JPH10166794A - Method for transferring curved surface - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative material by partly transferring not only a protruded part of an irregular surface but also a recessed interior to only an arbitrary part. SOLUTION: The method for transferring a curved surface comprises the steps of partly forming an adhesive layer A only on one partial area of any of a transfer layer of an irregular surface of an irregular base material B or a transfer sheet S having a support S1 and the transfer layer S2, opposing the transfer layer side of the transfer layer of the sheet having the support and the layer to the irregular surface side of the base material, colliding solid particles P with the support side of the sheet, bringing the sheet into pressure contact with the irregular surface of the base material by utilizing the pressure, and releasing to remove the support of the sheet after the transfer layer is adhered to the base material. The adhesive layer may be formed on the overall surface, and a release agent layer may be partly formed on the other article.

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 homes, furniture, home appliances and the like, and more particularly to a method for producing decorative panels having a decorative uneven surface.

[0002]

2. Description of the Related Art Conventionally, a method of manufacturing a decorative plate having an uneven surface by decorating a desired portion of the surface of the transfer surface, for example, only a convex portion by transfer, on an uneven substrate having an uneven surface is known. There are the following methods. The method disclosed in Japanese Patent Publication No. 60-59876 discloses a method in which an adhesive is applied only to a convex portion of an uneven substrate using a roll coater or the like, and a transfer sheet is stacked and pressed with a rubber roller to transfer the decorative layer only to the convex portion. How to That is, a step of applying a base coat to the entire surface of the uneven substrate having irregularities to form a base coat layer, and applying a heat-sensitive adhesive to the convex portions of the uneven substrate covered with the base coat layer to form a heat-sensitive adhesive. Forming a transfer sheet by forming a heat transferable ink layer by printing a pattern to be transferred with a heat-bondable ink on a support; and transferring the transfer sheet to the surface of the heat-sensitive adhesive layer. Abutting the heat transferable ink layer surface of the sheet, transferring the heat transferable ink layer onto the heat-sensitive adhesive layer by heating under pressure, and then peeling off the support of the transfer sheet, thereby forming a part of the uneven base material. The image is transferred only to the convex portion. A method disclosed in Japanese Patent Application Laid-Open No. 6-278400 discloses a method of forming a surface on a rough substrate having large irregularities and fine irregularities on the convex portions by using a roll coater or screen printing only on the convex portions having the large irregularities. The transfer sheet is placed thereon, and the transfer sheet is placed thereon. After pressing with a soft rubber roller having a rubber hardness of about 30 °, the support of the transfer sheet is peeled off to remove the transfer layer of the transfer sheet. This is a method of transferring only to the convex portions of the irregularities, and also to the inside of the concave portions of the fine irregularities in the convex portions. This method is a method in which a soft rubber roller having a rubber hardness of about 30 ° is used as a rubber roller serving as a pressing means of the transfer sheet.

[0003]

However, the above-mentioned conventional method has the following problems. According to the method (A), the transfer cannot be performed in the concave portion (the bottom portion or the side surface that is a connecting portion between the convex portion and the bottom portion) of the concave-convex base material, and the method can be applied to decoration of only the convex portion. (B) Further, when the surface of the convex portion has a finer uneven pattern (for example, hairline, satin finish, etc.), it is difficult to transfer the fine unevenness into the concave portion. (C) In addition, since a rubber roller was used to press the transfer sheet, transfer could not be performed even on a three-dimensional uneven surface having unevenness in the width direction of the roller. In the method of (B), when there is a finer uneven pattern on the surface of the convex portion (B), transfer can be performed.However, in order to use a soft rubber roller for pressing the transfer sheet, pressing and transferring are repeated. In addition, there is a disadvantage that the rubber roll is easily worn by the corners of the irregular shape of the base material. Moreover, the above (A) and
The problem (C) was not yet a solution that could be solved.

[0004]

In order to solve the above-mentioned problems, in the curved surface transfer method of the present invention, an area to be partially transferred is formed by forming an adhesive layer partially on a transfer sheet or an uneven base material. Then, the transfer is performed only on the portion where the adhesive layer is formed. Alternatively, even if the adhesive layer is formed on the entire surface, the release agent layer is further formed on the other surface or the adhesive layer surface. Was partially formed so that the transfer was performed only in the portion having no release agent layer and having the adhesive layer. Moreover, in the present invention,
As a means for pressing the transfer sheet composed of the support and the transfer layer against the uneven surface of the uneven base material, solid particles collide with the support side of the transfer sheet while the transfer layer side of the transfer sheet faces the uneven base material. By utilizing the collision pressure, the transfer sheet can be easily formed by following the surface shape of the uneven base material, so that not only the convex portions of the uneven surface but also the concave portions such as the concave bottom surface and the concave side surface. Any part of the uneven surface including the inside can be decorated by transfer.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The curved surface transfer method of the present invention will be further described below with reference to the drawings. First, FIG. 1 is a conceptual diagram showing a curved surface transfer method of the present invention, and FIG.
(B) shows another embodiment. FIG. 2 is an explanatory view of various methods for partially forming the adhesive layer. FIG. 3 is a conceptual diagram of an example of a curved surface transfer device capable of performing the curved surface transfer method of the present invention, and FIG.
FIG. 2B is a view of the blow nozzle portion of the apparatus of FIG. FIGS. 4A and 4B are plan views showing various configurations of a discharge nozzle arrangement for ejecting solid particles. FIG. 4A shows a staggered arrangement, and FIG. It is a staggered arrangement. FIG. 5 is an explanatory view in which a width direction distribution is provided for the collision pressure, FIG. 6 is a side view as viewed from a flow direction showing one form of a spraying direction, and FIG. 7 shows an example of three-dimensional surface unevenness of the uneven base material. It is a top view.

First, the method of the present invention will be described with reference to FIG. 1. In FIG.
An adhesive is applied to form the adhesive layer A only on the protrusions, and then the transfer sheet S is overlaid on the support S1 of the transfer sheet S.
The solid particles P are sprayed from the side to collide with each other, so that the transfer layer S2
Is adhered only to the projections of the uneven base material B via the adhesive layer A, then the support S1 of the transfer sheet S is peeled off, and the transfer layer S2 is transferred only to the projections of the uneven base material B. It is to let. Further, as shown in FIG. 1 (B), the desired area where the present invention transfers the transfer layer is not limited to only the convex portions of the uneven base material B. That is, FIG. 3 shows, as an example, a part of the convex part and a part of the concave part of the uneven substrate B as a desired area, an adhesive applied to the area of the uneven substrate B to form an adhesive layer, It is to be transferred to an arbitrary portion of the uneven substrate. The present invention is particularly characterized in that, as shown in FIG. 1 (B), it is possible to transfer to an arbitrary portion including a concave portion in addition to a convex portion. The conventional method uses a rubber roller as the pressing means,
This is because, in the present invention, since the collision pressure by the spraying of the solid particles is used, the transfer sheet can follow and form the inside of the concave portion.

In order to transfer the transfer layer to only a part of the uneven base material B, the adhesive layer and the release agent layer are partially formed on the uneven base material and the transfer sheet by the following various methods. ,
The transfer can be performed by pressing the transfer sheet against the uneven substrate and transferring the transfer sheet.

[0008] Partial forming method of adhesive layer: (1) Method of forming adhesive layer partially on uneven substrate: adhesive is partially applied to the area of the uneven substrate to be decorated, and the adhesive layer is partially formed. It is a method of forming the target. (A) As shown in FIG. 2 (A), the aforementioned Japanese Patent Publication No. Sho 60-598.
No. 76, Japanese Unexamined Patent Publication No. 6-278400, etc.
The adhesive layer A is printed only on the projections of the uneven base material B by silk screen printing, a roll coater, a gravure roll coater, or the like.
Apply by coating. However, this method is effective when the adhesive layer is formed only on the projections of the uneven substrate. (B) As shown in FIG. 2 (B), a liquid adhesive is applied to the entire surface of the uneven base material B, and then only the adhesive on the convex portion is wiped off with a doctor blade C3 or a roller, cloth, sponge or the like ( Scraping), filling the concave portion only with an adhesive (so-called wiping method), or once solidifying the adhesive, polishing and removing only the adhesive on the convex portion, and removing the adhesive layer only on the concave portion. Form A. (C) As shown in FIG. 2 (C), the adhesive is partially applied in a desired pattern on all or a part of the projections of the uneven substrate B using silk screen printing, gravure offset printing, or the like. Print on However, the upper surfaces of the projections are flat and the heights are uniform, which is effective for forming an adhesive layer only on the flat portions of the projections on a flat (flat) base material as a whole. In this case, the uneven substrate B can be regarded as the same as the completely flat substrate B '. (D) As shown in FIG. 2 (D), application is performed manually. An adhesive layer can be formed on an arbitrary portion of the uneven substrate (a convex portion, a bottom portion of a concave portion, a side surface of a concave portion, a portion from a convex portion to a concave portion) and the like.
Specifically, a brush or a brush is used.

(2) A method of partially forming an adhesive layer on a transfer sheet: a method of partially applying an adhesive to a region of a transfer layer to be transferred on a transfer sheet to partially form an adhesive layer. . As shown in FIG. 2 (E), an adhesive is partially applied only to a portion on the transfer layer of the transfer sheet S which requires transfer, and the adhesive layer A is partially formed by coating or printing. The adhesive layer is formed in a desired pattern by various printing methods such as a gravure printing method, manual application, drawing, and the like.

Method of forming part of release agent layer: (1) A material having a release property, ie, a release agent, which is not adhered to the transfer layer only on portions of the uneven substrate that do not need to be transferred, that is, is applied or printed. Partially applied to partially form the release agent layer. On the other hand, on the transfer sheet side, an adhesive layer is formed on at least the entire surface to be transferred. The method of forming the release agent on the uneven base material in the same manner as in the above (1) (A) to (D). However, in the case where the above (1) (A) to (D) are applied, and in the case of the combination of the same uneven base material and the same transfer sheet, it is not necessary to form the pattern and the pattern. The relationship with the parts is reversed. That is, in the method described above, the application pattern has a relationship between a positive image and a negative image. (2) A release agent layer is formed on only the transfer layer of the transfer sheet that is not to be transferred. On the other hand, on the uneven substrate side, an adhesive layer is formed on at least the entire surface to be transferred.

The adhesive used to partially form the adhesive layer A includes a heat-sensitive adhesive, a moisture-curable heat-sensitive adhesive, a hot-melt adhesive, a moisture-curable hot-melt adhesive, and a two-component curable adhesive. Various adhesives such as an adhesive, a thermosetting adhesive, an ionizing radiation-curable adhesive, a water-based adhesive, and a pressure-sensitive adhesive can be used. It is appropriately selected and used depending on the material of the adhesive surface such as the uneven base material and the transfer sheet, or the required physical properties of the obtained decorative board. The adhesive is applied to the uneven substrate or the transfer sheet immediately before or before the transfer. The adhesive is applied as a solution or dispersion dissolved or dispersed in a solvent, or without a solvent.
For example, a heat-melting adhesive or a moisture-curing heat-melting adhesive can be used as a solventless hot melt adhesive, respectively. In addition, an ionizing radiation-curable adhesive or the like can be applied without a solvent. The advantage that the adhesive can be applied without solvent is that even if applied immediately before transfer, solvent drying is not required and high-speed production can be performed. In particular, in the present invention, the collision pressure of the solid particles is used as the transfer pressing means, and the application is actually performed in the chamber. Therefore, when the adhesive is applied immediately before the transfer, the chamber is filled with the volatile solvent. It is not necessary to take explosion-proof measures against solvents in equipment. Also,
A water-based adhesive is also preferable in terms of explosion-proof measures, but it is not suitable for high-speed production because it requires drying. The thickness of the adhesive layer is usually about 10 to ²⁰⁰ g / m ^{2 in} terms of application amount,
The amount is appropriately adjusted according to the surface state of the uneven substrate, the type of the adhesive, and the like.

As the heat-sensitive adhesive, conventionally known adhesives such as polyvinyl acetate, acrylic resin, and polyamide resin obtained by condensation polymerization of dimer acid and hexamethylenediamine can be used.

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 to stand naturally. In addition, the moisture-curing heat-sensitive adhesive has the same adhesive strength as a normal heat-melting adhesive when pressed and peeled, but the crosslinking and curing reaction gradually proceeds due to moisture in the air when left naturally. To
Ultimately, there is no creep deformation and no heat melting, and it is excellent in heat resistance and the like, and a large adhesive strength is obtained. However, in order to promote the crosslinking and curing of the adhesive by moisture after the transfer is completed, the decorative board after the transfer is left to cure in air containing moisture. Preferable atmospheric conditions for curing are generally about 50% RH or higher relative humidity,
The temperature is 10 ° C or higher. The higher the temperature and relative humidity,
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-sensitive 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 at least one isocyanate group at each molecular terminal. Isocyanate groups react with each other due to moisture in the air to cause a chain extension reaction,
As a result, a reactant having a urea bond in the molecular chain is generated, and the isocyanate group at the molecular terminal further reacts with the urea bond to cause a biuret bond and branch 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 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.

[0016] In addition to the above-mentioned various polyisocyanate prepolymers, examples of the moisture-curable heat-sensitive adhesive include:
In order to adjust various physical properties, various auxiliary materials such as a thermoplastic resin, a tackifier, a plasticizer, and a filler can be further 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, tackifier such as rosin abietic acid ester, calcium carbonate, barium sulfate, silica ,
Filler (extender pigment) made of fine powder such as alumina, thixotropic agent such as organic bentonite (especially in the case of an uneven substrate having a large uneven step, it prevents the heat-sensitive adhesive from flowing from the convex portion to the concave portion. , A coloring pigment, a curing catalyst, a moisture removing agent, a storage stabilizer, an antioxidant, and the like.

Next, 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 compound in the molecule. Having a polymerizable functional group,
A composition curable by ionizing radiation, which is obtained by appropriately mixing a prepolymer (including a so-called oligomer) and / or a monomer, is preferably used. These prepolymers or monomers are used alone or as a mixture of two or more. Here, the ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking a molecule, and usually an ultraviolet ray (UV) or an electron beam (EB) is used. The above prepolymer or monomer is, specifically, a compound having a radical polymerizable unsaturated group such as a (meth) acryloyl group or a (meth) acryloyloxy group, a cationic polymerizable functional group such as an epoxy group in a molecule, or the like. Become. 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 system 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 system having a cationically polymerizable functional group, an aromatic diazonium salt, an aromatic sulfonium salt, an aromatic iodonium salt, a metallocene compound, a benzoinsulfonic 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.

Various additives can be added to the ionizing radiation-curable resin, if necessary. These additives include, for example, vinyl chloride-vinyl acetate copolymers, polyvinyl acetates, acrylic resins, thermoplastic resins such as cellulose resins, and fine powders such as calcium carbonate, barium sulfate, silica, and alumina. Thixotropic agents such as extenders (fillers) and organic bentonite (especially in the case of a substrate to be transferred having a large unevenness, if added to prevent the ionizing radiation-curable adhesive from flowing from the convex portion to the concave portion) Good.) If the diluting solvent is used without being added, there is no need to dry the solvent.

As the release agent that can be used to partially form the release agent layer, an emulsion paint of a fluororesin such as polyvinylidene fluoride, polyvinyl fluoride, and ethylene / tetrasefluoroethylene copolymer is used. It is possible,
This may be printed or applied, and the dispersion medium may be dried.
It is possible to use a monomer or a prepolymer obtained by adding a group containing an active hydrogen such as a hydroxyl group or a carboxyl group to a fluorohydrocarbon molecule or a prepolymer mixed with a crosslinking agent such as an isocyanate or a melamine resin. May be printed, applied and crosslinked / cured. Using a silicon resin, it is printed or applied and dried or cured. Tree wax,
A wax such as montan wax and paraffin wax is used, heated and melted, and printed or applied.

Next, the uneven substrate B that can be used in the present invention is:
Although the substrate to be transferred has an uneven shape, the present invention is particularly applicable to the conventional rubber roller transfer method (the above-mentioned Japanese Patent Publication No. 60-59876).
(See JP-A-6-278400 and JP-A-6-278400) when transferring to a substrate having fine irregularities superimposed on large irregularities, or in the concave bottom or concave portion of the irregular substrate. This is the case of an uneven substrate having a surface to be transferred to the side surface. The large pattern irregularities and the fine irregularities are those in which the irregularities of the irregular substrate are formed on the convex portions of the large irregularities, and the large pattern irregularities have a step of 1 to 10 mm and a width of the concave. Is 1 to 10 mm, and the width of the convex portion is 5 mm or more. The fine unevenness is smaller than the large unevenness in both the step and the width, and specifically, the step is 0.1 to 10 mm. The width of the concave portion and the width of the convex portion are about 5 mm, the width of the convex portion is 1 mm or more, and is less than half the width of the convex portion having a large irregular shape.

In addition, in the present invention, the irregularities of the irregular base material exhibit their true value even in the three-dimensional irregular shape as a whole, in addition to the irregular base material having large and small irregularities. In the conventional rubber roller transfer method, the direction is essentially determined by the rotation axis, and the uneven shape is a flat plate as a whole, and is substantially limited to a flat uneven substrate. However, in the present invention,
Since the collision pressure of solid particles that can behave fluidly is used, even if the surface unevenness has a three-dimensional shape having a curvature in an arbitrary direction, it has essentially no directionality of pressure application. (This directionality is a direction of a temporal position change of a point on the uneven substrate to which pressure is applied.) Therefore, the unevenness has a shape having unevenness in the feeding direction of the transfer sheet or the uneven substrate. A substrate may be used. 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. The point that the present invention does not have the directionality is that a single transfer sheet is placed on an uneven substrate and pressed one by one (in the present invention, such a form may be used).
It can be easily understood by considering how the collision pressure is applied by moving or fixing the blowing nozzle. Therefore, the uneven base material is not limited to a flat plate material as a whole, and may be a base material having two-dimensional unevenness curved in the feeding direction or width direction to be convex or concave in an arc shape, and the curved surface may be finer. There may be three-dimensional surface irregularities. In the present invention, it is possible to arbitrarily determine whether or not to transfer the two-dimensional unevenness such as the arc shape of the uneven base material in the width direction or the feed direction in consideration of workability and the like. The surface that constitutes the uneven surface is
From a plane only, a curved surface alone or a combination of a plane and a curved surface is optional. Therefore, the curved surface on the uneven substrate of the present invention also means an uneven surface having no curved surface composed of only a plurality of planes, 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 a side or a vertex of a cube.

The material of the uneven substrate is arbitrary, and for example,
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, phenol resin and the like may be used. On the surface of these uneven base materials, an undercoating for imparting a base color tone to the entire base material in advance, an easy-adhesion primer to assist in bonding with an adhesive,
Alternatively, a sealer may be applied to seal and seal fine irregularities and porosity on the surface. As a base coat, an easy-adhesion primer, or a sealer, a resin such as an isocyanate, a two-part curable urethane resin, an acrylic resin, or a vinyl chloride-vinyl acetate copolymer is applied. In the case of undercoating, a coloring agent such as a pigment or a dye is added to these resins.
In addition, in order to make the surface of the uneven base material as desired unevenness, press working, embossing, extrusion working, cutting work, forming work, or the like may be used. The uneven shape is arbitrary, for example, tiles and brick joints, unevenness of stone surface such as cleavage surface of granite, wood paneling, wood board surface unevenness such as floating wood grain, lysine tone, stucco tone, etc. These are irregularities on the spray-painted surface.

Next, the transfer sheet S that can be used in the present invention is:
It consists of a support and a transfer layer which transfers. The transfer layer comprises at least a decorative layer. Further, the adhesive may be partially formed in a desired area on the transfer sheet as an adhesive layer that becomes a part of the transfer layer.

The above-mentioned support can be made of paper or the like having no stretchability, provided that the uneven substrate is a two-dimensional uneven surface. However, in order to apply the present invention to a three-dimensional uneven surface exhibiting its true value, A stretchable support is used at least at the time of transfer. At the time of applying the collision pressure of the solid particles due to the stretchability, the transfer sheet follows and adheres to the inside of the concave portion of the concave and convex base material surface, and as an area target of the portion to be transferred, not only the convex portion of the concave and convex,
The bottom and side surfaces of the concave portion can also be transferred. If the transfer target area is only the protrusions of the uneven base material and the protrusions form a plane as a whole, the transfer sheet does not need to be stretchable, and paper or a resin film having poor stretchability can be used. However, an extensible transfer sheet is required to transfer the image to the inside of the concave portion. The stretchability of the entire transfer sheet is mainly governed by the stretchability of the support. Therefore, a rubber film that is stretched at normal temperature can be used as the support in addition to a conventionally known thermoplastic resin film. In the case of a thermoplastic resin film, when forming a transfer layer such as a decorative layer, there is almost no stretchability, and during transfer, a sufficient stretchability is exhibited by heating, and after cooling, the deformed shape is maintained, and the shape due to elasticity is maintained. As a transfer sheet that does not cause restoration, a transfer sheet that can be used in the present invention can be prepared as easily as a conventionally known ordinary transfer sheet. Specific examples of the stretchable support include biaxially stretched polyethylene terephthalate film, which has been widely used in the past, depending on the relationship between the portion to be transferred and the surface unevenness, the setting of heating conditions and collision pressure conditions is sufficient and sufficient. Transfer is possible because it can express
Polyester film such as polybutylene terephthalate or terephthalate isophthalate copolymer, polyolefin film such as polypropylene film, polyethylene film, polymethylpentene film, vinyl chloride resin film , Low-stretch or non-stretch film such as nylon film, natural rubber, synthetic rubber, urethane elastomer,
Rubber (elastomer) films such as olefin elastomers are also preferred supports. If necessary, a release layer may be formed on the support to improve the releasability from the transfer layer on the transfer layer side. The release layer is removed together with the support from the transfer layer when the support is released. As the release layer, for example, silicone resin, melamine resin,
Polyamide resin, urethane resin and the like are used.

The transfer layer comprises at least a decorative layer, and a release layer, an adhesive layer partially formed in advance, or the like may be a component of the transfer layer. For the decorative layer, a conventionally known method such as gravure printing, silk screen printing, offset printing, etc., a pattern layer or a colored solid layer on which a pattern or the like is printed with a material, a metal such as aluminum, chromium, gold, silver, etc., by a known vapor deposition method or the like. It is a metal thin film layer or the like formed partially or entirely on the substrate. As the picture, a wood grain pattern, a stone grain pattern, a cloth grain pattern, a tile pattern, a brick pattern, a solid pattern, or the like is used in accordance with the surface irregularities of the irregular substrate. In addition, an acrylic resin, a vinyl chloride-vinyl acetate copolymer, a polyester resin, a polytarene resin, a fluororesin, or the like is used as a binder resin for the ink for the picture layer or the colored solid layer. 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. Note that this release layer is transferred together with the decorative layer to the uneven substrate side at the time of transfer, and covers the surface of the decorative layer.

The solid particles P include inorganic particles such as glass beads, ceramic beads, calcium carbonate beads, and alumina beads, iron or pure iron, carbon steel,
Iron alloys such as stainless steel, aluminum or aluminum alloys such as duralumin, metal particles such as metal beads such as titanium, or fluorine resin beads, nylon beads, silicone resin beads, urethane resin beads, urea resin beads, phenol resin beads Organic particles such as resin beads such as crosslinked rubber beads 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 1000
It is about μm. If such solid particles are ejected from a blowing nozzle together with a gas flow and collide with a transfer sheet,
The collision pressure can be applied as a means for pressing the uneven base material of the transfer sheet. The gas used may be air, but may be an inert gas such as nitrogen gas.

By using heated solid particles as the solid particles, the transfer sheet can be stretched by heating the transfer sheet, the adhesive force can be activated by heating the heat-sensitive adhesive, and the thermosetting can be performed. Acceleration of thermosetting by heating the mold adhesive and the like can be performed together with pressing. In this case, the heating may be naturally performed to some extent by another heating means before the collision pressure is applied. In addition, in the case of activation by heating with a heat-sensitive adhesive or the like, 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 may be used as cooled solid particles. it can. Some or all of the solid particles can be used as heated solid particles and cooled solid particles, or can be used as heated solid particles and cooled solid particles. In addition, the transfer sheet or uneven substrate by other heating means,
It is also possible to sufficiently heat an adhesive or the like that requires heating and use the cooled solid particles to form and transfer and cool the transfer sheet almost simultaneously. The cooling and heating of the solid particles can be performed by cooling or heating the airflow for ejecting the solid particles from the blowing nozzle as a cold airflow or a heated airflow by heat conduction by the airflow, or while storing the solid particles in a hopper for storing the solid particles. Cooling and heating the particles. In a hopper or the like, heating is performed by heat conduction from the hopper, dielectric heating (when the solid particles are a dielectric), or induction heating (when the solid particles are a conductor or a magnetic material).

When the solid particles are actually used, it is preferable that the solid particles are not scattered to the surroundings and are recycled. Therefore,
Next, FIG. 3 is a conceptual diagram of a curved surface transfer apparatus that actually performs the curved surface transfer method of the present invention using solid particles, and the method of the present invention will be described in further detail with reference to FIG.

The apparatus shown in FIG. 3 uses a long transfer sheet S
And a transfer sheet S for transferring the uneven base material B in order to sequentially transfer a pattern or the like to the uneven base material B using
And a pressure application unit 30 that applies the collision pressure by causing the solid particles P to collide with the support side of the transfer sheet S from the blowing nozzle 31 and presses the transfer sheet against the uneven base material. A transfer sheet heating device 40, an uneven substrate heating device 41, an adhesive coating device 60 for applying an adhesive only to a desired portion of the uneven substrate, and a preliminary adhesion of the transfer sheet to the uneven substrate. It is also provided with a suction and exhaust device for facilitating.

First, in the apparatus shown in FIG.
Is transported one by one by a substrate transport device 10 such as a driving rotary roller row or a belt conveyor, and an adhesive is partially applied only to a desired portion such as only a convex portion by a substrate coating device 60.
If the adhesive has a solvent, the substrate heating device 4
In step 1, the base material and the adhesive are heated, and the evaporated components are volatilized and dried. Note that a plurality of the substrate coating devices 60 and the substrate heating devices 41 may be connected to each other, and the undercoating or the sealer coating before the undercoating may be performed simultaneously with the transfer before the adhesive is applied. Then, after the uneven substrate B is heated by the heating device 41, it is transported and supplied into the chamber 35 of the pressure applying unit 30. When the release agent is partially applied to the uneven base material, the release agent may be applied by the base material coating device 60.

The transfer sheet S is transferred to a sheet conveying device 2 including a sheet feeding device, a sheet supporting device, a sheet discharging device, and the like.
The tension is applied by 0, the paper is unwound from the supply roll set in the sheet feeding device 21, and enters the chamber 35 of the pressure applying unit 30 via the guide roller. In the case where the adhesive is partially applied to the transfer sheet at the time of transfer, the adhesive is applied by an adhesive coating device (not shown) while the transfer sheet is supplied from the sheet feeding device 21 to the pressure applying section 30. When coating and further drying with a solvent are required, the drying device (not shown) is dried and then supplied to the pressure applying unit.

If the release agent is applied partially instead of the adhesive, a release agent may be applied instead of the adhesive.
Further, if printing is performed instead of coating, a printing device may be provided instead of the coating device.

When the transfer sheet S enters the chamber 35, the uneven base material B is conveyed on the transfer layer side while the both ends in the width direction are sandwiched by the sheet support device 22.
It is conveyed at a constant speed in parallel with the conveyed uneven base material B with a slight space opened above the uneven base material B facing the side. The transfer sheet S is heated by the sheet heating device 40 until the transfer sheet S is nipped and conveyed by the sheet support device 22 and receives the application of the collision pressure. The sheet supporting device 22 is composed of a belt or the like that rotates in accordance with the transfer of the transfer sheet S while nipping both ends of the transfer sheet S having a width larger than the width of the uneven base material B. Material B
Until they are brought into contact with each other, they are transported while maintaining a gap between them. Also, in the same figure, the transfer sheet is heated by the sheet heating device 40 in a state where the uneven base material B and the transfer sheet S are conveyed in proximity.
, The adhesive on the uneven substrate is also heated. Therefore, if a heat-sensitive adhesive is used as the adhesive, the heating serves to improve the stretchability of the sheet and to activate the adhesive. The transfer sheet is also indirectly heated by the uneven base material heated by the base material heating device 41 and supplied to the pressure applying unit 30. The sheet heating device 40 can be omitted when the transfer sheet and the adhesive do not need to be preheated. When transferring the transfer sheet in the vicinity of the uneven substrate at the same transport speed, whether the transfer sheet is slightly separated from the uneven substrate or transferred in a state of contact is determined by the shape of the surface unevenness of the uneven substrate. The preheating temperature of the uneven substrate, the thermal deformability of the transfer sheet, the collision pressure of the solid particles, the activation temperature in the case of a hot-melt adhesive, and the like are appropriately considered. Further, in terms of the apparatus, the distance between the uneven substrate and the transfer sheet to be transferred is adjustable.

Next, the transfer sheet S is exposed to the collision of the solid particles P ejected from the ejection nozzle 31 together with the air flow. The amount of change in the momentum of these solid particles at the time of collision becomes the collision pressure for pressing the transfer sheet S against the uneven base material B. The blowing nozzles 31 are arranged in a plurality of rows in a straight line in a direction (= width direction) perpendicular to the transfer direction of the transfer sheet and the uneven substrate, and a large number of the blowing nozzles are arranged perpendicular to the back surface of the transfer sheet. The ejected solid particles apply a collision pressure in a linear band shape in the width direction over substantially the entire width of the transfer sheet. As a result, the solid particles ejected from the blowing nozzles spread in the direction of the transfer sheet while spreading somewhat, so that the solid particles also collide with the region between the plurality of blowing nozzles. Then, the transfer sheet is pressed against the uneven substrate by the solid particle collision pressure, and the transfer sheet is extended and deformed into the concave portion of the uneven surface of the uneven substrate, so that the transfer sheet is formed to follow the uneven surface shape. In addition, the transfer layer of the transfer sheet in only the portion where the adhesive layer is partially formed on the transfer sheet or the uneven substrate is in a state of being adhered to the uneven substrate.

The uneven base material B used in the description here
Is a plate material having an uneven surface, and is a flat plate material as a whole, and the transfer sheet S has a sheet support device 22 at both ends in the width direction of the transfer sheet S so that impact pressure or the like is not applied to the uneven substrate B. If not, the transfer sheet S is transported from a distant position. Therefore, the perfect adhesion of the transfer sheet S to the uneven base material B due to the collision pressure is temporally earlier in the width direction central portion near the both ends in the width direction. Is to be delayed.
This is because, as a whole, the transfer sheet S and the uneven base material B are transported at the same speed and are sequentially exposed to the collision pressure in the flow direction. This is one of the methods for preventing air from remaining in contact between the uneven substrate B and the transfer sheet S (especially near the center) when they adhere. Also, needless to say, if the area to be partially transferred is only the convex portion of the uneven base material and is not in the concave portion, it is necessary to form the transfer sheet along the uneven surface shape and completely adhere to the entire surface. Not to mention nothing.

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 part of the chamber 35, from which the drain pipe 3
At 6, it is sucked and collected in the original hopper 32. Further, air used for jetting the solid particles and jetted from the jet nozzle 31 is also sucked by the drain pipe 36, and the solid particles P are separated by the separating device 37 such as a filter.
Is discharged out of the system. In this way, the solid particles are prevented from flowing out of the chamber 35 to the surroundings with the air from the entrance opening through which the transfer sheet and the irregular substrate enter and exit. 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 chamber 3
It is good to make the inside of 5 lower than the outside.

Then, after the uneven substrate B with the transfer sheet S adhered thereto comes out of the chamber 35, the support of the transfer sheet S is peeled off from the uneven substrate B by the peeling roller 23.
The decorative plate D is obtained in which only the transfer layer portion of the transfer sheet is transferred to only the desired region of the uneven substrate by the adhesive. On the other hand, the support of the transfer sheet after passing through the peeling roller 23 is taken up by a sheet discharge device 24 as a discharge roll.

Hereinafter, the present invention will be described in more detail.

The blowing nozzle 31 blows out solid particles together with the gas flow. The structure of the blowing nozzle 31 is, for example, a hollow cylinder, a polygonal column, a cone, a polygonal pyramid, or a fish tail. Is used. The blowing nozzle may have a single opening, or may have an inside partitioned into a honeycomb shape. The spray pressure is usually 0.
1~10.0kg / cm ² or so, also, the flow rate of the air flow is usually about 5 to 20 m / sec. When the solid particles are conveyed and collided with the transfer sheet, the solid particles, the transfer sheet, or the uneven substrate may be charged. Therefore, in order to prevent electrification, the blowing nozzle, the drain pipe 36, etc. are grounded, the transfer sheet is brought into contact with a static elimination bar,
Alternatively, it is preferable to mix ions having a charge for neutralizing the charged charge into the airflow. The material of the blowing nozzle is
What is necessary is just to select suitably from ceramics, steel, etc. according to the kind of solid particle. The solid particles pass through the inside of the blowing nozzle while colliding with the inner wall of the nozzle. When metal beads or inorganic particles are used as the solid particles, the particles are hard. When resin beads are used for the solid particles, they may be made of steel because they are softer than metal particles.

Although it is possible to use only one blowing nozzle, it is preferable to use a plurality of blowing nozzles so that the collision area of the solid particles colliding with the transfer sheet has a desired shape. In the apparatus outlined in FIG. 3, the transfer sheet and the uneven substrate are arranged in a plurality of rows in a straight line at right angles to the feeding direction to form a collision area having a wide band shape linearly in the width direction. For example, FIG. 4A shows an arrangement in a staggered pattern, and FIG. 4B shows an arrangement in a single row, but an arrangement in which the center in the width direction collides on the upstream side in the feed direction. FIG.
In the arrangement (B), the pressing of the transfer sheet against the uneven base material by the collision pressure starts from the center in the width direction and is sequentially pressed toward both ends in the width direction. By doing so, it is possible to prevent the transfer sheet from adhering to the uneven substrate while holding the air in the center in the width direction. In order to lengthen the collision pressure application time, as shown in FIG. 3, it is preferable that the blowing nozzles are arranged in two or more rows in the feed direction of the transfer sheet and the uneven base material.

Further, the collision pressure of the solid particles does not need to be all uniform in the collision region. FIG. 5 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 blowing nozzle using, for example, the speed is controlled by controlling the speed of the solid particles and the gas flow ejected from the blowing nozzle. The setting of the pressure distribution as shown in FIG. 5 helps the pressure welding to proceed in a stepwise manner from a high pressure portion (the center portion in FIG. 5) to a low pressure portion (the both side portions in FIG. 5). 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. As a result, pressure is applied in contact and the transfer of the transfer sheet cannot be performed uniformly.

The arrangement of the uneven nozzles with respect to the transfer surface of the blow-out nozzles was arranged horizontally in a plurality of rows in the apparatus outlined in FIG. 3 because the uneven substrates were flat. This is an arrangement in which solid particles collide perpendicularly to the (total) transfer surface of the uneven substrate. The collision is caused vertically because basically the collision pressure can be utilized most effectively. Therefore, for example, as shown in FIG. 6, if the (total) transfer surface (cross section perpendicular to the transport direction) of the uneven base material B is a convexly curved surface in a semi-cylindrical shape, the plurality of blowing nozzles 31
It is preferable to arrange the blowing nozzles in the normal direction of the adjacent irregular substrate surface so that the solid particles collide substantially perpendicularly with the individual collision surfaces mainly served by the nozzles. In this manner, the arrangement of the blowing nozzle is preferably adjusted so that the solid particles collide with the solid particles as perpendicularly as possible according to the uneven shape of the target uneven substrate. Note that the direction of the blowing nozzle need not always be perpendicular to the back surface of the transfer sheet. However, if the blowing nozzle is perpendicular to the transfer sheet, the collision pressure of the solid particles can be used most effectively. Further, a large number of blowing nozzles may be provided, and some of the blowing nozzles may be closed depending on the uneven substrate to be manufactured.

In the case where the hot melt adhesive is directly applied to the entire surface of the transfer sheet (in this case, partial transfer of the transfer layer corresponds to partial formation of the release agent layer), the unevenness of the uneven base material is further increased. When it is necessary to transfer and modify the transfer sheet to follow the shape, inevitably 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 polypropylene-based resin. From another viewpoint, a material having low heat resistance is selected for the support. It means that you have to do it. Therefore, when the adhesive is melt-coated on the transfer sheet, when the adhesive layer is thickly applied, the support is softened by heat during the melt coating, and the applicator roll is heated in the adhesive coating apparatus. In some cases, the transfer sheet sticks to the sheet, and the transfer sheet may be stretched, distorted, or entangled by being dragged. Therefore, in such a case, it is preferable to apply a hot melt adhesive to the transfer sheet via a release sheet (separator) without directly applying the adhesive to the transfer sheet by melt coating. That is, a release sheet having heat resistance and release properties,
After the adhesive is heated and melt-coated, the release sheet and the transfer sheet S are once thermally laminated by a nip roller or the like with the applied adhesive, and then only the release sheet is separated from the transfer sheet by a release roll or the like. Further, the adhesive layer can be formed on the transfer sheet with less heat damage to the transfer 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.

The sheet heating device 40 and the substrate heating device 41 may be any heating means such as heater heating, infrared heating, dielectric heating, induction heating, hot air heating and the like. 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 uneven substrate. 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. Further, even when the collision pressure using the heated solid particles is being applied, the heat source of the heating device may be provided dispersed in the gap between the blowing nozzles. The preheating of the transfer sheet is preferably performed after the sheet support device 22 supports the sheet in the width direction. Before that, the sheet is likely to extend in the feed direction, which may hinder the transfer. Further, when the transfer sheet is sufficiently heated by indirect heating by the uneven substrate heated by the heating device 41 or heating by the heated solid particles or the ejected gas, the use of the heating device 40 for the transfer sheet is omitted. You can also. Also, the preheating of the uneven substrate
Induction heating and dielectric heating can be performed from the inside of the uneven substrate, but heater heating, infrared heating, hot air heating and the like are more efficiently performed from the uneven surface side. Further, if heating is performed immediately before or during the application of the collision pressure in the chamber, heating from the back surface side of the uneven substrate is preferable in terms of space.

If the adhesive does not become active even if heated before the impact pressure is applied, or if such a preheating process can be provided, the transfer sheet S is placed on the uneven surface of the uneven substrate B. To remove air from the gap between the transfer sheet and the uneven base material. By removing the air, the air between the transfer sheet S and the uneven substrate B remains during the transfer, so that "air seeping" and the occurrence of transfer omission caused by the air can be prevented. The air bleeding is performed by, for example, a suction and exhaust device 50 including a suction and exhaust nozzle 51 and a vacuum pump 52 as shown in FIG. The suction and exhaust nozzles 51 are provided in the transfer layer side of the transfer sheet and on both sides adjacent to both sides along the transport direction of the conveyed uneven substrate, along the transport direction of the uneven substrate, and provided with the transfer sheet and the uneven substrate. The air between them is supplied to the vacuum pump 52
It is only necessary to suck and exhaust. For example, if the outer periphery of the opening of the suction / exhaust nozzle 51 is surrounded by a brush and the tip of the brush is brought into contact with the uneven base material and the transfer sheet, air can be vented without any trouble. 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 in either order depending on the speed at which the transfer sheet is preheated and softened, and the degree of softening, or both may be started simultaneously. This air bleeding is effective when the transfer surface of the uneven substrate is partially transferred, for example, in a concave portion of the uneven surface such as a rock surface tone or a stucco tone.

In the case where a heat-sensitive adhesive or the like is used as the adhesive and an adhesive whose adhesion is fixed by cooling, after the transfer sheet is in close contact with the desired transfer surface of the uneven substrate, it is necessary to cool the transfer sheet. Then, the transfer sheet formed following the inside of the concave portion is fixed there, and the support of the transfer sheet can be peeled off and removed more quickly, so that transfer omission can be prevented and the production speed can be improved. For this purpose, it is preferable to use the cooled solid particles without releasing the collision pressure during the application of the collision pressure, or to cool the adhesive by another cooling means after the application of the collision pressure. When the heat capacity of the uneven substrate is large, the uneven substrate can be cooled from the back surface by spraying a low-temperature gas in addition to the cooled solid particles and cooling the rollers and the belt conveyor for transferring the substrate. 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 curved surface transfer method of the present invention is not limited to the examples shown in the drawings. For example, when a release agent is partially formed, the adhesive is partially formed instead of the entire surface on the other side, and the partially formed release agent layer and the partially formed adhesive layer are joined together. A complicated portion obtained as a result of the above may be used as a region to be transferred. Further, for example, in the description of the curved surface transfer method using the apparatus outlined in FIG. 3, a method in which the transfer sheet is pressed against the uneven substrate while the transfer sheet and the uneven substrate are respectively conveyed has been described. In the method according to the above method, the transfer sheet and the uneven substrate may be pressed against the uneven substrate only at that time, and the transfer sheet and the uneven substrate may be intermittently performed for each substrate (for example, a blowing nozzle Move). Further, the positional relationship between the transfer sheet and the ejection direction of the solid particles from the blowing nozzle is not limited to the positional relationship in which the transfer sheet is placed horizontally and the solid particles are ejected vertically downward from above the transfer sheet. Even if the ejection direction of the solid particles with respect to the back surface of the transfer sheet maintains the vertical relationship, the mounting or transport direction of the transfer sheet is
In addition to horizontal, the transfer sheet may be inclined, up, down, etc., and even when the transfer sheet is horizontal, the solid particles may be ejected from the bottom side, that is, from bottom to top. Of course, the solid particles may be ejected at an angle to the back surface of the transfer sheet.

The decorative plate obtained by the above-described curved surface transfer method of the present invention includes exterior materials such as outer walls, fences, roofs, gable boards, gates and the like, architectural interior materials such as walls and ceilings, window frames, doors, and the like.
Handrails, sills, doors and other fixtures, furniture surface materials, light electricity / OA
It can be used in various fields such as equipment cabinets or vehicle interior materials such as automobiles. Further, specific examples of the decorative pattern of the decorative plate having the three-dimensional surface unevenness and the unevenness of the combination of the large unevenness and the small unevenness, for example, a tile-like pattern having joints, a brickwork pattern, a stucco-like pattern It can be applied to stone grain tone, siding tone, wood grain tone of floating wood grain, etc. having uneven cleavage planes such as ricin, granite, etc.

Incidentally, a transparent protective layer may be further coated on the surface of the decorative plate 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, an ultraviolet absorber such as benzotriazole, ultrafine cerium oxide,
A paint to which a light stabilizer such as a hindered amine radical scavenger, a coloring pigment, an extender pigment, a lubricant and the like are added is used. Spray coating, flow coating, etc. are used for coating. The thickness of the transparent protective layer is about 1 to 100 μm.

[0051]

The present invention will be further described with reference to the following examples.

(Embodiment 1) First, as shown in FIG. 7, a concave and convex joint having a depth of 1.5 mm and a width of 6 mm and a convex part E having a large pattern as shown in FIG.
A 12 mm thick calcium silicate plate having a three-dimensional surface irregularity formed by engraving grooves with a depth of 1 mm and a width of 3 mm as fine irregularities on the convex part of the brick, and a square brick pattern of mx 100 mm length. Prepared. Next, a two-part curable polyurethane resin sealer / primer is applied to the entire surface at a rate of 10 g / m ² (at the time of drying) to apply an undercoat. The resin emulsion was applied at a rate of 100 g / m ² (at the time of drying), and an undercoat was applied. Further, as a transfer sheet, on one side of a polypropylene-based film having a thickness of 50 μm on a support, a pigment composed of carbon black, red iron oxide, titanium white, isoindolinone, an acrylic resin and a vinyl chloride-vinyl acetate copolymer resin were used. And a gravure-printed brick-like pattern as a decorative layer serving as a transfer layer was prepared using an ink composed of a mixture binder of 8 to 2 (weight ratio).

Next, using the apparatus shown in FIG. 3, the uneven base material B is mounted on a base material transfer device 10 comprising a row of transfer rollers with its uneven surface facing upward, and transferred. Coating device 60
Then, a non-solvent hot-melt type polyamide-based heat-sensitive adhesive heated and melted at a thickness of 30 g / m ² (solid content) is partially applied only to the convex portion of the brick, and then heated. 41
Then, the adhesive and the uneven substrate were heated and supplied to the pressure applying unit 30. On the other hand, the transfer sheet S was also supplied to the pressure applying unit 30 with its support side facing upward. When the uneven substrate B entered the chamber, the transfer sheet S was brought close to the uneven 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 that state,
From the support side of the transfer sheet S, preheating of the transfer sheet, activation of the adhesive, and heating of the uneven substrate were performed by a heating device 41 using radiant heat from a heating wire heater. Next, spherical nylon beads 5 having an average particle size of 0.8 mm as solid particles P
Was ejected from the blowing nozzles 31 having the arrangement shown in FIG. 4 (A) to collide with the side surface of the support of the transfer sheet S, thereby heating the transfer sheet and pressing against the surface irregularities of the irregular substrate. The spray pressure was 5 kg / cm ² , and the pressure distribution of the air flow was such that the center in the sheet width direction became maximum as shown in FIG. Then, the transfer sheet is extended into the concave portions of the joints and into the fine uneven pattern and adheres closely, and after coming out of the chamber and solidifying the adhesive, the support of the transfer sheet is peeled off by the peeling roller 23, and the makeup is removed. Plate D was obtained. Furthermore, an emulsion paint of polyvinylidene fluoride containing 2% by weight of a benzotriazole-based ultraviolet absorber is applied to the transfer layer surface of the decorative plate after transfer at a thickness of 10 μm to form a transparent protective layer, and a transparent protective layer is provided. Was obtained. In the obtained decorative board, the transfer layer was transferred only to the convex region of the brick partially applied with the adhesive, and the decorative board had a design by the base coat and the transfer layer. In addition, the transfer pattern follows the transfer sheet even in the transfer area portion within the fine unevenness without causing transfer failure in the concave portion of the fine unevenness pattern.

[0054]

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.
It can be easily obtained even if it has a wavy shape as a whole like a roof tile, a shape that is convexly or concavely curved, or a three-dimensional decorative surface having irregularities in the width direction of the roller. Further, unlike the conventional rubber roll pressing method, there is no wear of parts such as a roll due to the uneven portion of the uneven substrate. Moreover, it goes without saying that not only the decoration of the convex portion of the uneven substrate but also the inside of the concave portion of the uneven substrate (the bottom portion or the side surface which is the connecting portion between the convex portion and the bottom portion) can be decorated. An arbitrary part of an arbitrary part such as a concave part can be decorated by transfer. Therefore, a finer uneven pattern (for example,
Even if it has a hairline, satin finish, etc., it is possible to decorate by transfer to the inside of the concave portion of the fine unevenness. As a result, a decorative plate having extremely excellent design properties can be obtained.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram showing a curved surface transfer method according to the present invention, and FIG.
Shows one mode, and (B) shows another mode.

FIG. 2 is an explanatory view of various methods for partially forming an adhesive layer in the present invention.

3A and 3B are conceptual views of an example of a curved surface transfer device capable of performing the curved surface transfer method of the present invention, wherein FIG. 3A is a diagram viewed from a side in a substrate conveying direction, and FIG. It is the figure which looked at the blowing nozzle part from the substrate conveyance direction.

FIG. 4 is a plan view showing various forms of a discharge nozzle arrangement.
(A) is an arrangement arranged in a houndstooth check pattern, (B) is an arrangement in which the central portion is on the upstream side, and is shifted to the downstream side toward both ends.

FIG. 5 is an explanatory view in which a collision direction of solid particles is provided with a width distribution.

FIG. 6 is a side view showing one form of a blowing direction of a blowing nozzle viewed from a flow direction.

FIG. 7 is a plan view showing an example of three-dimensional surface unevenness of the uneven base material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Substrate conveyance device 20 Sheet conveyance device 21 Sheet sending device 22 Sheet support device 23 Peeling roller 24 Sheet discharge device 30 Pressure application part 31 Blowing nozzle 32 Hopper 33 Blower or compressor 34 Manifold 35 Chamber 36 Drain pipe 37 Separation device 38 Vacuum Pump 40 Sheet heating device 41 Substrate heating device 50 Suction / exhaust device 51 Suction / exhaust nozzle 52 Vacuum pump 60 Substrate coating device A Adhesive layer B Irregular substrate B ′ Completely flat substrate C1 Coating roller C2 Measuring roller C2 Doctor Blade D Decorative board E Convex part P Solid particles S Transfer sheet S1 Support S2 Transfer layer

Claims (2)

[Claims] An uneven surface of an uneven substrate having an uneven surface,
Or, the transfer layer of the transfer sheet composed of the support and the transfer layer, the adhesive layer is partially formed only in one of the partial areas of the transfer sheet, on the uneven surface side of the uneven substrate, the support and the transfer layer The transfer layer side of the transfer layer of the transfer sheet is made to oppose, the solid particles collide with the support side of the transfer sheet, and using the collision pressure, the transfer sheet is pressed against the uneven surface of the uneven substrate, A curved surface transfer method in which, after the transfer layer is adhered to the uneven substrate, the support of the transfer sheet is peeled off to transfer the transfer layer to the uneven substrate only in the region where the adhesive layer is formed. 2. An uneven surface of an uneven substrate having an uneven surface,
Alternatively, the release agent layer is partially formed only in one of the partial areas of the transfer layer of the transfer sheet, and the other transfer sheet or the irregular substrate on which the release agent layer is not formed is at least involved in the transfer. An adhesive layer is formed on the surface of the region to be transferred, and the transfer layer side of the transfer layer of the transfer sheet comprising the support and the transfer layer is opposed to the uneven surface side of the uneven substrate, and solid particles are formed on the support side of the transfer sheet. By using the collision pressure, the transfer sheet is pressed against the uneven surface of the uneven substrate, and after the transfer layer is adhered to the uneven substrate, the support of the transfer sheet is peeled off and removed. A curved surface transfer method in which a transfer layer is transferred to an uneven substrate only in a portion where an adhesive layer is formed and does not correspond to the release agent layer.