JPH09315095A - Method and apparatus for transferring curved surface - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to transfer even to a large three-dimensional uneven surface by colliding solid particles from the rear surface side of a transfer sheet opposed with a transfer layer to the uneven surface of a base material to be transferred, and bringing the sheet into pressure contact with the uneven surface of the base material to be transferred by utilizing the collision pressure. SOLUTION: A plate-like base material 1 having a surface to be transferred with an uneven surface is conveyed into the chamber 16 of a pressure applying part 6 by a base material conveyor 2, and a transfer sheet 3 is also introduced into the chamber 16 via a guide roller 8. The sheet 3 is exposed with the collision of solid particles 5 injected together with air flow from a nozzle 15. Then, the injected particles 5 apply the collision pressure in a laterally linearly band state substantially to the entire width of the sheet 3. Thus, the sheet 3 is brought into pressure contact with the material 1, further extended into the recesses of the uneven surface of the material 1 to be deformed, and hence brought into close contact with the uneven surface shape of the material 1 by following to it.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to decorative panels for exterior and interior materials of houses, furniture, home appliances, etc., and more particularly to a method and apparatus for manufacturing decorative panels having a pattern on an uneven surface.

[0002]

2. Description of the Related Art Conventionally, decorative boards having decorations such as pictures on a substrate surface of the decorative board 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 transfer sheet is placed on a substrate having a convexly curved surface, and is pressed from the back surface of the support with a rubber heat roll having a rubber hardness of 60 ° or less to transfer a picture, thereby obtaining a decorative plate. . 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. H11-27139 can handle three-dimensional curved surfaces, it basically uses elastic deformation of the rotating heat roll by rubber to follow the surface irregularities. Not applicable to irregularities. In addition, the soft rubber roll is liable to be worn by the corners of the unevenness of the base material to be transferred. Also,
With the structure in which the foamed 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.

[0004]

In order to solve the above-mentioned problems and to enable transfer to a large three-dimensional uneven surface, the curved surface transfer method and the curved surface transfer apparatus according to the present invention employ a base material to be transferred. Hereinafter, the transfer sheet is opposed to the uneven surface of the base material), and solid particles are sprayed and collided on the back side of the transfer sheet, and the transfer sheet is formed by utilizing the collision pressure of the solid particles. Pressing and contacting were performed by following the surface irregularities of the substrate. At the time of transfer, by appropriately heating one or more of the base material, the transfer sheet, and the solid particles to transfer, when the heat-deformable transfer sheet is used, the transfer sheet extends and the surface of the base material is transferred. It is made easier to follow the uneven shape, and when a heat-sensitive adhesive is used, the adhesive is activated so that it can be easily transferred.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The curved surface transfer method and the curved surface transfer device of the present invention will be further described below. FIG. 1 is a schematic device diagram showing one embodiment of the curved surface transfer device of the present invention, which can realize the curved surface transfer method of the present invention.

First, the curved transfer device of the present invention illustrated in FIG. 1 is a device for sequentially transferring a pattern or the like to a flat base material having an uneven surface using a long transfer sheet. The apparatus shown in FIG. 1 includes a base material transporting device 2 for a base material 1, a sheet feeding device 4 for a transfer sheet 3, and a pressure application unit 6 for colliding solid particles 5 against the back surface of the transfer sheet and applying a collision pressure.

The base material transporting device 2 is composed of an endless orbit type conveyor belt, a drive driving roller row, and the like, and sequentially transports the substrate 1 placed horizontally thereon. After the material surface is sequentially exposed to the collision pressure of the solid particles, the material is discharged.

The sheet feeder 4 includes a sheet feeder 7,
Guide roller 8, sheet supporting device 9, peeling roller 10,
It comprises a sheet discharging device 11 and the like. The sheet feeding device 4 transfers the transfer sheet 3 from the supply roll set in the sheet supply device 7 to the pressure applying section 6 via the guide roller 8, and in the pressure applying section 6, the collision pressure is not applied. The transfer sheet 3 is transported at the same transport speed as the base material 1 while leaving a slight gap between the transfer sheet 3 and the base material 1 so as to float. The transfer sheet 3 is supplied such that the transfer layer faces the substrate 1 side. The transfer sheet 3 and the base material 1
The space between them is maintained by a sheet supporting device 9 composed of a belt or the like that rotates in accordance with the transfer of the transfer sheet 3 while sandwiching both ends of the transfer sheet 3 from the front and back sides. Further, the sheet supporting device 9 prevents the solid particles 5 and the air flow for conveying the solid particles 5 from flowing between the transfer sheet 3 and the substrate 1. Then, the transfer sheet 3 (support) of the transfer sheet 3 adhered to the base material 1 by the pressure applying unit 6 is separated from the base material 1 by the separation roller 10 and wound up by the sheet discharge device 11.

[0009] The pressure applying unit 6 transfers the solid particles 5 to the transfer sheet 3.
To the back side (support side), and the solid particles 5 are collected and reused. The pressure applying unit 6 includes a hopper 12, a blower (or compressor) 13 such as a blower, a manifold 14, a nozzle 15, a chamber 16, a drain pipe 17, and a vacuum pump 18.
Etc. Solid particles 5 stored in hopper
Is the air fed from the blower 13 and the manifold 14
And are distributed from the manifold 14 and sent to the plurality of nozzles 15. Then, the solid particles 5 are ejected along with the airflow ejected from the nozzle 15. The solid particles 5 ejected from the nozzle 15 and having collided with the transfer sheet 3 collect in the lower part of the chamber 16, and the drain pipe 17 is sucked and transferred by the vacuum pump 18 from there, and collected in the original hopper 12. , Stored for reuse. Except for the transfer sheet 3 and the entrance of the base material 1, the chamber 16 is provided with the base material 1, the transfer sheet 3, the nozzle 15, and the like provided for transfer so as not to leak the solid particles 5 ejected from the nozzle 15 to the outside. It covers the surroundings. The pressure application unit 6 in the figure also includes a heating device 19 that preheats the transfer sheet 3 and the base material 1 before the solid particles 5 collide.

Next, one form of the curved surface transfer method of the present invention will be described.
A further description will be given using the apparatus of FIG. 1 described above. First, the base material 1 having a plate-like shape whose surface to be transferred has an uneven surface is processed one by one by the base material transfer device 2.
Conveyed inside. On the other hand, as the transfer sheet 3, a sheet in which a transfer layer composed of a decorative layer and a heat-sensitive adhesive layer is sequentially laminated on a support made of a thermoplastic resin film is used. The tension is applied by the sheet feeding device 4, and the transfer sheet 3 is unwound from the supply roll set in the sheet supply device 7, and enters the chamber 16 of the pressure applying unit 6 via the guide roller 8. In the chamber 16, the transfer sheet 3 is sandwiched at both ends in the width direction by the sheet support device 9,
The adhesive layer is conveyed at a constant speed in parallel with the conveyed base material 1 with a slight space opened above the base material 1 so as to face the side of the adhesive layer facing the conveyed base material 1 side. It should be noted that in the apparatus shown in the figure, the heating device 19 in the chamber 16 of the pressure applying unit 6 is used.
Thus, by preheating the transfer sheet 3 before applying the collision pressure, the stretchability of the sheet and the activation of the heat-sensitive adhesive layer are also performed. At the same time, the transfer surface of the base material 1 located below the transfer sheet 3 is also heated, and the adhesion is facilitated by the adhesive layer. Thus, the thermal bonding by the adhesive layer of the transfer sheet is smoothly performed.

Next, the transfer sheet 3 is exposed to the collision of the solid particles 5 ejected together with the air flow from the nozzle 15.
A large number of nozzles 15 are arranged linearly in a direction (= width direction) perpendicular to the transfer direction of the transfer sheet 3 and the base material 1 and perpendicular to the back surface of the transfer sheet, and as a result, the solid particles 5 ejected from the nozzle 15 are discharged. Applies a collision pressure in a linear band shape in the width direction over substantially the entire width of the transfer sheet 3. In addition, the solid particles 5 ejected from the nozzles 15 travel in the direction of the transfer sheet 3 while spreading somewhat, and as a result, the solid particles also collide with a region between the plurality of arranged nozzles 15. Then, the transfer sheet 3 which is moved by floating with a gap between the base material 1 and the base material 1 due to the collision pressure of the solid particles is pressed against the base material 1 and further transferred into the recesses on the uneven surface of the base material 1. By being stretched and deformed, the transfer sheet adheres closely to the uneven surface shape of the substrate 1. The base material 1 used in the description here is a plate material having a flat surface as a whole, and the transfer sheet 3 has both ends in the width direction of the transfer sheet 3 by the sheet supporting device 14. Since the transfer sheet 3 is moved to a distant position in a state where nothing is applied and a collision pressure is not applied to the transfer sheet 3, the transfer sheet 3 adheres to the base material 1 in the width direction at the central portion in time earlier. The vicinity of both ends of the direction is delayed. This means that, as a whole, the transfer sheet 3 and the base material 1 are transported at the same speed and are sequentially exposed to the collision pressure in the flow direction.
When the transfer sheet 3 comes into close contact with the uneven surface, the air is left between the base material 1 and the transfer sheet 3 so as not to make close contact.

On the other hand, the solid particles 5 which have been subjected to the collision with the transfer sheet 3 bypass the side surface of the sheet supporting device 9,
It is conveyed toward the lower part of the chamber 16 to which the drain pipe 17 is connected. Then, it is sucked from the lower part of the chamber 16 by the drain pipe 17 and collected in the original hopper 12. Further, the air used for jetting solid particles and jetted from the nozzle 15 is also sucked by the drain pipe 17 and discharged to the outside of the system by the vacuum pump 18. In this manner, the solid particles are prevented from flowing out to the surroundings together with the air from the opening of the entrance through which the transfer sheet and the base material enter and exit the chamber 16. At this time, setting the pressure inside the chamber 16 to a lower pressure than the outside is suitable for preventing the solid particles 5 from flowing out of the chamber 16.

Then, the transfer sheet 3 adhered to the substrate 1
Is discharged to the outside of the chamber 16 in a state in which the transfer sheet 3 is in close contact with the substrate 1, and then the transfer sheet 3 (support) is peeled from the substrate 1 by the peeling roller 10. As a result, a decorative plate 20 is obtained in which the decorative layer of the transfer sheet 3 has been transferred to the uneven surface of the substrate 1 via the adhesive layer. On the other hand, (the support of) the transfer sheet 3 after passing through the peeling roller 10 is transported obliquely upward and taken up by the sheet discharge device 11 as a discharge roll. The substrate 1 after passing through the peeling roller 10
Is transported in the horizontal direction by the substrate transport device 2.

The above is one mode of the curved surface transfer method of the present invention, and the method of the present invention will be described in more detail.

First, as the base material 1 that can be used, it is of course possible to apply a flat surface having a transferred surface, but the present invention is most effective when the transferred surface is an uneven surface, and in particular It is a three-dimensional substrate. Conventional holding jig that makes rotational contact (the aforementioned Japanese Patent Publication No. 61-5895).
Or a transfer roller made of rubber (see the above-mentioned JP-A-5-13909).
In Japanese Patent Application Laid-Open No. 7-207, the direction of the rotation axis is inherently limited, so that the applicable surface unevenness is limited to two-dimensional unevenness having a curvature only in one axial direction.
In the latter case, even if three-dimensional irregularities having a curvature in two axial directions are 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 roll having a special shape tailored to each base material shape is used. However, as described above, in the present invention, since the collision pressure of solid particles that can behave fluidly is used, the direction of pressure application is essentially limited to the three-dimensional shape of surface irregularities. do not have. (The directionality is a direction of a temporal change of a point on the substrate to which the pressure is applied.) Therefore, even a substrate having a shape having irregularities in the transfer direction of the transfer sheet or the substrate. Does not dance. That is, it can be applied to two-dimensional irregularities having irregularities only in the feed direction or the width direction, and three-dimensional irregularities having irregularities in both the feed direction and the width direction. In addition, the point that the present invention does not have the above-mentioned directivity is considered in view of a method and an apparatus (the present invention may have such a form) in which a single sheet of transfer sheet is placed on a substrate and pressed and adhered one by one. , Easy to understand. In addition, the base material is not limited to a flat plate material as a whole, and may be a base material having two-dimensional irregularities curved in the feed direction or width direction in a convex or concave shape in an arc shape, and a finer tertiary on the curved surface. There may be original 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 in the width direction or the feed direction in consideration of workability and the like. The surface forming the uneven surface may be a flat surface, a curved surface, or a combination of a flat surface and a curved surface. Therefore, the curved surface on the transferred substrate of the present invention means an uneven surface having no curved surface whose cross section is composed of only a plurality of flat surfaces, such as a tooth profile of a geta. The term “curvature” as used in the present invention also includes the case where the curvature is infinite (curvature radius = 0), which is angular such as around the sides or vertices of a cube.

The material of the base material 1 that can be used is arbitrary. For example, in the case of a plate material, a non-ceramic ceramic plate such as a calcium silicate plate, an extruded cement plate, an ALC (lightweight expanded concrete) plate, a wood veneer. And wood plywood, particle board, wood boards such as wood medium density fiberboard (MDF), metal boards such as iron, aluminum and copper, ceramics such as ceramics and glass, polypropylene, ABS resin, phenol resin, etc. It may be a resin molded product or the like. The surface of these base materials may be coated in advance with an easy-adhesion primer for assisting adhesion with an adhesive or a sealer agent for sealing and sealing fine irregularities and porosity on the surface. Isocyanate, 2
A resin such as a liquid-cured urethane resin, an acrylic resin, or a vinyl acetate resin is applied and formed. In order to make the surface of the base material have desired irregularities, press working, embossing, extrusion, cutting, molding, or the like may be used. Further, the uneven shape is arbitrary, for example, joints of tiles and bricks, unevenness of stone surface such as cleavage surface of granite, wood siding,
It is the unevenness of the wood board surface such as floating wood grain, the unevenness of the spray-painted surface such as ricin and stucco.

Next, as the transfer sheet 3 usable in the present invention, if the substrate is a two-dimensional uneven surface, a paper having no stretchability as a support can be used. In order to apply it to the three-dimensional uneven surface that demonstrates its true value,
At least at the time of transfer, a transfer sheet having stretchability is used. When the collision pressure of solid particles is applied due to stretchability,
The transfer sheet follows and adheres to the inside of the concave portion on the surface of the base material, and transfer is performed. The transfer sheet includes a support and a transfer layer that transfers and transfers. The transfer layer includes at least a decorative layer, and in a configuration in which an adhesive layer is further laminated, applying an adhesive to one or both of the transfer sheet and the base material during transfer can be omitted. The stretchability of the transfer sheet is mainly governed by the stretchability of the support. Therefore, if a rubber film is used as the support, without heating the transfer sheet or the like at the time of transfer due to the properties of rubber that is stretched at room temperature,
It is also possible to follow, adhere, and transfer to the uneven surface of the substrate. Also, if a thermoplastic resin film is used as the support, there is almost no extensibility at the time of forming the decorative layer, and at the time of transfer, as a transfer sheet that expresses sufficient extensibility by heating, as in the case of a conventionally known ordinary transfer sheet, A transfer sheet that can be used in the present invention can be prepared. In addition, in terms of stretchability, a biaxially stretched polyethylene terephthalate film, which has been widely used in the past, is required to exhibit necessary and sufficient stretchability by setting heating conditions and collision pressure conditions depending on the surface irregularities. Surface transfer is possible, but low-temperature, low-pressure, easy to develop stretchability.Polyolefin-based film such as polypropylene film, polyethylene film, polymethylpentene film, vinyl chloride resin film, nylon film, etc. Alternatively, a non-stretched film, a rubber (elastomer) film such as a natural rubber, a synthetic rubber, a urethane elastomer, and an olefin elastomer are also preferable supports.

The decorative layer is a conventionally known method such as gravure printing, silk screen printing, offset printing, etc., a pattern layer on which a pattern or the like is printed 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. As a pattern, according to the substrate surface irregularities,
A wood grain pattern, a stone pattern, a tile pattern, a brick pattern, a solid surface, or the like is used. In order to adjust the releasability between the support and the decorative layer, a layer such as a release layer is provided between these layers in the same manner as in a conventionally known transfer sheet. The adhesive layer is also a conventionally known one made of a thermoplastic resin such as polyvinyl acetate, an acrylic resin, or a blocked isocyanate-curable polyurethane resin. Incidentally, the adhesive layer of the transfer sheet, if the decorative layer itself has adhesiveness,
Alternatively, when an adhesive layer is provided on the transfer substrate side, it can be omitted.

There is a method of providing the adhesive layer on the transfer sheet, but it is not provided on the transfer sheet, but a method of providing it on the transfer sheet by coating or the like immediately before the transfer, or by adhering to the substrate side in advance or immediately before. Various forms such as a method of providing the agent layer by coating or the like, a method of providing the adhesive layer on both the transfer sheet and the base material in advance or immediately before may be used. The method in which the adhesive layer is provided in advance only on the transfer sheet side has an advantage that it can be formed by printing or the like at the same time as the decoration layer, and that the time and equipment required for the transfer can be omitted. When the adhesive is applied to one or both of the transfer sheet and the base material immediately before, an adhesive such as a pressure-sensitive adhesive or a water-based adhesive may be used. When the substrate is porous, it is convenient to dry the solvent of the adhesive applied immediately before. In this case, it is possible to use a guide roller 8 having a large number of needles as the guide roller 8 of the transfer sheet feeder 4 to pierce the transfer sheet when passing the sheet, and to assist drying by the holes.
The diameter of the hole is usually about 0.1 to 1.0 mm, and the interval between adjacent ventilation holes is usually about 5 to 50 mm.

The heating before the transfer is carried out, if necessary, for the stretchability of the transfer sheet, the activation of the adhesive layer, and the heating of the adhesive surface of the substrate. The heating means is optional, and as the heating means before the application of the collision pressure, for example, heater heating, infrared heating, dielectric heating, induction heating, hot air heating, etc., like the heating device 19 shown in the curved surface transfer device of FIG. It is. In the present invention, since the solid particles are used for applying pressure, the solid particles can be heated, and the solid particles can be used as a heating source for a transfer sheet or the like, and can be heated simultaneously with the close contact of the transfer. Note that heating the solid particles means that the heated gas also ejects the gas ejected from the nozzle together with the solid particles. When the gas contacts the back surface of the transfer sheet, the gas can also be used as a heating source. it can. Therefore,
Even when the transfer sheet or the like needs to be heated, a heating device for preheating can be omitted if heating with solid particles or ejected gas is sufficient.

As the solid particles 5 to be used, inorganic particles which are inorganic powders such as glass beads, ceramic beads, calcium carbonate beads, alumina beads, or fluororesin beads, nylon beads, silicone resin beads, urethane resin beads. Organic particles such as resin beads such as urea resin beads, phenol resin beads and crosslinked rubber beads are used. As the shape, a spherical shape or another shape is used. The gas used may be air, but may be nitrogen gas or the like. The particle size of the solid particles is usually about 10 to 1000 μm.

It is preferable to use a plurality of nozzles so that the collision area of the solid particles that collide with the transfer sheet has a desired shape. In the curved surface transfer device of FIG. 1, the transfer sheet and the base material are arranged in a line in a straight line at right angles to the feed direction of the transfer sheet to form a collision area in a band shape linearly in the width direction. For example,
FIG. 2A shows a configuration in which the collision areas are arranged in two rows in the feed direction in order to expand the collision area in the feed direction. FIG. 2 (b)
Although they are arranged in a line, the central part in the width direction is arranged to collide at the upstream side in the feed direction. In this arrangement, the pressure contact of the transfer sheet with the base material starts from the center portion in the width direction and is sequentially pressed toward both end portions in the width direction. With this configuration, it is possible to prevent the transfer sheet from adhering to the base material while holding the air in the center in the width direction.

The collision pressure of the solid particles does not have to be uniform in the collision area. FIG. 3 shows an example in which a mountain-shaped pressure distribution is set such that the maximum collision pressure is at the center in the width direction and the collision pressure decreases toward both ends in the width direction. The setting of the collision pressure is based on the opening / closing amount of the valve, the size of the inside diameter of the pipe that transports the solid particles connected to the valve, and the pressure regulator (regulator).
By adjusting the gas pressure immediately before the nozzle using, for example, the control is performed by controlling the speed of the solid particles and the gas flow ejected from the nozzle. Setting the pressure distribution as shown in FIG. 3 produces an effect similar to the effect of FIG. 2B described above. In the conventional curved surface transfer method using a rubber transfer roll, if the diameter of the center portion of the transfer roll 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. Sisters,
The transfer sheet is not uniformly fed due to pressure applied upon contact.

In the curved surface transfer device illustrated in FIG. 1, the nozzles are arranged horizontally in a horizontal direction because the substrate is flat. This is an arrangement in which solid particles collide perpendicularly to the transfer surface of the substrate. The collision is caused vertically because basically the collision pressure can be utilized most effectively. Therefore, for example, as shown in FIG. 4, if the transfer surface of the base material 1 (the cross-sectional shape perpendicular to the transport direction) is a convexly curved surface, a plurality of nozzles are prepared. The nozzle is preferably arranged perpendicularly to the surface of the object to be transferred so that the solid particles collide substantially perpendicularly with the collision surface. In this way, the nozzle arrangement should be adjusted so that the solid particles collide with the solid particles as perpendicularly as possible according to the uneven shape of the target substrate. The nozzle ejects solid particles together with a gas flow, and the structure thereof is, for example, a hollow columnar shape, a polygonal columnar shape, a fishtail shape, or the like. The nozzle may have a single opening, or may have a honeycomb (honeycomb) -shaped interior. The spray pressure is usually 0.1 ~
It is about 1.0 kg / cm ² . In addition, when the solid particles are conveyed and collide with the transfer sheet, the solid particles, the transfer sheet, or the substrate may be charged. Therefore, in order to prevent charging, the nozzle 15, the drain pipe 17 and the like are grounded, the charge removing bar is brought into contact with the transfer sheet, or ions having a charge for neutralizing the charged charge are mixed into the airflow. Is preferred.

The decorative materials obtained by the present invention described above include exterior materials such as outer walls, fences, roofs, gates, building interior materials such as wall surfaces and ceilings, window frames, doors, handrails, sills, kamois, etc. It can be used in various fields such as fittings, furniture surface materials, cabinets for low-voltage / OA equipment, and vehicle interior materials such as automobiles. In addition, as a specific example of the decorative pattern of the decorative board having three-dimensional surface irregularities, for example, tile-like, brick-like, stucco-like, lysine-like, stone-grained with a cleaved surface such as granite, paneling, Applicable to woodgrain etc. of floating woodgrain boards.
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. Benzotriazole, as needed
A paint to which an ultraviolet absorber such as ultrafine cerium oxide, a light stabilizer such as a hindered amine radical scavenger, a coloring pigment, an extender pigment, and the like are added is used. Spray coating, flow coating, etc. are used for coating. The thickness of the transparent protective layer is 1 to 100
It is about μm.

[0026]

The present invention will be further described with reference to Examples. First, as a base material having a three-dimensional surface unevenness, a calcium silicate plate having a brick-shaped three-dimensional surface unevenness 21 in which a joint portion has a concave portion as illustrated in FIG. 30g / sealer / primer
and m ² is applied. Further, as the transfer sheet, a polypropylene film having a thickness of 50 μm is used as a support, and a pigment composed of carbon black, rouge, titanium white, and yellow lead, an acrylic resin, and a vinyl chloride-vinyl acetate copolymer resin are used. A brick pattern was used as a decorative layer, and a heat-sensitive adhesive layer 10 μm made of a vinyl chloride-vinyl acetate copolymer resin was sequentially gravure-printed with the ink containing the binder. Next, using the apparatus shown in FIG. 1, the base material was placed horizontally with the uneven surface facing up, and the transfer sheet was placed with the adhesive layer surface down. Then, the transfer sheet and the base material are preheated from the transfer sheet side by radiant heat from a heating wire heater, and spherical nylon beads having a particle size distribution of 0.2 to 0.8 mm as solid particles are ejected from a nozzle together with air at room temperature. The transfer sheet was brought into contact with the back surface and pressed against the base material. Spraying pressure is 0.4 kg / cm ² ,
The pressure distribution of the air flow was maximized in the center of the sheet width direction as shown in FIG. Then, after the transfer sheet was extended into the concave portion of the joint and closely adhered thereto, the support of the transfer sheet was peeled off, and a decorative material was obtained. Furthermore, an emulsion paint of polyvinylidene fluoride is applied on the surface of the transfer layer to a thickness of 10 μm.
By coating, a transparent protective layer was formed to obtain a decorative material with a transparent protective layer.

[0027]

According to the present invention, a decorative plate 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. In addition to flat plate materials, even those with a wavy shape as a whole, such as tiles, or those with a convex or concave curved shape can be easily formed. can get. Also, continuous production is easy. Further, unlike the conventional rubber roll pressing method, there is no wear of parts such as rolls due to the unevenness of the base material.

[Brief description of drawings]

FIG. 1 is an explanatory diagram of a curved surface transfer method and a curved surface transfer device of the present invention. (A) is a schematic device view seen from the side in the substrate conveyance direction.
(B) is a schematic device diagram of a nozzle portion of the device of (a) viewed from a substrate transport direction.

FIG. 2 is a plan view showing various forms of nozzle arrangement. (A) is a horizontal two-row linear arrangement, and (b) is an arrangement in which the central portion is on the upstream side.

FIG. 3 is an explanatory diagram in which a collision direction is provided with a width distribution.

FIG. 4 is a side view showing one form of a spraying direction viewed from a flow direction.

FIG. 5 is a plan view showing an example of three-dimensional surface irregularities of a base material.

[Explanation of symbols]

 1 Base Material 2 Base Material Conveying Device 3 Transfer Sheet 4 Sheet Feeding Device 5 Solid Particle 6 Pressure Applying Section 7 Sheet Supplying Device 8 Guide Roller 9 Sheet Supporting Device 10 Peeling Roller 11 Sheet Discharging Device 12 Hopper 13 Blower 14 Manifold 15 Nozzle 16 Chamber 17 Drain pipe 18 Vacuum pump 19 Heating device 20 Decorative plate 21 Three-dimensional unevenness of brick pattern

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[Procedure amendment]

[Submission date] November 15, 1996

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claim 1

[Correction method] Change

[Correction contents]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] Claim 3

[Correction method] Change

[Correction contents]

[Procedure 3]

[Document name to be amended] Statement

[Correction target item name] 0004

[Correction method] Change

[Correction contents]

[0004]

SUMMARY OF THE INVENTION In order to solve the above problems and enable transfer to a large three-dimensional uneven surface, in the curved surface transfer method and the curved surface transfer apparatus of the present invention, the transferred substrate ( Hereinafter, simply referred to as "base material")
On the side, a transfer layer side <br/> of the transfer sheet comprising a support and the transfer layer facing, by blowing solid particles collide with the support side of the transfer sheet, utilizing impact pressure of the solid particles As a result, the transfer sheet was made to follow the surface irregularities of the base material, so that the transfer sheet could be transferred by pressure contact and close contact. When transferring,
By appropriately heating one or more of the transfer sheet and the solid particles to transfer the transfer sheet, when the heat-deformable transfer sheet is used, it is possible to further extend the transfer sheet and follow the surface irregularities of the substrate. In addition, when a heat-sensitive adhesive is used, the adhesive is activated so that it can be easily transferred. This
The curved surface transfer device for transferring the solid particles to the transfer substrate.
And the nozzle to be ejected and the substrate to be transferred face the nozzle.
A transfer device that transfers the transfer sheet to the position
And a sheet feeding device inserted between the transfer base material and the transfer base material.
Configuration.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0006

[Correction method] Change

[Correction contents]

First, the curved transfer device of the present invention illustrated in FIG. 1 is a device for sequentially transferring a pattern or the like to a flat base material having an uneven surface using a long transfer sheet. The apparatus shown in FIG. 1 includes a base material conveying device 2 for a base material 1, a sheet feeding device 4 for a transfer sheet 3, and a pressure applying unit 6 having a nozzle for applying solid particles 5 to the back surface of the transfer sheet to apply a collision pressure. Consists of.

[Procedure Amendment 5]

[Document name to be amended] Statement

[Correction target item name] 0011

[Correction method] Change

[Correction contents]

Next, the transfer sheet 3 is exposed to the collision of the solid particles 5 ejected together with the air flow from the nozzle 15.
A large number of nozzles 15 are arranged linearly in a direction (= width direction) perpendicular to the transfer direction of the transfer sheet 3 and the base material 1 and perpendicular to the back surface of the transfer sheet, and as a result, the solid particles 5 ejected from the nozzle 15 are discharged. Means that the collision pressure is applied in a linear band shape in the width direction over substantially the entire width of the transfer sheet 3 from the support side of the transfer sheet.
Et al. Is applied. The solid particles 5 ejected from the nozzle 15
Progresses in the direction of the transfer sheet 3 while spreading somewhat,
The solid particles also collide with the region between the plurality of arranged nozzles 15. Then, the transfer sheet 3 which is moved by floating with a gap between the base material 1 and the base material 1 due to the collision pressure of the solid particles is pressed against the base material 1 and further transferred into the recesses on the uneven surface of the base material 1. By being stretched and deformed, the transfer sheet adheres closely to the uneven surface shape of the substrate 1.
The base material 1 used in the description here is a plate material having a flat surface as a whole, and the transfer sheet 3 has both ends in the width direction of the transfer sheet 3 by the sheet supporting device 14. Since it is designed to be moved to a distant position in a state where nothing is applied to the collision pressure, etc.,
The transfer sheet 3 is adhered to the base material 1 at the central portion in the width direction with a time lag earlier in the vicinity of both ends in the width direction. This means that, as a whole, the transfer sheet 3 and the base material 1 are transported at the same speed and are sequentially exposed to the collision pressure in the flow direction, but the transfer sheet 3 is closely attached to the uneven surface of the base material 1. This is one of the reasons for leaving air between the base material 1 and the transfer sheet 3 so as not to adhere to each other.

[Procedure correction 6]

[Document name to be amended] Statement

[Correction target item name] 0015

[Correction method] Change

[Correction contents]

First, as the base material 1 that can be used, it is of course possible to apply a flat surface having a transferred surface, but the present invention is most effective when the transferred surface is an uneven surface, and in particular It is a three-dimensional substrate. Conventional holding jig that makes rotational contact (the aforementioned Japanese Patent Publication No. 61-5895).
Or a transfer roller made of rubber (see the above-mentioned JP-A-5-13909).
In Japanese Patent Application Laid-Open No. 7-207, the direction of the rotation axis is inherently limited, so that the applicable surface unevenness is limited to two-dimensional unevenness having a curvature only in one axial direction.
In the latter case, even if three-dimensional irregularities having a curvature in two axial directions are 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 roll having a special shape tailored to each base material shape is used. However, as described above, in the present invention, since the collision pressure of solid particles that can behave fluidly is used, the direction of pressure application is essentially limited to the three-dimensional shape of surface irregularities. do not have. (This directionality is the direction of the temporal position change of the point on the base material to which pressure is applied.) Therefore, even with a transfer sheet or a base material having irregularities in the feed direction of the base material. no I configuration. That is, it can be applied to two-dimensional irregularities having irregularities only in the feed direction or the width direction, and three-dimensional irregularities having irregularities in both the feed direction and the width direction. In addition, the point that the present invention does not have the above-mentioned directivity is considered in view of a method and an apparatus (the present invention may have such a form) in which a single sheet of transfer sheet is placed on a substrate and pressed and adhered one by one. , Easy to understand. In addition, the base material is not limited to a flat plate material as a whole, and may be a base material having two-dimensional irregularities curved in the feed direction or width direction in a convex or concave shape in an arc shape, and a finer tertiary on the curved surface. There may be original 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 in the width direction or the feed direction in consideration of workability and the like. The surface forming the uneven surface may be a flat surface, a curved surface, or a combination of a flat surface and a curved surface. Therefore, the curved surface on the transferred substrate of the present invention means an uneven surface having no curved surface whose cross section is composed of only a plurality of flat surfaces, such as a tooth profile of a geta. The term “curvature” as used in the present invention also includes the case where the curvature is infinite (curvature radius = 0), which is angular such as around the sides or vertices of a cube.

[Procedure amendment 7]

[Document name to be amended] Statement

[Correction target item name] 0020

[Correction method] Change

[Correction contents]

The heating before the transfer is carried out, if necessary, for the stretchability of the transfer sheet, the activation of the adhesive layer, and the heating of the adhesive surface of the substrate. The heating means is optional, and as the heating means before the application of the collision pressure, for example, heater heating, infrared heating, dielectric heating, induction heating, hot air heating, etc., like the heating device 19 shown in the curved surface transfer device of FIG. It is. In the present invention, since the solid particles are used for applying pressure, the solid particles can be heated, and the solid particles can be used as a heating source for a transfer sheet or the like, and can be heated simultaneously with the close contact of the transfer. Note that heating the solid particles means that the heated gas also ejects the gas ejected from the nozzle together with the solid particles, and this gas is the back surface of the transfer sheet (the surface on the support side).
The gas can also be used as a heat source by contacting with. Therefore, even if you need to heat the transfer sheet,
If the heating with solid particles or jetting gas is sufficient, the heating device for preheating can be omitted.

[Procedure amendment 8]

[Document name to be amended] Statement

[Correction target item name] 0026

[Correction method] Change

[Correction contents]

[0026]

The present invention will be further described with reference to Examples. First, as a base material having a three-dimensional surface unevenness, a calcium silicate plate having a brick-shaped three-dimensional surface unevenness 21 in which a joint portion has a concave portion as illustrated in FIG. 30g / sealer / primer
and m ² is applied. Further, as the transfer sheet, a polypropylene film having a thickness of 50 μm is used as a support, and a pigment composed of carbon black, rouge, titanium white, and yellow lead, an acrylic resin, and a vinyl chloride-vinyl acetate copolymer resin are used. A brick-like pattern was used as a decorative layer, and a heat-sensitive adhesive layer of 10 μm composed of a vinyl chloride-vinyl acetate copolymer resin was sequentially gravure-printed with the ink containing the binder to prepare a transfer layer . Next, using the apparatus shown in FIG. 1, the base material was placed horizontally with the uneven surface facing up, and the transfer sheet was placed with the adhesive layer surface down.
Then, preheating the transfer sheet and the substrate in the radiant heat by the heating wire heater from the support side of the transfer sheet, ejected as the solid particles of nylon beads spherical particle size distribution 0.2~0.8mm from a nozzle with air at room temperature Let transfer sheet back side
The transfer sheet was pressed against the base material by colliding with (side surface of the support) . The spray pressure was 0.4 kg / cm ² , and the pressure distribution of the air flow was maximized in the center of the sheet width direction as shown in FIG.
Then, after the transfer sheet was extended into the concave portion of the joint and closely adhered thereto, the support of the transfer sheet was peeled off, and a decorative material was obtained. Further, an emulsion paint of polyvinylidene fluoride was applied to the surface of the transfer layer at a thickness of 10 μm to form a transparent protective layer, and a decorative material with a transparent protective layer was obtained.

Claims (3)

[Claims] 1. Solid particles are made to collide from the back surface side of a transfer sheet, which is made to face the transfer layer, with the uneven surface of a substrate to be transferred having an uneven surface, and the collision pressure is utilized to bring the transfer sheet onto the uneven surface of the substrate. A curved surface transfer method that transfers by pressing. 2. The curved surface transfer method according to claim 1, wherein at least one of the substrate to be transferred, the transfer sheet, and the solid particles is transferred by heating. 3. A transfer layer of a transfer sheet is made to face an uneven surface of a transfer-receiving substrate having an uneven surface, solid particles are made to collide from the back side of the transfer sheet, and the transfer pressure is used to form the transfer sheet. A curved surface transfer device that presses and transfers to the uneven surface of the base material.