JP3235018B2 - Curved surface transfer method and curved surface transfer device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material for exterior and interior materials of a house, furniture, home electric appliances and the like, and more particularly to a method and an apparatus for producing a decorative material having a decorative uneven surface.

[0002]

2. Description of the Related Art Conventionally, decorative materials in which a decoration such as a picture is decorated on a base material surface of a decorative material by a direct printing method, a laminating method, a transfer method or the like have been used for various purposes. In this case, if the surface of the base material is flat, the decoration of the picture can be easily made, but the decoration of the pattern is applied to the uneven surface by a special device. For example, in the case of a columnar shape such as a window frame or a surface border material, the base material decorative surface is a two-dimensional unevenness (a shape having a curvature only in one direction (a direction perpendicular to the generating line or the height direction) like a cylinder). One applicable curved surface decoration technique is proposed in Japanese Patent Publication No. 61-5895. That is, the technology of the publication is a surface decoration method by a laminating method, in which a surface-coated sheet coated with an adhesive on one side is supplied, while the base material is horizontally conveyed at a speed synchronized with a supply speed of the surface-mounted sheet, and is installed side by side. While maintaining the state in which the end of the facing sheet is not adhered by the large number of holding jigs, the adhesive-applied surface side of the facing sheet is gradually pressed against the base material for each small area, and the It is to be adhered by heating to the material surface. This method is called a lapping method. Japanese Patent Application Laid-Open No. 5-139097 proposes a curved surface decoration technique applicable to the case where the surface unevenness is a three-dimensional unevenness such as an embossed shape (that is, a shape having a curvature in two directions like a hemisphere). Have been. That is, the technology of the same publication is a surface decoration method by a transfer method, a thermoplastic resin film is used as a support of a transfer sheet, and a release layer, a pattern layer, and an adhesive layer are sequentially provided on the support. A decorative material is obtained by placing a transfer sheet on a substrate having an uneven surface and pressing the back surface of the support with a rubber heat roller having a rubber hardness of 60 ° or less to transfer a picture. Further, a foamed layer which foams by heat during transfer is provided between the support and the release layer, and the foaming is also utilized to follow the uneven surface of the substrate.

[0003]

However, in the above-described conventional method, the technique disclosed in Japanese Patent Publication No. 61-5895 can only handle a two-dimensional curved surface. Although the technology proposed in Japanese Patent Application Publication No. H08-27139 can handle three-dimensional curved surfaces, it basically uses elastic deformation of the rotating heat roller by rubber to follow the surface irregularities. Not applicable to irregularities. In addition, the soft rubber roller is severely worn due to the corners of the irregularities of the transfer substrate. Further, in a configuration in which a foam layer is provided on the transfer sheet, the transfer sheet becomes too complicated and expensive. In addition, it is limited to a flat substrate as a whole. Furthermore, in the above-mentioned conventional technology, a heating roller is used, and when the heating roller is separated from the base material, the pressure is instantaneously lost. However, heat cannot be removed suddenly due to restrictions on heat capacity and thermal conductivity. For this reason, there has been a problem that the transfer sheet is released from the pressing of the heating roller without necessarily cooling the heat-sensitive adhesive sufficiently, so that the transfer sheet is lifted from the surface of the base material, resulting in a transfer failure in the concave portion.

[0004]

In order to solve the above problems, a curved surface transfer method and a curved surface transfer apparatus according to the present invention are:
As a means for pressing the transfer sheet comprising the support and the transfer layer against the uneven surface of the transfer substrate having the uneven surface, the transfer sheet is supported in a state in which the transfer layer side of the transfer sheet faces the transfer substrate. A large number of solid particles accelerated and ejected by a rotating impeller collide with the body side, and the collision pressure is used to form the transfer sheet so as to follow the surface shape of the substrate to be transferred. . The acceleration of the solid particles by the impeller has a plurality of blades outside the hollow portion at the center of rotation, and the solid particles are supplied to the hollow portion. To accelerate. Then, after the transfer sheet is pressed against and adhered to the surface of the substrate to be transferred by the collision pressure, the support of the transfer sheet is peeled off, and a decorative material having the transfer layer adhered to the uneven surface of the substrate to be transferred is obtained. Further, the curved surface transfer device of the present invention has a plurality of blades outside the hollow portion of the center of rotation as an apparatus for performing at least before peeling and removal of the support among the above, and solid particles are in the hollow portion. Equipped with a jetting means for jetting accelerated solid particles by a supplied particle accelerator consisting of a rotating impeller, the collision pressure of the solid particles jetted from the jetting means is applied to the transfer sheet, and the transfer sheet is transferred. Pressing means for pressing against the base material, at least the base material conveying means for conveying the transferred base material to a position facing the jetting means, and a transfer sheet, at least the jetting means and the transferred base material; And a sheet conveying means for supplying the sheet to the gap.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The curved surface transfer method and apparatus of the present invention will be described below in detail with reference to the drawings. First, FIG. 1 is a conceptual diagram of one embodiment of the curved surface transfer method and apparatus of the present invention.
FIG. 2 is a schematic device view as viewed from a side surface in a substrate transport direction, and FIG. 2B is a schematic device diagram as viewed from a substrate transport direction of an ejector portion which is an ejection unit of the device of FIG. FIG. 2 is an explanatory view showing an example of the shape of an impeller as a particle accelerator, and a state in which solid particles are accelerated by the impeller and a transfer sheet is pressed against a substrate to be transferred. FIG. 3 is a perspective view of the impeller of FIG.
(A) and FIG. 4 (B) are explanatory diagrams in which an impelling direction regulating means is additionally provided in the impeller.

In the present invention, the collision pressure of the solid particles is used as the pressing means for applying the transfer pressure. However, when the solid particles are actually used, it is preferable that the solid particles are not scattered around and recycled. Then, next, as an embodiment of the curved surface transfer method of the present invention, a conceptual diagram of one embodiment of the curved surface transfer device of the present invention which performs continuous transfer while preventing scattering and circulating reuse of solid particles by using a chamber. The present invention will be described in further detail with reference to FIG.

The curved surface transfer device of the present invention illustrated in FIG.
This is an apparatus for sequentially transferring a decorative layer and the like to a flat substrate to be transferred B having an uneven surface (however, the unevenness of the surface is not shown) using a long transfer sheet S. The apparatus shown in the figure is a substrate transporting device 10 for transporting a substrate B to be transferred as a substrate transporting means.
And a sheet conveying device 20 that conveys the transfer sheet S as sheet conveying means, and a jetting guide 81 that accelerates solid particles P supplied from a hopper 31 as pressing means by a particle accelerator 80 using a rotating impeller. The solid particles P ejected from the ejector 32 (ejection means) ejected from the inside of the chamber 33 collide against the support side of the transfer sheet S in the chamber 33, and the collision pressure is applied to press the transfer sheet against the substrate to be transferred. An application unit 30 is provided. Further, the apparatus shown in the figure also includes a sheet heating device 40 for the transfer sheet S and a substrate heating device 41 for the substrate B to be transferred. These heating devices also serve as a heating means for activating the adhesive force when the adhesive for bonding the transfer layer to the substrate to be transferred is a heat-sensitive adhesive. Further, the transfer-receiving substrate B
When the adhesive has a solvent component, the heating device 41 also serves as a drying device for drying the solvent. Further, a peeling roller 60 as a peeling means is provided, and a suction / exhaust device 90 as a suction / exhaust means including a suction / exhaust nozzle 91 and a vacuum pump 92 is also provided. It is a device that can be performed appropriately.

[0008] A substrate transporting device 10 as a substrate transporting means includes:
An impact pressure is applied so as to successively transport the transfer-receiving base material B, which is composed of a row of transport driving rotary rollers, and is horizontally mounted thereon, to a position where the solid particles ejected from the ejector 32 collide. After the surface of the substrate to be transferred is sequentially exposed to the collision pressure of the solid particles in the unit 30, the substrate is further discharged from the collision pressure application unit 30.
Then, the transfer base material B is further transferred to the transfer sheet S (support).
It is discharged as a decorative material D through a peeling roller 60 for peeling off. In addition, the substrate conveying means may be an endless track type conveyor belt or the like.

A sheet conveying device 20 as a sheet conveying means
Is composed of a guide roller and the like in addition to the sheet feeding device 21, the sheet supporting device 22, and the sheet discharging device 23. The sheet conveying device 20 supplies the transfer sheet S to the collision pressure applying unit 30 from a supply roll set in the sheet feeding device 21 so as to supply the transfer sheet S between the jetting device 32 and the base material B to be transferred. In the collision pressure application unit 30, the transfer sheet S and the transfer base material B may be placed in a state where no collision pressure is applied or in a state where the air between the transfer sheet S and the transfer base material B is not sucked and exhausted. The transfer sheet S is transported at the same transport speed as the substrate B to be transferred while leaving a slight gap to float. The transfer sheet S is supplied to the collision pressure applying unit 30 such that the transfer layer faces the base material B side. The gap between the transfer sheet S and the transfer base material B rotates in accordance with the transfer of the transfer sheet S while holding both ends of the transfer sheet S wider than the width of the transfer base material B from both sides. The gap between the transfer sheet S and the transfer base material B is maintained by the sheet support device 22 including a belt or the like until the transfer sheet S comes into contact with the base material B. Further, the sheet supporting device 22 prevents the solid particles from wrapping around from both ends of the transfer sheet S and flowing between the transfer sheet S and the base material B to be transferred. Further, even if the transfer sheet S is heated by the sheet heating device 40, the sheet supporting device 22 prevents the transfer sheet S from extending in the feeding direction due to its extensibility or from hanging downward. Then, the transfer sheet S (support) of the transfer sheet S adhered to the transfer base material B by the collision pressure applying unit 30 is separated from the transfer base material B by the separation roller 60, and the sheet discharge device 2
Wind up with 3. Of course, the transfer base material B of the transfer sheet S
In the case where the separation from the sheet is performed by another apparatus in another process or when the separation is performed manually, the separation roller 60 is omitted.

[0010] The collision pressure applying section 30 as a pressing means causes the solid particles P to sequentially collide with the side surface of the support of the transfer sheet S, presses the transfer sheet S against the uneven surface of the base material B to be transferred, and is formed by following. Crimp. The solid particles P after the collision are collected and reused. The collision pressure applying unit 30 includes a hopper 31 that stores and supplies solid particles, an ejector 32 that is an ejection unit configured to eject solid particles accelerated by a particle accelerator 80 using an impeller from an ejection guide 81, a chamber 33, and a drain. It comprises a tube 34, a separation device 35 for separating gas and solid particles, a vacuum pump 36 and the like. The collision pressure application unit 30 of the apparatus shown in FIG.
Is a sheet heating device 40 serving as a heating unit for the transfer sheet S.
It also has a built-in.

The jetting device 32 as jetting means is provided with at least a particle accelerator 80 using an impeller, and if necessary, as shown in FIG. 1, only a portion for jetting out and ejecting solid particles is opened. A jet guide 81 that covers the periphery of the accelerator may be provided so that the jet directions of the solid particles accelerated by the particle accelerator 80 are aligned by the jet guide 81. The shape of the opening of the ejection guide 81 is, for example, a hollow cylindrical shape, a polygonal column shape, a conical shape, a polygonal pyramid shape, a fish tail shape, or the like. The ejection guide may have a single opening, or may have an interior partitioned into a honeycomb shape. If the solid particles, the transfer sheet, or the substrate to be transferred are charged when the solid particles are conveyed and collided with the transfer sheet, the particle accelerator 80, the ejection guide 81, or the drain It is preferable that the tube 34 and the like be grounded, that a charge eliminating bar is brought into contact with the transfer sheet, or that ions having a charge for neutralizing charged charges are mixed in the airflow.

The particle accelerator 80 includes an impeller and a rotary drive source such as a motor for rotating the impeller. As the particle accelerator 80, a certain type of a centrifugal blasting device that sprays powder for sandblasting can be used. Here, an impeller 82 serving as the particle accelerator 80 used in the present invention is shown in the conceptual diagrams of FIGS. In these drawings,
The impeller 82 has a plurality of blades 83 fixed on both sides by two side plates 84, and a rotation center portion is a hollow portion 85 without the blades 83. Etc. through a transport tube. The side plate 8
A rotating shaft 87 rotatably supported by bearings 86 and rotatably driven by a rotating power source (not shown) such as an electric motor is fixed to the rotation center of 4, and the impeller 82 rotates. The rotating shaft 87 does not penetrate between the two side plates 84 having the blades 83 therebetween, and forms a space without a shaft. Then, the solid particles supplied to the hollow portion are guided to the space between the blades and come to the blade portion outside the hollow portion by the action of the rotating impeller, where they are accelerated by the rotational force of the impeller 82 and Erupts from In FIG. 3, the rotating shaft 87 is configured so as not to penetrate to the hollow portion 85 only outside the side plate 84, but in addition, a rotating shaft smaller than the diameter of the hollow portion is connected to the hollow shaft 85. A configuration may be adopted in which the inside of a hollow cylindrical rotary shaft having an opening through which solid particles pass through is formed as a hollow part (not shown). Feather 8
The shape of 3 is typically a rectangular flat plate (rectangular parallelepiped) as shown in FIGS. 2 to 4, but in addition, a curved curved plate, a propeller shape such as a screw propeller, etc. can be used.
Select according to purpose. The number of blades is usually selected from a range of 2 to 10 blades. By adjusting the shape, the number, the rotational speed, and the supply speed and supply direction of the solid particles of the impeller, the ejection direction, the ejection speed, the ejection diffusion angle, and the like of the accelerated solid particles are adjusted. Usually, the solid particles are supplied from above (directly or obliquely above) the particle accelerator. Also,
The ejection direction of the solid particles is substantially vertically downward as shown in FIGS. 2 to 4, but may be horizontal or obliquely downward (not shown). To control the ejection direction of solid particles,
And an outer periphery of the blade 83, a part of the outer periphery has an opening 88 which is open in the circumferential direction, has a hollow cylindrical shape, has the same rotation axis as the rotation axis of the impeller, and is independent of the impeller. By providing a rotatable direction controller 89, the direction can be adjusted by the direction of the opening of the direction controller. FIG. 4 (A) and FIG. 4 (B)
FIG. 4 is a conceptual diagram of the ejection direction control by the direction controller 89 (in FIGS. 4A and 4B, the direction controllers are fixed at the illustrated positions, respectively). Of course, the outer periphery of the impeller may be further covered with the ejection guide 81 except for the direction in which the solid particles are ejected. Further, by adjusting the size of the opening of the direction controller 89 in the circumferential direction and the width direction, it is possible to adjust the ejection amount of the solid particles.

The size of an impeller serving as a particle accelerator is usually about 5 to 50 cm in diameter, the width of the impeller is about 5 to 20 cm, the length of the impeller is about the diameter of the impeller, and the rotation speed of the impeller is 50 to 50. It is about 5000 [rpm]. The ejection speed of the solid particles is about 10 to 50 [m / s]. The material of the impeller of the particle accelerator 80 may be appropriately selected depending on the type of solid particles, such as ceramic or metal such as steel or titanium. Since solid particles are accelerated by contact with the impeller, when metal beads or inorganic particles are used for the solid particles, the particles are hard, and therefore, the impeller is preferably made of ceramic having good wear resistance. . When resin beads are used for the solid particles, they may be made of steel because they are softer than metal particles.

Although only one jetting device can be used depending on the area of the collision pressure application region, if the required area is large, a plurality of jetting devices are used to obtain a collision region of solid particles colliding with the transfer sheet. It is good to have the shape of. For example, a plurality of rows are arranged in a straight line in the width direction perpendicular to the feeding direction of the transfer sheet and the transfer-receiving base material to form a wide and band-shaped collision region in the width direction. Alternatively, a staggered arrangement may be used. Alternatively, the central portion is located upstream of both ends in the width direction, and the pressing of the transfer sheet by the collision pressure against the base material to be transferred starts from the central portion in the width direction and is sequentially pressed toward both ends in the width direction. May be. With this configuration, it is possible to prevent the transfer sheet from closely adhering to the transfer-receiving substrate while holding the air in the center in the width direction. In order to lengthen the collision pressure application time, it is preferable that the ejectors be arranged in two or more rows in the feed direction of the transfer sheet and the base material to be transferred.

Further, it is not necessary to make the collision pressures all uniform in the collision area. For example, there is a mountain-shaped pressure distribution in which the center portion in the width direction perpendicular to the transfer direction of the transfer sheet has the maximum collision pressure, and the collision pressure decreases toward both ends in the width direction. This setting assists the pressure contact to progress in a stepwise manner from a place where the pressure is high (the center part in the width direction) to a place where the pressure is low (the two sides of the sheet in the width direction). However, for example, in the case of a mountain-shaped pressure distribution in which the pressure is large at the center, the impact pressure on the transfer-receiving substrate is such that the transfer onto the desired uneven surface can be completely performed, and the transfer sheet is excessively pressurized. The adjustment is performed so that the pressure falls within an appropriate pressure range where distortion, deformation, breakage, and the like of the substrate to be transferred do not occur. In the curved surface transfer method using a rubber transfer roller, if the diameter of the center portion of the transfer roller is increased, the center portion can be strengthened in terms of pressure, but the circumferential length differs between the center portion and both end portions. Contact is applied and pressure is applied, so that the transfer sheet cannot be fed uniformly. The setting of the collision pressure is adjusted by controlling the speed of the solid particles colliding with the transfer sheet by controlling the rotation speed of the impeller, or by controlling the number of solid particles to be supplied per unit time and the mass of one particle. I do.

When a plurality of ejectors are arranged on the surface of the substrate to be transferred, each ejector is parallel to the substrate to be transferred, and the ejection direction of each ejector is The basic arrangement is such that it is in the normal direction. Such a parallel arrangement
This is because solid particles collide perpendicularly to the envelope surface of the transfer-receiving surface of the transfer-receiving substrate, and the collision pressure can be basically and effectively used to the maximum. Therefore, for example, if the envelope surface (the cross-sectional shape perpendicular to the transport direction) of the transfer-receiving surface of the transfer-receiving substrate is a cylindrical convex curved surface having a circular shape, a plurality of ejectors are prepared. For each collision surface (tangent plane of convex curved surface)
It is preferable to arrange the ejector so that the direction of the ejector is normal to the adjacent envelope surface of the surface of the substrate to be transferred so that the solid particles collide substantially vertically. In this way, it is preferable to arrange the ejector in such a manner that the ejecting direction of the ejector is such that the solid particles collide as perpendicularly as possible according to the uneven shape of the target substrate to be transferred. However, the direction of the ejector need not necessarily be perpendicular to the side surface of the transfer sheet support. Further, a large number of ejectors may be provided, and some ejectors may be stopped depending on a substrate to be transferred.

The chamber 33 is provided with a transfer base material B and a transfer base material B, which are provided for transfer, except for the entrance of the transfer sheet S and the transfer base material B so that the solid particles P jetted from the jetting device 32 do not leak outside. The sheet S covers the periphery of the ejector 32. The solid particles P that have collided with the transfer sheet S
3, the drain pipe 34 is sucked by the vacuum pump 36 and transported there, separated from the gas by the separator 35, collected in the original hopper 31, and stored for reuse.

The sheet heating device 40 includes an impact pressure applying unit 30
The transfer sheet S is supplied to the inside of the chamber 33, and is placed in the space on the transfer sheet support side from immediately after both ends of the transfer sheet S are sandwiched by the sheet support device 22 to immediately before the application of the collision pressure. The heating means of the sheet heating device 40 includes an electric heater, an infrared heater, hot air, induction heating,
Heating means such as dielectric heating is used. Sheet heating device 40
Preheats the transfer sheet S, and also indirectly preheats the base material B to be transferred to some extent through the transfer sheet S. In addition, the adhesive applied to the transfer sheet or the base material to be transferred is also heated. Note that the sheet heating device 40 does not require preheating of the transfer sheet S, and may be omitted when the adhesive is heated by another heating method such as heating of the substrate to be transferred or heating of solid particles.

The apparatus shown in FIG. 1 further includes a substrate coating device 50 and a substrate heating device 41 (also a drying device) in this order from the upstream side of the collision pressure applying section 30. The same heating means as that of the sheet heating device 40 can be used. The base material coating device 50 performs coating of an adhesive and undercoating on the base material B to be transferred. When the adhesive is applied to the substrate B to be transferred, the substrate heating device 41 also serves as a heating unit for the adhesive. The substrate heating device 41 heats the substrate B to be transferred, and when it is necessary to dry a volatile component such as a solvent by applying an adhesive solution and drying a volatile component such as a solvent, May also be used as a drying device. Do not apply an adhesive to the substrate to be transferred during transfer,
When the undercoating is not performed, the substrate coating device 50 can be omitted. The substrate heating device 41 can also be omitted when the transfer substrate does not need to be heated and does not need to be dried. When performing both adhesive coating and undercoating, illustration is omitted,
If another substrate coating device and a drying device (not shown) are provided on the further upstream side of the substrate coating device 50, a continuous processing device can be obtained. The undercoating is performed for the purpose of coloring the substrate to be transferred prior to the transfer, a primer treatment for easy adhesion, a sealing treatment and the like.

Next, the curved surface transfer method of the present invention in the case of the apparatus described above will be further described.

First, the plate-shaped substrate to be transferred B is transported one by one by the substrate transporting device 10 and coated with an adhesive by the substrate coating device 50. When the adhesive has a solvent component, the substrate and the adhesive are heated by the substrate heating device 41, and the evaporated components are evaporated and dried. Note that a plurality of the base material coating devices 50 and the base material heating devices 41 may be connected to each other to continuously perform the undercoating or the sealer coating before the undercoating before the adhesive is applied.
Then, the transfer target substrate B is transported and supplied into the chamber 33 of the collision pressure applying unit 30.

On the other hand, the transfer sheet S
The tension is applied by 0, and the transfer sheet S is unwound from the supply roll set in the sheet feeding device 21 and enters the chamber 33 of the collision pressure applying unit 30 via the guide roller. When an adhesive is applied to the transfer sheet at the time of transfer, the adhesive is applied by an adhesive application device while the transfer sheet is supplied from the sheet feeding device 21 to the collision pressure applying unit 30. If it is necessary to further dry it, it is further dried by a drying device and then supplied to the collision pressure applying unit. Further, when the transfer sheet S enters the chamber 33, it is opposed to the transfer sheet side while the both ends in the width direction are sandwiched by the sheet support device 22 so that the surface on the transfer layer side faces the transferred base material B side. A slight space is opened above the substrate B to be transferred (when no collision pressure is applied and nothing is performed), the substrate B is transferred at a constant speed in parallel with the substrate B to be conveyed, and receives the collision pressure. Until it is brought into contact with the transfer-receiving substrate, it is conveyed while maintaining the gap between the two. When the transfer sheet is transported in the vicinity of the transfer substrate at the same transport speed, whether the transfer sheet is slightly separated from the transfer substrate or transported while being in contact with the transfer substrate depends on the surface of the transfer substrate. The selection is made in consideration of the shape of the irregularities, the preheating temperature of the substrate to be transferred, the thermal deformability of the transfer sheet, the collision pressure of solid particles, the activation temperature of the heat-sensitive adhesive, and the like. Further, in terms of the apparatus, the distance between the substrate to be transferred and the transfer sheet to be transferred can be adjusted. The transfer sheet S is heated and softened by the sheet heating device 40 before being nipped and conveyed by the sheet supporting device 22 and subjected to the application of the collision pressure, and is easily stretched when the collision pressure is applied. Further, a heat-sensitive adhesive or the like is also heated and activated. Since the sheet heating device 40 is provided in the chamber in the same drawing, it is better to reduce the air volume in the case of hot air heating. This is because air enters the chamber, hinders maintenance of a negative pressure in the chamber and agitates the solid particles, as described later. The transfer sheet is also indirectly heated by the transferred substrate that is heated by the substrate heating device and supplied to the collision pressure applying unit. Heating by the sheet heating device can be omitted when preheating of the transfer sheet is unnecessary.

On the other hand, the solid particles P are supplied from a hopper 31 to a hollow portion provided in a center portion of a rotating shaft of a rotating impeller of an ejector 32 in a chamber 33, and then the impeller blades and the impeller And is accelerated by a rotating impeller and ejects toward the transfer sheet in the chamber. Then, the transfer sheet is exposed to collision of solid particles ejected from the ejector. The amount of change in the momentum of the solid particles at the time of collision is the collision pressure that presses the transfer sheet against the substrate to be transferred. Here, since the envelope surface of the transfer substrate is substantially flat, the solid particles mainly collide against the support side of the transfer sheet substantially vertically, and collide with the entire width of the transfer substrate and the transfer sheet being conveyed. Area. Then, as the transfer base material and the transfer sheet are conveyed, the entire region in the longitudinal direction is sequentially exposed to the collision pressure. The sheet supporting device also prevents the solid particles from wrapping around from both ends in the width direction of the transfer sheet and flowing between the transfer sheet and the base material. Then, the transfer sheet is pressed against the substrate to be transferred by the solid particle collision pressure, and the transfer sheet is extended and deformed into the concave portion of the uneven surface of the transferred substrate, so that the transfer sheet follows the uneven surface shape. Then, the adhesive is brought into close contact with the substrate to be transferred, so that the substrate is pressed against the substrate to be transferred.

The transfer base material B used in the description here
Is a flat plate material (envelope surface shape) as a whole having irregularities on the surface, and the transfer sheet S has both ends in the width direction with respect to the base material B to be transferred by the sheet supporting device 22. In a state where nothing is applied without impact pressure, etc., the transfer sheet S is transported at a distant position. Therefore, the complete contact of the transfer sheet S with the transfer target substrate B due to the impact pressure takes time at the center in the width direction. First, the vicinity of both ends in the width direction is delayed. This means that, as a whole, the transfer sheet S and the transfer base material B are transported at the same speed and are sequentially exposed to the collision pressure in the flow direction.
When the transfer sheet S is brought into close contact with the uneven surface of the transfer sheet B, air is left between the base material B to be transferred and the transfer sheet S (particularly near the center) to prevent the transfer sheet S from coming into contact. Also, needless to say, the area to be transferred is only the convex portion of the base material to be transferred, and if the inside of the concave portion is unnecessary, the transfer sheet is completely formed along the uneven surface shape, and the entire surface is completely formed. Needless to say, there is no need to make them adhere.

On the other hand, the solid particles P that have been subjected to the collision with the transfer sheet S bypass the side surface of the sheet supporting device 22 and collect in the lower portion of the chamber 33, from which the drain tube 3
At 4, it is sucked and collected in the original hopper 31. Further, the air in the chamber 33 for collecting and transporting the solid particles P is also sucked by the drain tube 34 together with the solid particles P, and is transported to the airflow and solid particle separation device 35 above the hopper 31. In the separation device 35, as shown in the drawing, the solid particles P conveyed by a gas flow are discharged horizontally into the device cavity, and the solid particles having a high density with respect to the gas fall downward by their own weight, leaving the gas as it is. The remaining solid particles P which flow horizontally and are going to move with the airflow by the filter are filtered, and then discharged out of the system by the vacuum pump 36. In this way, the solid particles
The transfer sheet and the base material to be transferred are prevented from flowing out to the surroundings together with the air from the entrance opening of the chamber 33 into and out of which the transfer sheet enters and exits. In order to prevent the solid particles from flowing out of the chamber system and to prevent the solid particles from flowing back from the chamber to the hopper, the inside of the chamber 33 may be set to a lower pressure than the outside. The pressure of the chamber is adjusted by adjusting the exhaust amount of the vacuum pump 36, the amount of gas flowing out of the chamber by connecting an exhaust fan (not shown) to the chamber, and the amount of gas blown out of the chamber. This is performed by adjusting the balance with the amount of gas ejected together with solid particles from an ejector such as an ejection nozzle into the chamber.

Then, after the transfer base material B with the transfer sheet S in close contact comes out of the chamber 33, the transfer sheet S
The support is peeled off from the base material B by the peeling roller 60. As a result, the decorative material D in which the transfer layer of the transfer sheet is transferred and formed on the uneven surface of the base material to be transferred is obtained. On the other hand, (the support of) the transfer sheet after passing through the peeling roller 60
Is wound around the sheet discharge device 23 as a discharge roll.

Now that the method and apparatus for transferring a curved surface of the present invention have been described, the present invention will be described in further detail.

The sheet heating device 40, the substrate heating device 41, etc., which are heating means before the application of the collision pressure, are optional. Further, the heating means may be arranged on any of the front side, the back side, and both the front and back sides of the transfer sheet or the base material to be transferred. Further, even during the application of collision pressure for heating and used as heated solid particles, the heat source of the heating device may be provided dispersed in the gap between the ejectors. In addition,
When hot air heating is performed in the chamber, it is better to reduce the blowing air volume. This is because, in addition to the air used for blowing the solid particles, air is further introduced into the chamber, and the load on the vacuum pump for collecting the solid particles increases.

The heating device for preheating the transfer sheet and the substrate to be transferred may be provided outside the chamber until they enter the chamber, inside the chamber, inside and outside the chamber. If provided outside and inside the chamber, even when sufficient preheating is required, for example, when a substrate to be transferred having a large heat capacity is heated, heating can be performed using a long transport distance. If the internal volume of the chamber itself becomes large in order to provide a long heating device inside the chamber, it is better to provide some or all of the heating device outside the chamber and reduce the internal volume of the chamber. This is because it is advantageous in handling in consideration of scattering, collection, and the like. An advantage of disposing the heating device inside the chamber is that the heating can be performed immediately before the application of the collision pressure or even during the application of the collision pressure. Particularly, the transfer substrate having a large heat capacity is effective only in the vicinity of the transfer surface. For example, when preheating is attempted. The preheating of the transfer sheet is preferably performed after both ends in the width direction are supported by the sheet supporting device 22.
Before that, the sheet is likely to be stretched in the feeding direction and hinder the transfer.

Further, if the base material to be transferred is coated with a sealer and the solvent is dried using the base material heating device 41 or the like as a drying device, the base material to be transferred is heated by the drying device. The transfer sheet can be heated to some extent indirectly from the material. Therefore, when the heating is sufficient by indirect heating from the substrate to be transferred or heating by the heated solid particles, the heating device for the transfer sheet can be omitted. In addition, in the case of a heating device that also has a role of evaporating a solvent or moisture in order to dry the coating by the coating device arranged on the upstream side, it is not preferable to arrange the heating device inside the chamber. A means for exhausting the evaporated solvent or moisture filled in the chamber is required, and in the case of a solvent, it is necessary to consider explosion-proof measures. Even if the heating device for such a purpose is arranged outside the chamber or inside the chamber, it is preferable to separately arrange a heating device (drying furnace) for evaporation outside. Of course, if the undercoating is performed on a separate line, it is not necessary to use the heating device also as the drying device.

Further, if the adhesive to be the transfer layer or the adhesive layer on the substrate to be transferred is not activated even if heated before application of the collision pressure, or if the adhesive before heating is not activated, If the process can be used, non-adhesive contact between the transfer substrate and the transfer sheet can be performed, so that the transfer sheet is brought into contact with the uneven surface of the transfer substrate and the air in the gap between the transfer sheet and the transfer substrate is It is recommended to forcibly remove the air, and to “bleed air”. By removing air, the air between the transfer sheet and the base material to be transferred can be prevented from remaining "at the time of transfer", and furthermore, the transfer omission caused by this can be prevented. The air bleeding is performed, for example, in the apparatus shown in FIG.
This is performed by a suction / exhaust device 90 including a suction / exhaust nozzle 91 and a vacuum pump 92. The suction and exhaust nozzles 91 are provided in the transfer layer side of the transfer sheet and on both sides adjacent to both sides along the transfer direction of the transferred base material along the transfer direction of the transfer base material. The air between the transfer substrates may be sucked and exhausted by the vacuum pump 92. Suction and exhaust nozzle 9
For example, if the outer periphery of the opening 1 is surrounded by a brush and the tip of the brush is brought into contact with the base material to be transferred and the transfer sheet, air can be vented without any trouble in transporting them. Further, it is preferable that the air be removed until the collision pressure is applied. The timing of the air release and the preheating of the transfer sheet may be started first, or both may be started simultaneously, depending on the speed at which the transfer sheet is preheated and softened, and the degree of softening. Air bleeding is effective when the surface to be transferred of the base material to be transferred has a rough surface such as a rock surface tone or a stucco tone.

In the case where an adhesive which is fixed by cooling, such as a heat-sensitive adhesive, is used for the adhesive layer on the substrate to be transferred or for the adhesive layer of the transfer layer, the transfer sheet is formed of the material to be transferred. After the contact with the desired transfer surface, cooling of the adhesive may be promoted by cooling means such as cold air. The promotion of cooling also prevents the transfer sheet formed following the inside of the concave portion of the concave-convex surface of the transfer-receiving substrate from returning to the case where there is a restoring force after releasing the collision pressure. In addition, since the transfer sheet (support) can be peeled off and removed more quickly, transfer loss can be prevented and the production speed can be improved. For cooling, it is preferable to use cooled solid particles without releasing the collision pressure during the application of the collision pressure, or to cool the adhesive layer by another cooling means after the application of the collision pressure. When the heat capacity of the substrate to be transferred is large, the substrate to be transferred can be cooled from the back surface by blowing low-temperature gas and cooling rollers and belt conveyors for transferring the substrate in addition to the solid particles. Alternatively, after the cooling in the chamber, the cooling may be performed by blowing cool air from the front or back, or the like, outside the chamber after cooling inside the chamber, or without cooling inside the chamber, only outside the chamber.

The method and apparatus for transferring a curved surface of the present invention described above are not limited to the examples shown in the drawings. For example, in the description of the curved surface transfer method using the curved surface transfer device shown in FIG. 1, the pressing of the transfer sheet to the substrate to be transferred is performed by using a long belt-shaped transfer sheet and a single sheet of the substrate to be transferred, and integrating them. In the form of continuously applying solid particle collision pressure with a fixed ejector while transferring and moving the transfer sheet, pressing the transfer sheet against the transfer base material stops the transfer sheet and the transfer base material only at that time. It may be performed intermittently for each base material (for example, the ejector is moved to these). Also,
Both the substrate to be transferred and the transfer sheet may be supplied in the form of a single sheet. Further, the positional relationship between the ejection direction of the solid particles of the ejector and the transfer sheet and the substrate to be transferred is not limited to the positional relationship in which both are placed on a horizontal plane and the solid particles are ejected vertically downward from above. Even if the transfer sheet support side surface and the ejection direction maintain the vertical relationship, the transfer sheet mounting or transport direction is not only in the horizontal plane, but also in the inclined plane, in the vertical plane, and even when the transfer sheet is in the horizontal plane. Alternatively, solid particles may be ejected from the lower side of the support, that is, from bottom to top, and collided. Of course, the solid particles may be ejected at an angle to the back surface of the transfer sheet. Further, before applying the collision pressure, the transfer sheet may be preliminarily pressed against the transfer base material by the elastic roller. Further, when the chamber is filled with an inert gas such as nitrogen and an ionizing radiation-curable resin (before curing) is used for a base coat layer of the transfer layer, oxygen, water vapor, etc. in the air may be filled with the resin. May be prevented from hindering the curing. Further, by using a transfer-receiving base material partially formed with an adhesive layer, or a transfer layer, a transfer sheet partially formed with an adhesive layer of a transfer layer, a decorative material partially transferred with a transfer layer can be used. You can also get. For the partial formation, a printing method is used in addition to the coating method. Further, in order to partially transfer the transfer layer, a transfer sheet in which a release layer made of a fluororesin, a silicon resin, or the like is partially provided on the transfer layer or the substrate to be transferred may be used.

Now that the present invention has been described, the material aspect will be described in more detail.

Solid Particles Solid particles P include non-metallic inorganic particles which are inorganic powders such as glass beads, ceramic beads, calcium carbonate beads, alumina beads, zirconia beads, iron alloys such as iron, carbon steel, and stainless steel. Metal particles such as aluminum or aluminum alloy such as duralumin, metal beads such as titanium, or resin beads such as fluorine resin beads, nylon beads, silicone resin beads, urethane resin beads, urea resin beads, phenol resin beads, crosslinked rubber beads, etc. And the like can be used. The shape is preferably spherical, but other shapes may be used. The particle size of the solid particles is usually 10 to 10
It is about 00 μm.

Incidentally, the solid particles can also serve as a heating means and a cooling means. When heated solid particles are used, the activation of the adhesive by heating or the improvement of the stretchability by heating the transfer sheet can be performed together with the pressing of the transfer sheet. When using the heated solid particles, the transfer sheet and the substrate to be transferred may be heated to some extent by another heating method before the application of the collision pressure. For the purpose of promoting cooling after bonding, solid particles having a temperature lower than the temperature of the adhesive at the time of bonding can be used as the cooling solid particles. Also,
Some or all of the solid particles may be used as heated solid particles or cooled solid particles, or the solid particles may be used in combination with the heated solid particles and then collided with the cooled solid particles. Also,
Heating the transfer sheet, the substrate to be transferred, the adhesive and the like that needs to be heated by another heating method is sufficiently heated, and the transfer sheet is molded, bonded and cooled almost simultaneously using the cooled solid particles. You can also. In order to cool or heat the solid particles, the solid particles are cooled or heated while being stored in a tank for storing the solid particles. Heating and cooling in the tank
Heating and cooling are performed by an electric heater, heated steam, refrigerant, or the like provided in the tank or on the outer wall of the tank.

The substrate to be transferred B can of course be applied to a flat surface where the surface to be transferred is flat. However, the present invention is most effective in the case where the surface to be transferred is an uneven surface, and in particular, the unevenness of the surface. This is a three-dimensionally transferred substrate. In a conventional holding jig which makes rotary contact (the above-mentioned Japanese Patent Publication No. 61-5895) or a rubber transfer roller (see the above-mentioned Japanese Patent Application Laid-Open No. 5-13997),
Because it has essentially the direction of the rotation axis,
Applicable surface irregularities are limited. That is, in the former,
Limited to two-dimensional irregularities having a curvature only in one axis direction,
Further, in the latter case, even if transfer to three-dimensional irregularities having a curvature in two axial directions is possible, the three-dimensional shape cannot be uniformly applied to an arbitrary direction. For example, unless the longitudinal direction of the wood grain conduit pattern is parallel to the feed direction of the transfer sheet, it cannot be successfully transferred to the concave portion of the conduit. Moreover, in the latter case, the shape of the base material is practically limited to a flat plate shape, and otherwise, it is impossible unless a transfer roller having a special shape tailored to each base material shape is used.
However, in the present invention, as described above, since the collision pressure of a group of solid particles that can behave fluidly is used, the three-dimensional shape of the surface irregularities indicates the planar direction of the pressure application region. Has essentially no. (The directionality is a direction of a temporal position change of a point on the transfer-receiving substrate to which pressure is applied.) Therefore, a shape having irregularities in the feeding direction of the transfer sheet or the transfer-receiving substrate is considered. The substrate to be transferred may be used. That is, it can be applied to two-dimensional unevenness having unevenness only in one direction such as only the feeding direction or only the width direction, and three-dimensional unevenness having unevenness in two directions such as both the feeding direction and the width direction. The point that the present invention does not have the above-mentioned directivity is that a method and an apparatus (the present invention may have such a form) in which a single transfer sheet is placed on a substrate to be transferred and press-contacted one by one. It can be easily understood by moving the ejector that ejects the solid particles, or moving the transfer sheet and the transfer-receiving substrate while the ejector is fixed, and considering the manner in which the region where the collision pressure is applied moves. . Further, the substrate to be transferred is not limited to a plate material having a flat plate shape (envelope surface shape) as a whole, and may be a substrate having two-dimensional irregularities curved in a feeding direction or a width direction in a convex or concave shape in an arc shape. The curved surface may have finer three-dimensional surface irregularities. In the present invention, it is possible to arbitrarily decide whether to transfer the two-dimensional irregularities such as the arc shape of the base material to be transferred, for example, in the width direction or in the feed direction, in consideration of workability and the like. Further, a transferred substrate having an uneven surface superimposed on large irregularities and having fine irregularities, or a transferred substrate having a surface to be transferred to the bottom of the concave portion or the inner surface of the concave portion of the irregular surface is also possible. The large irregularities and the fine irregularities are, for example, as shown in FIG. 5, the irregularities of the substrate to be transferred are composed of the minute irregularities on the convex portions of the large irregularities.
10 to 10 mm, width of concave portion is 1 to 10 mm, width of convex portion is 5 m
m, the fine unevenness is smaller than the large unevenness in both the step and the width, specifically, the step is about 0.1 to 5 mm, the width of the recess and the width of the protrusion. The width is not less than 0.1 mm, and is less than about の of the width of the convex portion having a large pattern. In addition, each of the surfaces constituting the uneven surface is not limited to a flat surface, may be only a curved surface, or may be a combination of a flat surface and a curved surface. Therefore, the curved surface on the substrate to be transferred according to the present invention also means a concavo-convex surface having no curved surface composed of only a plurality of flat surfaces, such as a tooth profile of a clog. Further, the curvature in the present invention includes a case where the curvature is infinite (the radius of curvature = 0) which is angular like the periphery of the side or the vertex of the cube.

The material of the substrate to be transferred is arbitrary.
Non-porcelain ceramic plates such as calcium silicate plate, extruded cement plate, ALC (lightweight foamed concrete) plate, GRC (glass fiber reinforced concrete) plate, veneer veneer, wood plywood, particle board, or wood Wood plates such as medium density fiberboard (MDF), metal plates such as iron, aluminum and copper, ceramics such as ceramics and glass,
A resin molded product such as polypropylene, ABS resin, and phenol resin may be used. In addition, the surface of these substrates to be transferred,
An easy-adhesion primer for assisting the adhesion with the adhesive or a sealer for sealing and sealing fine irregularities and porosity on the surface may be applied in advance. A resin such as an isocyanate, a two-component curable urethane resin, an epoxy resin, an acrylic resin, or a vinyl acetate resin is applied as an easy-adhesion primer or a sealer. Pressing, embossing,
Extrusion, cutting, molding, etc. may be used. Although the specific pattern of the uneven shape is arbitrary, for example, tiles and bricks having joints, a two-dimensional array of stones, cleaved surfaces of granite, unevenness of stone surfaces such as travertine marble plates, joints,
Surface unevenness of a wood panel such as a wood paneled board having a sane, sashimi or the like, a floating wood grain board, or the like, and an unevenness of a spray painted surface such as a lysine tone, a stucco tone or the like.

Transfer Sheet The transfer sheet S is composed of a support and a transfer layer that transfers and transfers. The transfer layer comprises at least a decorative layer. Also, an adhesive such as a heat-sensitive adhesive may be formed on the transfer sheet as an adhesive layer that becomes a part of the transfer layer.

If the substrate to be transferred is a two-dimensional uneven surface, paper or the like having no stretchability can be used as the support. However, in order to apply the present invention to a three-dimensional uneven surface where the present invention shows its true value, Is
At least at the time of transfer, a support having stretchability is used. Due to the stretchability, when the collision pressure of the solid particles is applied, the transfer sheet can be closely adhered and transferred to the inside of the concave portion on the surface of the transfer-receiving substrate. The stretchability of the entire transfer sheet is mainly governed by the stretchability of the support. Therefore, in addition to a conventionally known thermoplastic resin film, a rubber film that can be stretched even at normal temperature can be used as the support. In the case of a thermoplastic resin film, there is almost no stretchability when a transfer layer such as a decorative layer is formed, and at the time of transfer,
As a transfer sheet that develops sufficient stretchability by heating, and keeps its deformed shape after cooling, and does not restore its shape due to elasticity, it is easily used in the present invention similarly to a conventionally known ordinary transfer sheet. The resulting transfer sheet can be prepared. As a specific example of the support, in terms of stretchability, even a biaxially stretched polyethylene terephthalate film, which has been widely used in the past, can provide necessary and sufficient stretchability by setting heating conditions, collision pressure conditions, and the like, depending on the surface unevenness. Curved surface transfer is possible because it can be expressed, but it is easier to develop stretchability at low temperature and low pressure, for example, polybutylene terephthalate,
Or copolymer polyester film such as terephthalate isophthalate copolymer, polypropylene film,
Polyolefin-based films such as polyethylene films and polymethylpentene films, low-stretch or non-stretch films such as polyvinyl chloride resin films and nylon films, and rubber (elastomer) films such as natural rubber, synthetic rubber, urethane elastomers, and olefin-based elastomers Are also preferred supports. Moreover, in order to improve the releasability of the transfer layer on the transfer layer side, if necessary,
A release layer may be provided. The release layer is removed together with the support from the transfer layer when the support is released. As the release layer, for example, a simple substance such as a silicone resin, a melamine resin, a polyamide resin, a urethane resin, a polyolefin resin, a wax, or a mixture containing these is used.

If an uneven pattern is provided on the surface of the support which is in contact with the transfer layer, the uneven pattern can be formed on the surface of the transfer layer after transfer. The uneven pattern is, for example,
Hairline, line-shaped groove, unevenness pattern of cleavage surface of granite, wood grain conduit groove, wood grain ring pattern, surface texture of cloth, squeezing, characters, geometric pattern, etc. The uneven pattern may be formed by embossing, sandblasting, or hairline processing the resin sheet of the support by hot pressing, or by using an ink (2) using a resin having releasability as a binder on the support. Liquid-cured urethane, silicone resin, melamine resin, polyfunctional acrylate or methacrylate monomer or prepolymer cross-linkable by ultraviolet light or electron beam, etc. There is a method of providing a shape layer and using it as a support having a shape layer. The shaping layer has the function of the release layer.

The transfer layer comprises at least a decorative layer, and a release layer, an adhesive layer, etc. may be a component of the transfer layer as appropriate. In the configuration having the adhesive layer, it is possible to omit applying the adhesive to one or both of the transfer sheet and the base material to be transferred at the time of transfer. The decorative layer is a conventionally known method such as gravure printing, silk screen printing, offset printing, etc., a pattern layer printed with a pattern by a material, aluminum, chrome,
A metal thin film layer or the like in which a metal such as gold, silver or the like is partially or entirely formed by using a known vapor deposition method or the like. A wood pattern, a stone pattern, a cloth pattern, a tile pattern, a brick pattern, a leather pattern, a character, a geometric pattern, a solid pattern, or the like is used as the pattern according to the surface irregularities of the substrate to be transferred. The ink for a picture layer is composed of a vehicle such as a binder, a coloring agent such as a pigment or a dye, and various additives appropriately added thereto. The binder is made of an acrylic resin, a vinyl chloride-vinyl acetate copolymer, a polyester resin, a cellulosic resin, a polyurethane resin, a fluororesin or the like, or a mixture containing these. As the pigment of the coloring agent, inorganic pigments such as titanium white, carbon black, red iron oxide, graphite, ultramarine blue and the like, and organic pigments such as aniline black, quinacridone, isoindolinone, phthalocyanine blue and the like are used. Conventionally, a release layer is provided between the support or the release layer and the decorative layer to adjust the releasability between the decorative layer and to protect the surface of the decorative layer after transfer. This is the same as a known transfer sheet. The release layer is transferred to the transfer-receiving substrate together with the decorative layer during transfer, and covers the surface of the decorative layer. Further, in order to facilitate removal of residual air between the transfer sheet and the base material to be transferred, a number of small holes may be formed through the entire transfer sheet.

Adhesive The adhesive is applied as an adhesive layer constituting a transfer layer of a transfer sheet or as an adhesive layer on a substrate to be transferred by online coating or offline coating before or immediately before transfer. . When applied to a substrate to be transferred, the adhesive layer of the transfer sheet transfer layer can be omitted. The adhesive to be used may be appropriately selected depending on the application, required physical properties, and the like. For example, a heat-sensitive adhesive, a moisture-curable heat-sensitive adhesive, a hot-melt adhesive, a moisture-curable hot-melt adhesive, a two-component curable adhesive Various adhesives such as an adhesive, an ionizing radiation-curable adhesive, a water-based adhesive, or a pressure-sensitive adhesive using an adhesive can be used. As the heat-sensitive adhesive, any of a heat-sealing adhesive using a thermoplastic resin and a thermosetting adhesive using a thermosetting resin can be used.
However, from the viewpoint that the bonding is completed in a short time, a heat-fusion type (heat-sensitive adhesive) is preferable. The adhesive may be diluted with a solvent or without a solvent, or may be a liquid or a solid at room temperature. In the case of an adhesive other than a pressure-sensitive adhesive exhibiting tackiness, a transfer layer can be formed with only a single adhesive layer. If a colorant such as a pigment is added to the adhesive layer, it can be said that the adhesive layer is a decorative layer composed of a solid ink layer over the entire surface.

Examples of the heat-sensitive adhesive include polyvinyl acetate resins, acrylic resins, thermoplastic polyester resins,
Conventionally known adhesives such as a thermoplastic urethane resin and a polyamide resin obtained by polycondensation of dimer acid and ethylenediamine can be used. As the thermosetting adhesive, a phenol resin, a urea resin, a diallyl phthalate resin, a thermosetting urethane resin, an epoxy resin or the like can be used.

Further, a moisture-curable heat-sensitive adhesive is also a kind of heat-sensitive adhesive. The moisture-curable heat-sensitive adhesive is applied immediately before transfer from the viewpoint of work stability because the curing reaction proceeds with moisture in the air when left as it is in nature. Immediately after transfer, the moisture-curable heat-sensitive adhesive has the same adhesive strength as a normal heat-melt adhesive, but the cross-linking / curing reaction gradually proceeds with moisture in the air when left naturally, It is excellent in heat resistance without creep deformation and heat melting, and a large adhesive strength is obtained. However, in order to promote the crosslinking and curing of the adhesive with moisture after the transfer is completed, the cosmetic material after the transfer is left to cure in air containing moisture. Preferable atmospheric conditions for curing are generally about 50% RH or more and 10 ° C.
That is all. When the temperature and the relative humidity are both higher, the curing is completed in a shorter time. The standard curing completion time is usually about 10 hours in an atmosphere of 20 ° C. and 60% RH.

The moisture-curable heat-melting adhesive is a composition containing a prepolymer having an isocyanate group at a molecular terminal as an essential component. The prepolymer is usually a polyisocyanate prepolymer having one or more isocyanate groups at both molecular terminals, and is a solid thermoplastic resin at room temperature. Isocyanate groups react with each other due to moisture in the air to cause a chain extension reaction, and as a result, a reactant having a urea bond in a molecular chain is generated,
The urea bond further reacts with the isocyanate group at the molecular terminal, causing a biuret bond and branching to cause a crosslinking reaction. Although the skeleton structure of the molecular chain of the prepolymer having an isocyanate group at the molecular terminal is arbitrary, specific examples include a polyurethane skeleton having a urethane bond, a polyester skeleton having an ester bond, and a polybutazine skeleton.
Adhesive properties can be adjusted by appropriately employing one or more of these skeletal structures. If a urethane bond is present in the molecular chain, the terminal isocyanate group also reacts with the urethane bond to form an allophanate bond, which also causes a cross-linking reaction.

Specific examples of the polyisocyanate prepolymer include, for example, an isocyanate group at a molecular terminal obtained by reacting an excess of polyisocyanate with a polyol;
There is a urethane prepolymer having a polyurethane skeleton having a urethane bond in a molecular chain. Also, Japanese Unexamined Patent Publication No.
No. 14287, a polyester skeleton and a polybutadiene skeleton obtained by adding a polyester polyol and a polyol having a polybutadiene skeleton in an arbitrary order to a polyisocyanate and subjecting them to an addition reaction are bonded by a urethane bond. Crystalline urethane prepolymer having an isolated structure and having an isocyanate group at the molecular terminal, or a molecule obtained by reacting a polycarbonate polyol with a polyisocyanate as disclosed in JP-A-2-305882. A polycarbonate-based urethane prepolymer having two or more isocyanate groups therein, a polyester-based urethane prepolymer having two or more isocyanate groups in a molecule obtained by reacting a polyester polyol and a polyisocyanate, and the like. It is.

As the moisture-curable heat-sensitive adhesive, other than the above-mentioned various polyisocyanate prepolymers,
In order to adjust various physical properties, various auxiliary materials such as a thermoplastic resin, a tackifier, a plasticizer, and a filler can be added to the above-mentioned essential reaction components, if necessary. As these auxiliary materials, for example, ethylene-vinyl acetate copolymer,
Low molecular weight polyethylene, modified polyolefin, atactic polypropylene, linear polyester, thermoplastic resin such as ethylene-ethyl acrylate (EAA), terpene-phenol resin, tackifiers such as rosin abietic acid ester, calcium carbonate, barium sulfate, silica ,
Fillers (extended pigments) made of fine powder such as alumina, coloring pigments, curing catalysts, moisture removers, storage stabilizers, antioxidants and the like.

The ionizing radiation-curable resin which can be used as the ionizing radiation-curable adhesive is a composition curable by ionizing radiation, and specifically includes a radical polymerizable unsaturated bond or a cationic polymerizable functional group in the molecule. A prepolymer (including a so-called oligomer) having a group and / or a composition which is appropriately mixed with a monomer and which can be cured by ionizing radiation is preferably used. These prepolymers or monomers are used alone or as a mixture of two or more.

The above-mentioned prepolymer or monomer specifically has a radical polymerizable unsaturated group such as a (meth) acryloyl group and a (meth) acryloyloxy group, a cationic polymerizable functional group such as an epoxy group in the molecule. Consisting of a compound having Further, a polyene / thiol prepolymer based on a combination of polyene and polythiol is also preferably used. In addition, for example, a (meth) acryloyl group is
It means an acryloyl group or a methacryloyl group. Examples of the prepolymer having a radical polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, melamine (meth) acrylate, and triazine (meth) acrylate. The molecular weight is usually 250
Approximately 100,000 are used. Examples of the monomer having a radical polymerizable unsaturated group include monofunctional monomers such as methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, and phenoxyethyl (meth) acrylate. As polyfunctional monomers, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, trimethylpropane tri (meth) acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, dipentaerythritol penta (meth) acrylate And dipentaerythritol hexa (meth) acrylate. Examples of the prepolymer having a cationically polymerizable functional group include bisphenol type epoxy resins, epoxy resins such as novolak type epoxy compounds,
There are prepolymers of vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. Examples of the thiol include polythiols such as trimethylolpropane trithioglycolate and pentaerythritol tetrathioglycolate. Examples of the polyene include those obtained by adding allyl alcohol to both ends of a polyurethane made of a diol and a diisocyanate.

When curing with ultraviolet light or visible light, a photopolymerization initiator is further added to the ionizing radiation-curable resin. In the case of a resin having a radical polymerizable unsaturated group, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ethers can be used alone or in combination as a photopolymerization initiator. In the case of a resin having a cationically polymerizable functional group, an aromatic diazonium salt, an aromatic sulfonium salt, an aromatic iodonium salt, a metallocene compound, a benzoin sulfonic acid ester, or the like is used alone or as a mixture as a photopolymerization initiator. be able to. In addition,
The addition amount of these photopolymerization initiators is about 0.1 to 10 parts by weight based on 100 parts by weight of the ionizing radiation-curable resin. In addition, as the ionizing radiation, an electromagnetic wave or a charged particle having a photon capable of crosslinking a molecule in the adhesive is used. Usually, ultraviolet rays or electron beams are used, but it is also possible to use visible rays, X-rays, ion beams, or the like. As the ultraviolet light source, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, and a metal halide lamp is used. As a wavelength of the ultraviolet light, a wavelength range of 190 to 380 nm is usually mainly used. As the electron beam source, various electron beam accelerators such as a Cockcroft-Walton type, a Van degraft type, a resonance transformer type, an insulating core transformer type, a linear type, a dynamitron type, and a high frequency type are used.
Irradiating electrons having an energy of keV, preferably 100 to 300 keV is used.

If necessary, a thermoplastic resin such as a vinyl chloride-vinyl acetate copolymer, polyvinyl acetate, an acrylic resin or a cellulose resin may be added to the ionizing radiation-curable resin. If used without adding a diluting solvent, it becomes a hot melt adhesive.

When an ionizing radiation-curable adhesive is used, an ionizing radiation irradiating device for irradiating an ultraviolet ray or an electron beam to a curved surface transfer device can be incorporated. The irradiation is performed during, after, or after and after the application of the collision pressure.

Further, various additives may be further added to the various resins as required. Examples of these additives include calcium carbonate, barium sulfate,
An extender (filler) composed of fine powder of silica, alumina, etc., a thixotropic agent such as organic bentonite (especially, in the case of a substrate to be transferred having a large uneven step, the adhesive is prevented from flowing from the convex portion to the concave portion. And so on.).

The adhesive is applied to the transfer sheet, the substrate to be transferred, or both the transfer sheet and the substrate to be transferred. To apply the adhesive to a sheet such as a transfer sheet or the substrate to be transferred, The solution is applied in the form of a solution or dispersion dissolved or dispersed in a solvent or without a solvent, but may be applied by a conventionally known solution coating method using a gravure roll coat or the like, or a melt coating method using an applicator or the like. When used without adding a diluting solvent, solvent drying is unnecessary. For example, heat-sensitive adhesives can be used as solventless hot-melt adhesives, respectively. In addition, an ionizing radiation-curable adhesive or the like can be applied without a solvent. When used as a hot-melt adhesive, there is no solvent, so solvent drying is not required even immediately before coating, and high-speed production is possible. The amount of the adhesive applied varies depending on the composition of the adhesive, the type of the substrate to be transferred, and the surface state.
Usually, it is about 10 to ²⁰⁰ g / m ² (solid content). When the adhesive is applied to the substrate to be transferred at the time of transfer, the substrate coating device 50 can be used. Further, when an adhesive is applied to the transfer sheet, a coating apparatus similar to the substrate can be used.

In the case where the adhesive is used as a hot-melt adhesive, and when the transfer sheet is further modified so as to follow the irregular shape of the substrate to be transferred, the polypropylene is necessarily used as a support for the transfer sheet. It is necessary to select a material exhibiting thermoplasticity or rubber elasticity at room temperature or in a heated state, such as a thermoplastic resin sheet such as a system resin. However, from another viewpoint, a material having low heat resistance should be selected for the support. Means that you don't get it. Therefore, when the adhesive is melt-coated to form a transfer sheet, when the adhesive layer is thickly applied, the support is softened by heat during the melt coating, and the adhesive is heated in an adhesive coating apparatus. The sheet may stick to the applicator roller and be stretched, distorted, or entangled by dragging. Therefore, in such a case, the transfer sheet may be formed by applying an adhesive via a release sheet (separator) without directly applying the adhesive to the sheet by melt coating. That is, the adhesive is heated and melt-coated on a release sheet having heat resistance and release properties, and then the release sheet and the sheet to be the transfer sheet are once thermally laminated by a nip roller or the like with the applied adhesive. Then, by peeling only the release sheet from the sheet by a peeling roller or the like,
The transfer sheet having the adhesive layer formed thereon can be obtained by reducing heat damage to the sheet. The release sheet does not need to be stretchable. A heat-resistant resin sheet such as biaxially stretched polyethylene terephthalate sheet, polyethylene naphthalate, polyarylate, or polyimide, or paper is used as a base material. For example, a conventionally known release sheet subjected to a release treatment by such coating can be used. The thickness of the release sheet is usually about 50 to 200 μm.

Note that a heat-melting adhesive is used as the adhesive,
The timing of heating to activate and thermally fuse the adhesive may be before the application of the collision pressure, during the application of the collision pressure, or before and during the application of the collision pressure. The heating of the adhesive is performed by heating the transfer sheet or the substrate to be transferred. The material (transfer sheet or transfer substrate) to which the adhesive has been applied may be heated,
The material to which the adhesive is not applied may be heated, or both materials may be heated. Further, for the heating during the application of the collision pressure, heated solid particles may be used.

Cosmetic materials Cosmetic materials obtained by the method and apparatus for transferring a curved surface according to the present invention described above include exterior materials such as outer walls, walls, roofs, gates, gable boards, building interior materials such as wall surfaces and ceilings, and windows. It can be used in various fields such as frames, doors, handrails, thresholds, doors and other fittings, furniture surface materials such as chests, cabinets for light electric / OA equipment, and vehicle interior materials such as automobiles. Note that a transparent protective layer may be further applied on the surface of the decorative material after the transfer. As such a transparent protective layer, one or two or more of a fluororesin such as polytetrafluoroethylene and polyvinylidene fluoride, an acrylic resin such as polymethyl methacrylate, a silicone resin, and a urethane resin are used as a binder. If necessary, use a paint to which an ultraviolet absorber such as benzotriazole or ultrafine cerium oxide, a light stabilizer such as a hindered amine radical scavenger, a coloring pigment, an extender pigment, or a lubricant is added. Spray coating, flow coating, etc. are used for coating. The thickness of the transparent protective layer is about 1 to 100 μm.

[0059]

EXAMPLE First, a 15 mm-thick calcium silicate plate was prepared as a transfer substrate B having three-dimensional surface irregularities. This flat plate had a rectangular parallelepiped shape as a whole (envelope surface), and used a surface in which large irregularities and fine irregularities were superimposed on the surface. Fig. 5
The groove-like concave portion 401 of the joint portion as shown in FIG.
A diagram having a depth of 2 mm and a flat convex portion 402 of 50 mm × 150 mm on one side on the surface, and a finer unevenness only on the flat convex portion with a 10-point average roughness of JIS-B-0601 of 500 μm. Pear-skinned fine irregularities 40 like 5 (B)
3 is a plate material having three-dimensional surface unevenness of a brickwork pattern. Then, the base material and the undercoat were applied to this plate material off-line by another apparatus. The transfer sheet was prepared by successively gravure-printing a brick-like pattern as a decorative layer serving as a transfer layer on one side of a polypropylene-based film having a thickness of 50 μm on a support. Next, using a device having a process as shown in FIG. 1 and applying a collision pressure, using a device as shown in FIGS. The substrate is transported by placing it on a substrate transport device 10 composed of a row of rollers, and applying a solvent-free hot-melt heat-sensitive adhesive that has been heated and melted by a substrate coating device 50 in a solvent-free applicator. After hot-melt coating, the heat-sensitive adhesive and the substrate to be transferred were heated by the substrate heating device 41 and supplied to the collision pressure applying unit 30. On the other hand, the transfer sheet S was also supplied to the collision pressure applying unit 30 with its support side up. When the transfer target substrate B enters the chamber, the transfer sheet S
Was brought closer to the transfer-receiving substrate B. Then, the front and back of the transfer sheet S were nipped by a pair of endless belt-shaped sheet support devices 22. In this state, the sheet heating device 40 using the radiant heat from the heating wire heater from the support side of the transfer sheet S
The preheating of the transfer sheet, the activation of the heat-sensitive adhesive, and the heating of the substrate to be transferred were carried out. Next, spherical iron beads having an average particle diameter of 0.8 mm as solid particles P are ejected from an ejector 32 using a rotating impeller made of titanium as a particle accelerator, and collide with the support side surface of the transfer sheet S. The transfer sheet was pressed against the surface irregularities of the substrate to be transferred. The particle accelerator used had the form shown in FIGS. The solid particles P are supplied by freely dropping beads in a hopper into a hollow portion provided at the center of the rotating shaft of the impeller, and eject the solid particles accelerated at 4 [m / s] in the vertical direction. Was.
The rotation speed of the impeller was 3600 rpm, the diameter of the impeller was 20 cm, and the width of the blade 311 was 10 cm. Further, both the transfer sheet and the substrate to be transferred were transported while being supported such that the surface was in a horizontal plane as shown in FIG. Then, the transfer sheet is extended into the concave portion of the joint and closely adhered thereto, and the chamber 3
3 and the adhesive layer was cooled and solidified. After that, the support of the transfer sheet was peeled off by a peeling roller 60 to obtain a decorative material D.

[0060]

According to the present invention, a decorative material having a large three-dimensional uneven surface decorated can be easily obtained. Of course, two-dimensional irregularities such as window frames and sashes are also possible.
It can be easily obtained even if it has a wavy shape as a whole like a roof tile, or a convex or concavely curved shape. Further, unlike the conventional rubber roller pressing method, there is no wear of parts such as the roller due to the concave and convex portions of the substrate to be transferred. In addition, it is possible to transfer on the convex portion of the large irregular surface and also inside the concave portion (the bottom portion or the side surface which is the connecting portion between the convex portion and the bottom portion). Also,
On top of the large irregularities, more fine irregularities (for example,
Even if there is a hairline, satin finish, etc., it is possible to decorate by transfer even in the concave portion of the fine unevenness. As a result, a decorative material having extremely excellent design properties can be obtained as never before.

[Brief description of the drawings]

FIG. 1 is a conceptual explanatory view of one embodiment of a curved surface transfer method and a curved surface transfer device of the present invention. (A) is a schematic device diagram viewed from the side in the substrate transport direction. FIG. 2B is a schematic device diagram of the ejector portion of the device of FIG.

FIG. 2 is a conceptual diagram (front view) illustrating an ejector using an impeller as a particle accelerator.

FIG. 3 is a perspective view of the particle accelerator of FIG. 2;

FIG. 4 is an explanatory diagram for adjusting the ejection direction by a particle accelerator using an impeller.

FIGS. 5A and 5B are explanatory diagrams showing an example of three-dimensional surface irregularities of a substrate to be transferred; FIG. 5A is a plan view and FIG.

[Explanation of symbols]

 Reference Signs List 10 substrate transport device (substrate transport device) 20 sheet transport device (sheet transport device) 21 sheet feeding device 22 sheet support device 23 sheet discharge device 30 collision pressure application section (collision pressure application device) 31 hopper 32 ejector (solid) 33 chamber 34 drain pipe 35 separation device 36 vacuum pump 40 sheet heating device 41 substrate heating device 50 substrate coating device 60 peeling roller (peeling device) 80 particle accelerator 81 ejection guide 82 impeller 83 blade 84 side Face plate 85 Hollow portion 86 Bearing 87 Rotation shaft 88 Opening 89 Direction controller 90 Suction / exhaust device (Suction / exhaust means) 91 Suction / exhaust nozzle 92 Vacuum pump 401 Groove-shaped concave portion 402 Flat convex portion 403 Fine unevenness B Substrate to be transferred D Make-up Material P Solid particles S Transfer sheet

Claims (2)

(57) [Claims] 1. A transfer sheet comprising a support and a transfer layer, wherein the transfer layer side of a transfer sheet comprising a support and a transfer layer is opposed to the uneven surface side of the transfer-receiving base material having the uneven surface, and solid particles collide with the support side of the transfer sheet. Utilizing the collision pressure, the transfer sheet is pressed against the uneven surface of the substrate to be transferred, and after the transfer layer adheres to the substrate to be transferred, the support of the transfer sheet is peeled off to remove the transfer layer. A curved surface transfer method for transferring to a transfer-receiving substrate, wherein acceleration of the solid particles to collide with a transfer sheet is performed by a rotating impeller, and the plurality of impellers are provided outside a hollow portion at a center of rotation. A curved surface transfer method comprising: supplying solid particles to the hollow portion, accelerating the solid particles by a rotating impeller, and causing the solid particles to collide with a transfer sheet. 2. The transfer layer side of a transfer sheet comprising a support and a transfer layer is opposed to the uneven surface side of the substrate to be transferred having the uneven surface, and solid particles are caused to collide with the support side of the transfer sheet. An apparatus for performing at least a process until the transfer layer is pressed against the transfer substrate in order to transfer the transfer sheet by pressing the transfer sheet to the uneven surface of the transfer substrate using the collision pressure. A plurality of blades are provided outside the hollow portion at the center of rotation, and the solid particles are supplied to the hollow portion. A jetting device for jetting the accelerated solid particles by a particle accelerator composed of a rotating impeller is provided. Pressing means for applying a collision pressure of the solid particles ejected from the ejection means to the transfer sheet to press the transfer sheet against the transfer substrate; and at least the transfer substrate opposed to the ejection means. Substrate transfer means for transferring to a position, A curved surface transfer device, comprising: at least a sheet conveying means for supplying a transfer sheet at least between the jetting means and the substrate to be transferred.