer of the substantially same outer periphery shape are shown. It is the schematic which shows the process of manufacturing the conventional embossing sheet. It is the schematic which shows the process of the conventional foil transfer printing process.

Explanation of symbols

  1, 31; Embossed sheet, 3; Foil transfer sheet, 33; Transfer sheet, 4, 34; Adhesive layer, 4a; Hot melt adhesive, 12, 42; Support film, 13, 13 ′, 13 ″; 15; Embossing type, 17; Convex part, 18; Dough, 19; Concave part, 20; Heating part for adhesion.

Claims (7)

  The adhesive layer and the fabric of the transfer sheet having the support layer and the adhesive layer are overlapped, and the transfer sheet and the fabric are heated and pressed from the transfer sheet side by an embossed convex portion to form a recess in the fabric. A method for producing an embossed sheet, wherein a part of the adhesive layer is adhered only to the recess.   The method for producing an embossed sheet according to claim 1, wherein the adhesive layer comprises a hot melt adhesive.   The transfer sheet further includes a foil layer interposed between the support layer and the adhesive layer, and the adhesive layer and the foil layer are formed only in the concave portion when heated and pressed by the convex portion of the emboss type. The method for producing an embossed sheet according to claim 1 or 2, wherein a part thereof is adhered.   A heating part for bonding is provided on a part of the front surface side of the embossed convex part, and the concave part is formed in the fabric by the embossed convex part at the time of heating and pressing by the embossed convex part. The adhesive layer is melted by the bonding heating section, and the adhesive layer having substantially the same shape as the bonding heating section is bonded to a part of the bottom surface of the concave portion. The manufacturing method of the embossed sheet as described in 2.   The method for producing an embossed sheet according to any one of claims 1 to 4, wherein only the embossed convex portion is brought into contact with the transfer sheet at the time of heating and pressing by the embossed convex portion. An embossed sheet having a recess in the fabric,
An embossed sheet, wherein a part of the adhesive layer transferred from a transfer sheet having a support layer and an adhesive layer is adhered only to the concave portion.   The embossed sheet according to claim 6, wherein the adhesive layer is bonded to a part of the bottom surface of the recess.

Images