JPH11128829A - Production of decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily produce a decorative material having the ruggednesses consisting of plural top faces divided by a groove-shaped recess and with the respective top faces painted in different colors. SOLUTION: A substrate having the ruggednesses consisting of the plural top faces 2 divided by a groove-shaped recess 1 on the surface is prepared, the respective top faces are painted in at least two different colors in the coating stage, and the top faces are painted in the different colors. Otherwise, an ornamental layer is transferred on the substrate surface in the first stage. The transfer pressure is applied by the pressing of an elastic roller or the collision pressure of the solid particle obtained by colliding many solid particles with the support side of the transfer sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material used for exterior and interior materials of houses, furniture and the like, and has a surface irregularity comprising a plurality of top surfaces partitioned by groove-shaped concave portions serving as joints and the like. The present invention relates to a method for manufacturing a material. In particular, the present invention relates to a method for manufacturing a decorative material in which each top surface portion has a different color.

[0002]

2. Description of the Related Art In the design of wall materials in recent years, a block-like tone with joints is preferred as seen in old brickwork. However, in actual work at the time of construction, instead of actually stacking bricks one by one, in order to simplify the process, for example, brick In many cases, a decorative board having the same pattern as that described above is produced in a factory, and the on-site construction often involves simply attaching the decorative board.

[0003] In the case of manufacturing such a decorative material such as a decorative board, a base material having no irregularities formed by a plurality of top surfaces partitioned by groove-shaped recesses on the surface is used, and the base material is used as a pattern by printing or the like. There is also a method of forming a decorative pattern by forming a patterned pattern and a patterned pattern in a groove-shaped concave portion. However, in this case, there is no actual unevenness due to the top surface portion and the groove-shaped concave portion, but virtual unevenness due to the pattern, the entire surface is flush, and the texture is basically the same, and the cosmetics with excellent design feeling No material can be obtained. In order to provide a decorative material having realistic surface irregularities and an excellent design feeling, it is sufficient to decorate a base material having actual irregularities due to the top surface and the groove-shaped concave portions. However, it is necessary to use a certain technique to decorate the top surface portion and the groove-shaped concave portion while distinguishing them. Initially, there were many decoration methods such as applying a single-color coating to the entire uneven surface. However, with the need for higher design, there has been a growing demand for color arrangement patterns and multicolor patterns that can be printed, which cannot be achieved by painting. Heretofore, there have been gravure offset printing, roller transfer, and the like as decoration methods that can respond to this. These and both are decoration methods in which a pattern or the like is printed and formed on the top surface portion, which is a convex portion, by utilizing a height difference (concavity and convexity) between the groove-shaped concave portion and the top surface portion.

The roller transfer method is a method in which even if there are small irregularities on the top surface, decoration can be performed in the small irregularities by making the elastic roller used as the transfer roller flexible. For example,
JP-B-60-59876, JP-A-5-27019
In the transfer method disclosed in Japanese Patent Application Laid-Open No. 9-205, a transfer sheet having a uniform decorative layer on the entire transfer layer is placed on a substrate, and a transfer roller made of hard rubber having a JIS rubber hardness of 70 ° or more is used. And the transfer sheet is transferred only to the top surface portion by pressing the transfer sheet only with the top surface portion. In addition, the top surface portion has many flat surfaces in the case of a tiled pattern or the like, but also has a small unevenness in the top surface portion in the case of a brickwork pattern or the like, which is smaller than the unevenness due to the groove-shaped concave portion and the top surface portion. . If it is possible to decorate even the top surface with small irregularities, it is possible to make a decorative material richer in design. In order to decorate the top surface with such small irregularities by transfer, for example, see
The transfer method proposed in JP-A-139097 can be used. That is, in the same publication, a transfer sheet having a configuration in which a release layer, a picture layer, and an adhesive layer are sequentially provided on a support of a thermoplastic resin film is placed on a substrate, and a transfer roller is provided from the back of the support. The pattern is transferred only to the top surface by pressing with a rubber heat roller having a JIS rubber hardness of 60 ° or less.

[0005]

Incidentally, as one type of decorative design, there is a case in which a plurality of top surfaces serving as individual bricks and tiles have different patterns and color arrangements.
In order to provide such a decoration, even if any of the above and above printing methods that can provide a color pattern or a multicolor pattern is adopted, the surface irregularities are specified by the shape, size, arrangement, etc. of the top surface For each of the substrates having the above-mentioned design, a dedicated printing plate having a pattern synchronized with the pattern of the concavo-convex design (for example, see FIG. 6) was required. Therefore, when the uneven design of the base material is different, a dedicated printing plate has been prepared. In addition, even if the design of the concavities and convexities is the same, if the coloration pattern of the coloration on each top surface is different, a dedicated printing plate is still required. Also, in the case of transfer, even if the color arrangement pattern is the same, but only the color to be arranged is different (for example, even if the top surface part 2 which is colored a in FIG. ), It was necessary to prepare a dedicated transfer sheet for each.

[0006]

Therefore, in order to solve the above-mentioned problems, in the method of manufacturing a decorative material according to the present invention, a base material having a plurality of top surfaces formed by a plurality of top surfaces partitioned by groove-shaped recesses is prepared. Then, each top surface portion of the base material was separately painted into at least two or more different colors as a separate painting process. As a result, without using a dedicated printing plate or transfer sheet, it is possible to easily obtain a decorative material of a design expression in which each of the plurality of top surfaces is arranged in at least two different colors. Moreover, since the color scheme on each top surface is supported by painting instead of printing, even if the pattern of the surface unevenness design due to the shape, size, arrangement, etc. of the top surface is different,
Can be easily handled. Further, in the method for producing a decorative material according to the present invention, a transfer step of first transferring the decorative layer to the surface of the base material is performed in the production method, and then each top surface portion is separately applied to at least two different colors. A separate coating process was performed. As a result, the decorative layer can make the design even more sophisticated, and even if the design of the unevenness due to the top surface and the color arrangement on the top surface are different, the color arrangement is handled in the painting process, so the formation of the decoration layer is less with a printing plate or transfer sheet. Can respond. In the method of manufacturing a decorative material according to the present invention, the transfer pressure is applied in the transfer step by pressing an elastic roller or by a solid particle collision pressure. In particular, in the case of the latter due to the solid particle collision pressure, even if there are irregularities on the top surface portion, it is possible to transfer the whole surface of the top surface portion including the inside of the concave portion and, if desired, the inside of the groove-shaped concave portion. As a result, the design can be further improved.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of a method for producing a decorative material according to the present invention will be described.

[Method of separately coating the top surface] First, FIG.
FIG. 3 is a conceptual diagram illustrating an example in which a top surface portion is separately painted as a separately painting process in the method for producing a decorative material of the present invention. FIG. 1 is a plan view of a decorative material D (or a base material therefor) obtained by the present invention. FIG. 3 shows a perspective view of an essential part of a base material D having a brickwork-patterned uneven design as an example of unevenness formed by a plurality of top surfaces 2 partitioned by groove-shaped concave portions 1 on the surface. In addition, in the example of the coloring of the top part in FIG. 1, in the figure, the alphabetic characters “a”, “b”,
“C” indicates that the paint is separately applied to a color, b color, and c color. Here, the colors a, b, and c are arbitrary colors different from each other. Therefore, FIG. 1 shows an example in which the top surface is separately painted in three colors for convenience. Note that different colors mean that at least one of hue, lightness, and saturation is different. As described above, in the present invention, each of the plurality of top surfaces 2 defined by the groove-shaped concave portions 1 is painted in at least two different colors. As shown in FIG. 1, in the case of a base material in which the divided top surfaces are two-dimensionally arranged, when all the top surfaces adjacent to each other on the side (via the groove-shaped concave portion) are painted in different colors, the minimum is It suffices to have four colors (this is similar to the four-color problem in topology).
The groove-shaped concave portion 1 is one if all are connected (refer to FIGS. 1 and 3), but may be plural (for example, an abstract in which the groove-shaped concave portions independently have a discrete triangle shape or the like). Irregularities in patterns, irregularities in letters, etc.). The coating of the groove-shaped concave portion 1 is performed if the base material can make use of its base material.
The substrate may be exposed as it is without painting. But,
If the base material cannot be used, or if the base material cannot be used, the groove-shaped concave portions may be painted. The coating of the groove-shaped recess is efficient at the same time as the top surface. At that time, paint the top surface part so that it spreads to the groove-shaped recess,
If the colors of the adjacent tops overlap slightly,
It is possible to prevent the occurrence of coating drip that exposes the base material, and it is efficient because there is no need for a color and coating dedicated to the groove-shaped recess. Alternatively, if there is a color (for example, a dark color) that can be used for the groove-shaped concave portion among the colors used for the top surface portion, the color may be simultaneously applied to the top surface portion.

In order to apply different colors to the top surfaces, for example, as shown in FIG. 2, a selective shielding means 5 having an opening 3 corresponding to a portion to be painted and a shielding portion 4 corresponding to a portion not to be painted is used. Just paint it. The selective shielding means in FIG. 2 is for painting the color a in FIG. The pattern of one or a plurality of openings 3 provided in the selective shielding unit 5 matches the color arrangement pattern of the corresponding color. Such selective shielding means may be used only for the number of colors to be applied. The selection shielding means 5 is, for example, a mask board. As the mask board, an object such as an iron plate or a wooden board, which has a shape along the coating surface of the base material (the shape of the envelope surface) and is substantially the same as the shape of the coating surface (the shape of the envelope surface) may be used. For example, if the envelope surface is planar, the envelope surface may be flat, and if the envelope surface is a convex curved surface such as a semi-cylindrical cross section, the envelope surface may be semi-cylindrical. The coating is optional such as spray coating, but may be roller coating or brush coating. In addition, the productivity can be improved by using a selective shielding means, especially in manual coating, but preferably, mechanical coating is more excellent in productivity. If the mask board 5 is painted along the painted surface of the substrate, the portion of the substrate corresponding to the opening 3 is exposed and painted, and the portion shielded by the shielding portion 4 can be left unpainted. As another method of separately painting each top surface, NC (numerical control) painting may be used. In the NC painting, painting is performed by a painting robot or the like, which has previously learned a pattern to be painted. However, even in this case, the area around the painted part is also slightly painted,
If there is a problem, the above-mentioned selective shielding means may be used together.

Further, it is sufficient that the top surface is separately painted as a result. Therefore, multiple coatings may be used. For example, if the paints are to be applied in three colors, the paint may use three colors having the same number of colors as the paints to be applied (see FIG. 1). It can also be applied separately to the top part or the whole top part. FIG. 4 shows a color, b
This is an example in which three colors of paints of colors c and c are combined and over-applied, the top surface portion 2 is painted in four colors of a + b, a + c, b + c, and a + b + c, and the entire top surface portion is separately painted by over-painting (of course. However, it is not necessary to apply a part of the top surface to the coating). Here, “a + b” indicates the overcoating of the “a” color and the “b” color. At this time, it does not matter which of the color a or the color b is applied first, or the simultaneous application (for example, spray coating). When the paint is applied later, the color is, of course, a transparent paint that is transparent to the extent that the paint applied earlier can be seen.
However, it is not always necessary to be transparent as long as the previously applied paint is still in a fluid state and the next paint is applied and mixed with the next paint to some extent and the color changes. As can be seen from the above description, the term "overcoating" means not only the layer of the upper color is overlaid on the layer of the lower color, but also the mixing (mixing) of different color paints by coating.

FIG. 4 shows an example of overpainting of different colors, while FIG. 5 shows an example of overpainting with the same color. In FIG. 5, the color of the paint is only one color a,
The top surface portion 2 is an example in which three colors of a, a + a, and a + a + a are separately applied. If a transparent (colored) paint is applied repeatedly and the number of times of application is different on each top surface, the color density can be increased corresponding to the number of times of application. In the figure, a + a indicates the same color a twice, and a + a + a indicates the same color a three times. As described above, the separate coating process in which the same color or a different color is applied by selective shielding means such as a mask board, NC coating, or the like has been described. However, the method of applying different colors may be other methods.

[Paint] The paint used for the separate coating is not particularly limited and is optional. Depending on the use of the cosmetic material, the required physical properties, the above-mentioned separate coating method, etc., it may be appropriately selected and used from conventionally known ones. For example, as a binder of the paint, an acrylic resin-based paint (solvent-based), a two-part curable urethane resin-based paint (solvent-based), a fluororesin-based paint (solvent-based), or a silicone resin-based paint such as an acrylic silicone resin (Solvent-based) or acrylic emulsion-based (water-based) paint. As a coloring agent for the paint, a pigment such as an inorganic pigment or an organic pigment, or a dye is used. For example, inorganic pigments such as titanium white, carbon black, red iron oxide, graphite, and ultramarine blue; and organic pigments such as aniline black, quinacridone, isoindolinone, and phthalocyanine blue. Inorganic pigments are suitable when the decorative material is for exterior use. Note that a transparent (colored) paint is used in order to make use of the color of the base material or the lower color at the time of recoating, or to make use of the decoration of the lower transfer layer. In addition, a transparent protective layer or the like may be further formed by applying a transparent paint on the surface of the decorative material after the separate coating in order to impart durability, design feeling, and the like. This transparent paint is usually an uncolored paint. However, finally, a transparent coloring paint may be applied to the entire surface to obtain a final color scheme. The transparent (uncolored or colored) paint and the paint for separate application may include, if necessary, an ultraviolet absorber such as benzotriazole and ultrafine cerium oxide, and a light stabilizer such as a hindered amine radical scavenger. Extender pigment,
A lubricant or the like may be added.

[Substrate] The substrate B used in the present invention comprises at least a plurality of top surfaces 2 defined by groove-shaped recesses 1 in which the unevenness of the surface serving as the painted surface is at least as shown in FIG. It has irregularities. In addition, as shown in FIG. 3, for example, as shown in FIG. 3, the unevenness of the surface is smaller than that of the small unevenness 6 such as fine unevenness on the top surface 2 and the unevenness of the groove-shaped recess 1 and the top surface 2. Small irregularities may be present. In terms of the design of the decorative material, the top surface portion 2 is a portion that is usually regarded as a unit material composed of a three-dimensional object such as a plate or a block such as a brick or a tile. On the other hand, the groove-shaped concave portion 1 is a concave seam portion in a structure in which the unit materials are arranged in one-dimensional direction (vertical direction, horizontal direction, etc.) or two-dimensional direction (vertical direction, horizontal direction, etc.). However, in order to finally use it as a decorative material for decoration,
It does not need to be an actual seam in the substrate. This is because the seam may be imitated. Therefore, the groove-shaped concave portion of the base material used for the decorative material is usually a concave portion for imitating an actual seam, and the base material is usually an integral structure made of the same material. However, needless to say, the groove-shaped concave portion may be a concave portion formed by actual seams such as a portion obtained by embedding a part of a unit material made of a real or imitated material such as a brick or a tile in cement or the like. In the case where the base material has an integral structure, a processing method such as pressing, embossing, extrusion, cutting, molding, or the like can be used to make the surface uneven.

FIG. 6 is a plan view showing various pattern examples of the arrangement of the top surface portion 2 which are patterns of the surface unevenness design. The one-dimensional array in FIG. 6A is an array in which a plurality of rectangular top surfaces 2 are partitioned by a plurality of rectangular groove-shaped concave portions 1 and are arranged in a one-dimensional direction (the left-right direction in the figure). The groove-shaped concave portion 1 and the top surface portion 2 are usually linear. The one-dimensional array is, for example, a siding board. In the congruent pattern arrangement shown in FIG. 6 (B), the top surface portion 2 having a single shape and dimensions is divided by a plurality of connected one groove-shaped concave portions 1,
The array is arranged in a two-dimensional direction (in the figure, the horizontal direction and the vertical direction). The joint pattern arrangement is, for example, an arrangement of brickwork. The non-congruent array in FIG. 6C is an array with at least two types of top surfaces having different shapes and dimensions. FIG.
(C) Top faces 2a and 2b having different shapes and dimensions from each other.
Is an example in which a plurality are arranged. The non-congruent array is, for example, a tiled array.

The surface of the top surface 2 of the base material may be a smooth surface or an uneven surface. FIG. 3 is a perspective view of an example in which the top surface portion 2 has an uneven surface composed of small unevenness 6. The surface irregularities of the top surface portion are, for example, specifically, those having a step of about 0.1 to 5 mm, a width of the concave portion and a width of the convex portion of about 0.1 mm to 5 mm. The size of the top surface portion 2 is, for example, 15 mm or more on one side. The size of the groove-shaped recess is, for example, about 1 to 10 mm in depth and about 1 to 10 mm in width.
As an example of a substrate having a top surface portion having an uneven surface, a large pattern unevenness is formed from the groove-shaped concave portion and the top surface portion, and the surface unevenness of the top surface portion is a small unevenness smaller than the large pattern unevenness in both the step and the width. It is a base material having a combination of large pattern irregularities and fine irregularities, which constitutes fine irregularities. As a specific example of the uneven pattern of the decorative material using such a base material, for example, a tile material, a brick, a stone, or the like as a unit material, and a stucco-like, lysine-like, etc. spray coating as fine unevenness on the top surface of the unit material. Concavo-convex pattern on surface, stone-grained irregularity pattern such as cleaved surface of granite or irregularity on stone material surface such as travertine marble plate, or wood plate material as unit material, conduit grooves, hairline, embossed as fine irregularities on the top surface Wood-grain uneven patterns having annual rings and the like can be given.

In addition, as a whole, the shape of the substrate is not only a flat plate material having a flat envelope shape on the surface of the unevenness having the groove-shaped concave portion and the top surface portion, but also a cross section formed by the envelope shape is a circle. A substrate having two-dimensional irregularities curved or convex in an arc-shaped convex or concave feed direction (painting direction or transfer pressure applying direction described later) or a width direction may be used. Unless it is roller coating (for example, spray coating), there is no special shape restriction.

However, when the transfer step is performed before coating in the method for producing a decorative material of the present invention, the shape of the base material is subject to certain restrictions depending on the type of transfer pressure applied. However, in the case where the solid particle collision pressure is used as the transfer pressure, the envelope shape of the transfer target surface which can be applied as in the conventional transfer method is not restricted, so that the envelope such as the above-mentioned two-dimensional unevenness having an arc shape or a curved shape is used. A surface shape is also possible. That is, conventional transfer rollers made of rubber (for example, the aforementioned Japanese Patent Publication No. 60-59876, Japanese Patent Application Laid-Open No. 5-270199, and Japanese Patent Application Laid-Open No. 5-139097).
In Japanese Patent Application Laid-Open No. H10-163, the envelope shape is essentially limited to a flat plate-shaped plane because of the inherent directionality of the rotation axis. This is not possible unless a transfer roller with a special shape is used. In addition, the surface unevenness of the base material is such that in the transfer by the transfer pressure due to the solid particle collision pressure, a large number of solid particles can behave in a fluid manner, so that only the transfer direction of the transfer sheet or the base material or only the width direction is used. In addition to two-dimensional irregularities having irregularities only in one direction, three-dimensional irregularities having irregularities in two directions such as both in the feed direction and the width direction may be used.

Materials of the base material are brick, stone, gypsum, cement (ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), pulp cement, slag cement, etc.), ceramics (porcelain, glass, etc.), metal ( iron,
Aluminum, copper, etc.), calcium silicate, wood (single veneer, plywood, laminated wood, fiberboard such as MDF (woody medium density fiberboard), particle board, etc.), resin (polypropylene, vinyl chloride resin, phenolic resin, ABS resin, etc.) ) Etc. are optional. These are used as a unit material or a base material to be a top surface portion.

[Transfer Step of Decorative Layer] Further, in the method for producing a decorative material of the present invention, a transfer step of first transferring the decorative layer to the surface of the substrate may be performed before performing the above-mentioned separate coating.
At this time, the paint applied on the decorative layer is usually transparent enough to make the decorative layer visible. However, when the paint is scattered so that the decorative layer is partially exposed and visible, it may be opaque. In this manner, if the decorative layer is transferred and formed before painting, a pattern or the like by printing or the like, which cannot be achieved by painting, can be provided, and the decorative material can be made more sophisticated. In addition, when the decoration layer by transfer and the separate coating are used in combination, even if the design of the top surface is uneven or the color on the top is different, the color is handled in the painting process, so the transfer sheet (and the printing plate for that)
Can be added with a common one without preparing a dedicated one for each. Therefore, compared with the case of printing all, including the coloring by coating, it is possible to cope with fewer printing plates and transfer sheets. To transfer the decorative layer to the substrate, the material and shape of the substrate, the application of the decorative material, depending on the required physical properties, etc., may be appropriately selected from conventionally known transfer sheets and transfer pressure applying methods, and in particular Not limited. For example, transfer pressure application
A roller transfer method performed by pressing with an elastic roller may be used. In the case of the roller transfer method, the decoration layer can be easily transferred with a simple transfer device. However, the transfer method using the solid particle collision pressure for applying the transfer pressure, which is one embodiment of the present invention, is a novel and excellent method that can transfer even to a substrate uneven shape that cannot be achieved by an elastic roller. About this method, hereinafter, after a transfer sheet, a roller transfer method using an elastic roller is briefly described,
It will be described in detail.

(Transfer Sheet) As shown in FIGS. 7 and 8, the transfer sheet S comprises a support 7 and a transfer layer 8, and the transfer layer comprises at least a decorative layer.

When the transfer surface of the substrate to be transferred is flat as a whole (for example, transfer is performed only on a flat top surface having the same height), the support may be made of non-stretchable paper. .
However, when the image is transferred to the side surface inside the concave portion, when the top surface portion has further small irregularities, or when the surface to be transferred is a non-planar three-dimensional irregular surface, a stretchable support is used at least at the time of transfer. As the stretchable support, a rubber film that can be stretched even at room temperature can be used 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. As a specific example of the support, in terms of stretchability, even a biaxially stretched polyethylene terephthalate film, which has been widely used in the past, depends on the surface unevenness of the surface to be transferred, depending on the setting of heating conditions, transfer pressure conditions, and the like. In addition, necessary and sufficient stretchability can be exhibited. Of course, if the transfer surface is flat,
It can be used without exhibiting stretchability. However, preferred supports that easily exhibit stretchability at lower temperatures and lower pressures include, for example, thermoplastic polyester resins such as ethylene terephthalate / isophthalate copolymer polyester, polybutylene terephthalate, polypropylene, polyethylene, and polymethylpentene. Use a resin film with a single layer or a mixture of different layers of polyolefin resin, vinyl chloride resin, polyamide resin, or natural rubber, synthetic rubber, olefin-based thermoplastic elastomer, urethane-based thermoplastic elastomer, etc., alone or as a mixture. Comes. These resin films are preferably low stretched or unstretched.
For example, specifically, a polypropylene-based thermoplastic elastomer film is one of the supports that are excellent in stretching properties, do not generate hydrochloric acid gas during waste combustion, and are environmentally friendly. The thickness of the support is usually from 20 to 200 μm.

The support may be provided with a release layer on the transfer layer side, if necessary, in order to improve the releasability from the transfer layer. The release layer is removed together with the support from the transfer layer when the support is released. As the release layer, for example, a simple substance such as a silicone resin, a melamine resin, a polyamide resin, a urethane resin, a polyolefin resin, a wax, or a mixture containing these is used.

The transfer layer comprises at least a decorative layer, and a release layer, an adhesive layer, etc. may be a component of the transfer layer as appropriate. In a configuration having an adhesive layer, it is possible to omit applying an adhesive to one or both of the transfer sheet and the base material during transfer. The decorative layer may be a layer formed by coating,
In order to provide a design feeling different from the painting by separate coating, a layer formed by a printing method or a vapor deposition method is preferred, which provides a decorative feeling that cannot be formed by painting (coating). Therefore, the decorative layer, gravure printing, silk screen printing, conventionally known methods such as offset printing, a pattern layer printed with a pattern or the like with a material, aluminum, chrome,
A metal thin film layer or the like in which a metal such as gold, silver or the like is partially or entirely formed by using a known vapor deposition method or the like. A wood pattern, a stone pattern, a grain pattern, a tile pattern, a brick pattern, a leather pattern, a character, a geometric pattern, a solid pattern, or the like is used in accordance with the surface irregularities of the base material. The picture layer ink is composed of a vehicle such as a binder, a coloring agent such as a pigment or a dye, and various additives appropriately added thereto. Acrylic resin,
Vinyl chloride-vinyl acetate copolymer, polyester resin,
A simple substance such as a cellulose resin, a polyurethane resin, a fluororesin, or a mixture containing these is used. As the pigment of the colorant, inorganic pigments such as titanium white, carbon black, red iron oxide, graphite, and ultramarine blue, and organic pigments such as aniline black, quinacridone, isoindolinone, and phthalocyanine blue are used.

The decorative layer may be a layer having a uniform pattern on the entire surface. However, when the decorative layer is transferred to the inside of the groove-shaped concave portion by the transfer using solid particle impact pressure, the groove-shaped concave portion is decorated with a pattern dedicated to the groove-shaped concave portion. Is also good. For example, it is a pattern formed by a pattern corresponding to a groove-shaped concave portion expressing a desired color, gloss, pattern, or the like serving as a joint or the like. This makes it possible to make a decoration utilizing the three-dimensional groove-shaped recess. The pattern is a pattern substantially matching the pattern of the groove-shaped recess. The transfer is performed by adjusting the positional relationship between the base material and the transfer sheet artificially or mechanically so as to be synchronized with the groove-shaped concave portion, and performing the registration (register) to obtain a desired positional relationship. good. Further, in order to adjust the releasability between the support or the release layer and the decorative layer, the release layer is provided between these layers in the same manner as a conventionally known transfer sheet.
Further, the release layer may be provided for improving the coating suitability of the separate coating on the decorative layer after the transfer, the adhesion of the paint, and the like. For the release layer, for example, a resin or the like used as a binder of the picture layer ink is used. This release layer is transferred to the substrate side together with the decorative layer at the time of transfer, and becomes a layer between the decorative layer and the layer formed by separate coating. Further, the transfer sheet may be provided with a number of small holes penetrating through all layers of the transfer sheet, if necessary, in order to facilitate removal of air remaining by being embraced between the base material and the transfer sheet.

The adhesive for adhering the transfer layer to the substrate is as follows:
As an adhesive layer constituting a transfer layer of a transfer sheet, or as an adhesive layer on a substrate, it is applied in advance or immediately before transfer by in-line coating or off-line coating. When applied to a substrate, the adhesive layer of the transfer sheet transfer layer can be omitted. The adhesive may be appropriately selected depending on the application, required physical properties, and the like. Examples of the adhesive include a heat-sensitive adhesive, a moisture-curable heat-sensitive adhesive, a hot-melt adhesive, a moisture-curable hot-melt adhesive, a two-part curable adhesive, an ionizing radiation-curable adhesive, and an aqueous adhesive. Various adhesives such as a pressure-sensitive adhesive or an adhesive can be used. As the heat-sensitive adhesive,
Either a heat fusion type using a thermoplastic resin or a thermosetting type using a thermosetting resin may be used. The adhesive may be diluted with a solvent or without a solvent, or may be a liquid or a solid at room temperature. As a specific example of the adhesive, for example, as a heat-sensitive adhesive, polyvinyl acetate resin, vinyl chloride-vinyl acetate copolymer, acrylic resin, thermoplastic polyester resin, thermoplastic polyurethane resin, dimer acid and ethylenediamine A conventionally known adhesive such as a polyamide resin obtained by condensation polymerization can be used. Also,
For example, as the thermosetting adhesive, a phenol resin, a urea resin, a diallyl phthalate resin, a thermosetting polyurethane resin, an epoxy resin, or the like can be used. The application amount of the adhesive varies depending on the composition of the adhesive, the type of the base material, and the surface state, but is usually about 10 to ²⁰⁰ g / m ² (solid content).

(Roller Transfer Method) A so-called roller transfer method using an elastic roller for applying a transfer pressure is disclosed in Japanese Patent Publication No. 60-5987.
No. 6, JP-A-5-270199, JP-A-5-270199
This is a transfer method using an elastic roller as a transfer roller, as described in Japanese Patent Publication No. 139097. FIG.
FIG. 4 is an explanatory diagram of a roller transfer method. The transfer sheet S including the support 7 and the transfer layer 8 is pressed against the base material B by pressing the transfer layer side toward the base material side with the elastic roller R from the support side and applying a transfer pressure. After the transfer layer is adhered to the substrate, the support is peeled off to transfer the transfer layer to the substrate. As the elastic roller R used for the transfer roller, a roller in which a surface of a rigid rotating shaft core R1 such as iron is covered with a soft elastic member R2 is usually used. Rubber such as silicone rubber, neoprene rubber, fluorine rubber, styrene-butadiene rubber, butadiene rubber, and natural rubber is used as the elastic body R2. In particular, silicone rubber is preferable in terms of heat resistance, durability, elasticity, and the like. In particular, when the unevenness of the surface to be transferred of the base material to be transferred is large, it is preferable to use an elastic body having a JIS standard rubber hardness of 60 ° or less so that the transfer sheet follows the uneven surface. Preferred for The diameter of the elastic roller is usually about 5 to 20 cm. Also,
Usually, the elastic roller is heated by an internal or external heating source and used also as a heating roller.

(Transfer Method Using Solid Particle Impact Pressure) The transfer method using solid particle impact pressure, which is a novel transfer method, is a method capable of transferring even a particularly large uneven surface such as a three-dimensional shape. In this method, the transfer layer side of a transfer sheet composed of a support and a transfer layer is opposed to the uneven surface side of a substrate having unevenness composed of a plurality of top surfaces partitioned by groove-shaped recesses on the surface, The solid particles collide against the support side of the sheet, and the pressure of the collision is used to press the transfer sheet against the uneven surface of the substrate, and after the transfer layer adheres to the substrate, the transfer sheet support is peeled off. By doing so, it can be said that this is a kind of curved surface transfer method for transferring a transfer layer to a substrate. That is, as shown in the conceptual diagram of FIG. 8, a large number of solid particles P collide from the support side of the transfer sheet S including the support 7 and the transfer layer 8 (including the decoration layer), and the collision pressure is reduced. To form the transfer sheet so as to follow the surface shape of the base material and press the transfer sheet against at least the surface of the base material to which the transfer is to be performed. The transfer sheet is pressed against the base material by the solid particle collision pressure, and follows the top surface portion 2 and, if necessary, the inside of the groove-shaped concave portion 1 and is formed. Thereafter, if only the support is peeled off, the transfer is completed. The arrow added to the solid particles P indicates a velocity vector of the solid particles. This transfer method is a method capable of transferring to a substrate having a large surface irregularity such as a three-dimensional shape which cannot be performed by a roller transfer method or the like. For example, the top surface of the base material is the same height, the envelope shape of the surface to be transferred is flat, and even if the surface on the top surface is flat or uneven, the decoration layer is transferred only on the top surface. If so, the above roller transfer method can be applied sufficiently. However, when the top surfaces of the base material are not at the same height, when the envelope shape of the transfer target surface is not flat, when the unevenness of the surface on the top surface is large, even inside the groove-shaped recess in addition to the top surface When the shape of the transfer-receiving surface desired to be transferred, such as in the case of transfer, is a three-dimensional shape or the like that cannot be performed by the roller transfer method, any transfer method in which the transfer pressure is applied by the solid particle collision pressure is applicable. is there.

Solid particles : Solid particles P include non-metallic inorganic particles such as glass beads, ceramic beads, calcium carbonate beads, alumina beads, zirconia beads, alundum beads, corundum beads and the like;
Iron or carbon steel, iron alloys such as stainless steel, aluminum, or aluminum alloys such as duralumin, titanium,
Metal particles such as metal beads such as zinc, or organic particles such as resin beads such as fluororesin beads, nylon beads, silicone resin beads, urethane resin beads, urea resin beads, phenol resin beads, crosslinked rubber beads, or metals And inorganic / resin composite particles composed of an inorganic particle and a resin. When liquid water is used as the solid particle accelerating fluid, the solid particles are preferably non-metals such as stainless beads, glass beads, ceramic beads, and resin beads that do not rust or corrode with water. The shape is preferably spherical, but spheroidal, polyhedral, scaly, amorphous, and other shapes can also be used. The particle size of the solid particles is usually about 10 to 1000 μm.

Incidentally, the solid particles can also serve as a heating means and a cooling means. When heated solid particles are used, the activation of the adhesive by heating and the promotion of crosslinking and curing thereof, or the improvement of the stretchability by heating the transfer sheet can be performed together with the pressing of the transfer sheet. In this case, the transfer sheet and the base material may be heated to some extent by another heating method before the application of the collision pressure. For the purpose of promoting cooling after bonding, solid particles having a temperature lower than the temperature of the adhesive at the time of bonding can be used as the cooling solid particles. The solid particles may be used in combination with a part or all of the solid particles as heated solid particles or cooled solid particles, or after the heated solid particles collide with the cooled solid particles. In addition, the transfer sheet, the base material, the adhesive, etc., which need to be heated by another heating method are sufficiently heated, and the transfer sheet is molded, bonded and cooled almost simultaneously using the cooled solid particles. You can also. In order to heat or cool the solid particles, when storing the solid particles in a tank such as a hopper or the like, the solid particles may be heated or cooled during storage. Further, the solid particles may be heated or cooled while passing through the transport tube.

Transfer pressure application by collision pressure of solid particles: The transfer pressure by collision pressure is applied by causing the solid particles to collide with the transfer sheet, and the transfer sheet is pressed against the substrate. A large number of solid particles are continuously ejected toward the transfer sheet to apply a collision pressure to the transfer sheet. A large number of solid particles collide with the transfer sheet as solid particles. Typically, an impeller or a blowing nozzle is used for the ejector. The impeller accelerates the solid particles by its rotation, and the blowing nozzle conveys and accelerates the solid particles by a high-speed fluid flow as a solid particle accelerating fluid. Sandblasting, shot blasting, shot peening and the like used in the blasting field can be used for the impeller and the blowing nozzle. For example, a centrifugal blast device is used for the impeller, and a pressurized or suction blast device, a wet blast device, or the like is used for the blowing nozzle. The centrifugal blast device accelerates and ejects solid particles by the rotational force of the impeller. The pressurized blast device ejects solid particles mixed with compressed air together with air. The suction-type blast device sucks solid particles into a negative pressure portion generated by a high-speed flow of compressed air, and ejects the solid particles together with the air. The wet blast device mixes and ejects solid particles with a liquid. In addition to the blowing nozzle and the impeller, a method of accelerating solid particles using free fall due to gravity, a method of accelerating magnetic particles by a magnetic field, and the like can be used for the ejector. In the case of an ejector using an impeller, gravity, and a magnetic field, it is also possible to eject solid particles toward a transfer sheet in a vacuum.

Ejector / Impeller : FIGS. 9 to 12 show conceptual diagrams of an example of an impeller that can be used as a particle accelerator of the ejector. These correspond to centrifugal blasting devices used in the blasting field. In the drawing, the impeller 812 is
A plurality of blades 813 are fixed on both sides by two side plates 814, and the center of rotation is a hollow portion 81 having no blades 813.
It is 5. Further, a direction controller 816 is provided inside the hollow portion 815. The direction controller 816 has an opening 817 that is partially open in the circumferential direction, has a hollow cylindrical shape, and has the same rotation axis as the rotation axis of the impeller 812, and rotates independently of the impeller. It is free. When using the impeller, the opening of the direction controller is fixed so as to face an appropriate direction, and the ejection direction of the solid particles is adjusted. Further, inside the directional controller, another impeller having a hollow shaft and the same rotation axis as that of the impeller 812 is internally provided as a sprayer 818 (see FIG. 11). The spreader 818 rotates with the outer impeller 812. A rotation shaft 819 is fixed to the rotation center of the side plate 814, and the rotation shaft 819 is
At 0, it is rotatably supported and driven and rotated by a rotary power source (not shown) such as an electric motor, and the impeller 812 rotates.
The rotating shaft 819 does not penetrate between the two side plates 814 having the blades 813 therebetween, and forms a space without a shaft. Then, the solid particles P are supplied into the sprayer 818 from a hopper or the like through a transport pipe. Usually, the solid particles are supplied from above (directly above or obliquely above) the impeller.
The solid particles supplied into the sprayer are scattered outward by the impeller of the sprayer. The scattered solid particles are supplied to the direction controller 816.
Only in the direction allowed by the opening 817 of the
It is supplied between the blades 813 of the outer impeller 812. Then, it collides with the blade 813 and the impeller 81
It is accelerated by the torque of 2 and squirts from the impeller.

The ejection direction of the solid particles is shown in FIGS.
At 0, it is substantially vertically downward, but may be horizontal or obliquely downward (not shown) as shown in FIG. 13B. FIG.
(A) and FIG. 12 (B) show the opening 8 of the direction controller 816.
FIG. 12 is a conceptual diagram of the ejection direction control for adjusting the ejection direction of the solid particles from the setting of the direction 17 (the direction controllers are fixed at the illustrated positions in FIGS. 12A and 12B).
Note that the direction controller 816 can also adjust the ejection amount of the solid particles by adjusting the size of the opening in the circumferential direction and the width direction. In FIG. 10, the rotating shaft 819 is configured to be only outside the side plate 814 and not penetrate to the hollow portion 815. A configuration may be adopted in which the inside of a hollow cylindrical rotary shaft having an opening through which solid particles pass through is formed as a hollow part (not shown). The shape of the blade 813 is typically a rectangular flat plate (a rectangular parallelepiped) as shown in FIGS. 9 to 12, but in addition, a propeller shape such as a curved curved plate, a screw propeller, or the like can be used. , Select according to purpose. The number of blades is usually selected from a range of up to about 10 blades. By the combination of the shape, number, rotation speed, and the mass and supply speed and supply direction of the solid particles, the opening size and direction of the direction controller, the ejection direction of the accelerated solid particles, the ejection speed, Adjust the projection density, ejection angle, etc.

FIG. 13 is a conceptual diagram showing another example of the impeller. The impeller 812a shown in the drawing has a structure in which a plurality of flat blades 813a are fixed on both sides by two side plates 814a. Usually, the solid particles P are supplied from above (directly above or obliquely above) the impeller. Also, the side plate 81
4a also regulates the ejection direction in the width direction with respect to the rotating shaft 819a. By adjusting the shape, the number, the rotation speed, the mass of the solid particles, the supply speed and the supply direction of the impellers, the direction of the ejection (spout) of the accelerated solid particles, the ejection speed, the projection density, the ejection diffusion angle, etc. are adjusted. . The ejection direction of the solid particles can be vertically downward (not shown), horizontal (FIG. 13), obliquely downward (not shown), or the like.

Further, the impellers such as the above-mentioned impellers 812 and 812a are further provided with an ejection guide (not shown) for opening only a portion for ejecting and ejecting solid particles and covering the periphery of the other impellers, if necessary. Provision of the solid particle ejecting direction makes it possible to control the ejecting direction of the solid particles such as aligning the ejecting direction of the solid particles. The shape of the opening of the ejection guide is, for example, a hollow cylindrical shape, a polygonal column shape, a conical shape, a polygonal pyramid shape, a fish tail shape, or the like. The ejection guide may have a single opening, or may have an interior partitioned into a honeycomb shape.

The dimensions of the impellers such as the impellers 812 and 812a are usually about 5 to 60 cm in diameter, and the width of the impeller is 5 to 20 c.
m, the length of the impeller is about the diameter of the impeller, and the rotation speed of the impeller is about 500-5000 [rpm]. The ejection speed of the solid particles is about 10 to 50 [m / s], and the projection density (total weight of the solid particles to be collided per unit area of the base material) is about 10 to 150 [kg / m ² ].

The material of the impeller blades may be appropriately selected from ceramics, metals such as steel, high chromium cast steel, titanium, and titanium alloys. Since the solid particles are accelerated upon contact with the blade, it is preferable to use a high chromium cast steel or ceramic having good wear resistance for the blade.

Ejector / Blowout Nozzle : FIG. 14 is a conceptual diagram of an example of the ejector 840 using a blowout nozzle. Note that the ejector 840 shown in the figure is an example of an ejector that uses a gas as a solid particle accelerating fluid and mixes and ejects the gas and the solid particles when ejecting the solid particles. Spouter 840 in FIG.
A guide chamber 841 for mixing the solid particles P and the fluid F, an internal nozzle 842 for jetting the fluid F into the guide chamber 841,
It comprises a blowing nozzle 844 for blowing out the solid particles P and the fluid F from the nozzle opening 843. When the fluid F sent from a compressor or a blower (not shown) through an appropriate pressurized tank (not shown) is ejected from the internal nozzle 842 and ejected from the nozzle opening 843 of the nozzle 844 via the guide chamber 841, In the induction chamber 841 in the vessel, a negative pressure is created by the action of the fluid flow flowing at a high speed, and the negative pressure guides and mixes the solid particles into the fluid flow, accelerates and transports the solid particles with the fluid flow, and generates the nozzle 844. Are ejected from the nozzle opening 843 together with the fluid flow. It should be noted that the blowing nozzle includes a blowing nozzle using a liquid as a solid particle accelerating fluid. In the case of liquid, the fluid and solid particles are mixed and stored in a pressurized tank (not shown) by, for example, a pump (not shown, when the fluid is a liquid), and the mixed solution is discharged from the nozzle opening of the blowing nozzle. What gushes etc. is used.

As the shape of the nozzle opening, a hollow cylindrical shape, polygonal column shape, conical shape, polygonal pyramid shape, fish tail shape or the like is used. The blowing nozzle may have a single opening, or may have an inside partitioned into a honeycomb shape. Fluid pressure is spraying pressure, usually 0.1-100k
g / cm ² . The flow velocity of the fluid flow is usually about 1 to 20 m / sec for the liquid flow, and is usually about 5 to 80 m / sec for the air flow. The material of the ejector such as the induction chamber and the nozzle is made of solid particles, such as ceramic, steel, titanium, titanium alloy, etc.
What is necessary is just to select suitably according to the kind of fluid. If the fluid is a liquid, select a material that does not cause rust, dissolution, corrosion, etc. For example, if the fluid is water, stainless steel, titanium, a titanium alloy, a synthetic resin, or ceramic is used. However, steel or the like may be used if the surface is waterproofed. Since solid particles pass through the inner wall of the ejector in contact with metal particles or inorganic particles when solid particles are used, since the particles are hard,
It is preferable to use ceramics having good wear resistance. When resin beads are used as solid particles, stainless steel may be used because they are softer than metal particles.

The fluid F is used as a solid particle accelerating fluid when the solid particles are accelerated and conveyed by the fluid flow, and the solid particles are ejected together with the fluid from the solid particle ejection means (eg, an ejection nozzle). The fluid F is a solid particle acceleration fluid for accelerating the solid particles. As the fluid, both gas and liquid can be used, but usually, gas that is easy to handle is used. The gas is typically air, but may be carbon dioxide, nitrogen or the like. The liquid is not necessarily limited, but water is one of the preferred materials because of its nonflammability, ease of drying, non-toxicity, low cost, availability, and the like. In addition, Freon,
Nonflammable liquids such as glycerin and silicone oil can also be used. A liquid (as well as a gas) can be impinged on the transfer sheet along with the solid particles. Naturally,
Since liquid has a higher density than gas, liquid is easier to accelerate when solid particles are accelerated by a fluid flow than gas, and when liquid collides with a transfer sheet, even when it collides with gas at the same speed. In addition, the collision pressure is higher than that of gas, and a practical collision pressure can be obtained. (Since the difference in density from the solid particles is small, the solid particles can be easily transported.) Therefore, in the case of a liquid, in addition to the collision pressure of the solid particles, the collision pressure of the liquid can be used as the transfer pressure. The transfer pressure can be applied, and as a result, a large transfer effect can be obtained by forming the transfer sheet by following the surface irregularities of the substrate. Further, when a fluid is used as the heating or cooling means when the collision pressure is applied, the liquid has a higher specific heat than the gas, so that a greater heating or cooling effect can be obtained. In addition, when the liquid is an electric conductor such as water, explosion-proof measures against electrostatic charging are easier than in the case of a gas.

Impact pressure application form : The use of a single ejector is possible depending on the area of the impact pressure application area, but if the required area is large, a plurality of ejectors are used to impinge on the transfer sheet and impact solid particles. It is preferable that the region has a desired shape. When applying the collision pressure while transporting the base material, for example, a plurality of rows are arranged in a straight line in the width direction orthogonal to the transfer direction of the transfer sheet and the base material, and a wide band shape is linear in the width direction. Collision area. Alternatively, the arrangement of the ejectors 9 in FIG. 15A is a staggered arrangement, and FIG.
Are arranged in a line, but the central part in the width direction is arranged to collide on the upstream side in the feed direction. In the arrangement of FIG.
The pressing of the transfer sheet against the 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. 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. When a plurality of ejectors are arranged in the width direction as shown in FIG. 15, it is preferable that the pressurized areas of the individual ejectors are partially overlapped with each other and arranged so that pressure can be applied without fail over the entire width. FIG. 15B shows an example of such an arrangement.
In this figure, the dotted line indicates the (effective) pressure area. In order to lengthen the collision pressure application time, it is preferable that the ejectors are arranged in a multi-stage arrangement in which two or more rows are arranged in the feed direction of the transfer sheet and the base material.

Further, it is not always necessary to make the collision pressure all uniform within the collision area. FIG. 16 is a setting example of a mountain-shaped pressure distribution in which the central portion in the width direction orthogonal to the transfer direction of the transfer sheet has the maximum collision pressure, and the collision pressure decreases toward both ends in the width direction. This setting assists the pressure welding to progress in a stepwise manner from a place where the pressure is high (the center in the figure) to a place where the pressure is low (the sides in the figure). However, in the case of a pressure distribution as shown in FIG. 16, the impact pressure on the base material is such that transfer to a desired uneven surface can be completely performed, and the transfer sheet is deformed due to excessive pressure, deformation of the base material, Adjust so that it is all within the appropriate pressure range where breakage does not occur. In the roller transfer method using an elastic roller as the transfer roller, if the diameter of the central portion of the transfer roller is made large, the central portion can be strengthened in terms of pressure, but the circumferential length differs between the central portion and both end portions. As a result, pressure is applied in contact and transfer of the transfer sheet cannot be performed uniformly. The collision pressure is adjusted by controlling the speed of solid particles colliding from the ejector with the transfer sheet, the number of solid particles colliding per unit time, the amount of projection, and the mass of one particle. Of these, to adjust the speed of solid particles,
For example, in the case of an ejector using an impeller, adjustment is performed by the rotation speed of the impeller, the diameter of the impeller, and the like. In the case of an ejector using a blowing nozzle, the opening / closing amount of a valve, the size of an inner diameter of a pipe for conveying solid particles connected to the valve, the fluid pressure (fluid) immediately before the ejector using a pressure regulator (regulator) or the like. By controlling the velocity of the ejected solid particles and the flow of the fluid, the adjustment is performed by controlling the single particles or the mixture of the fluid and the solid particles.

Method of arranging the ejector with respect to the substrate : In the case of the ejector using the impeller, the ejection direction of the solid particles does not spread so much in principle in the direction parallel to the impeller rotation axis. They tend to spread in orthogonal directions. On the other hand, in the case of the blowing nozzle, the spread of the solid particles to be blown out is smaller than that in the case of the blower using the impeller, and even if it spreads, it is usually uniform and isotropic in all directions. The arrangement of the ejectors may be determined in consideration of such characteristics of the ejectors. However, when one ejector cannot achieve the desired collision area size, a plurality of ejectors may be used. When a plurality of ejectors are arranged on the transfer surface of the base material in this manner, each ejector is parallel to the base material, and the ejection direction of each ejector is in the normal direction of the base material. Arrangement is fundamental. This is because such a parallel arrangement allows the solid particles to collide perpendicularly to the envelope surface of the transfer surface of the substrate, and basically allows the collision pressure to be used most effectively. Therefore, when the collision pressure is applied while the base material is being conveyed, for example, as shown in FIG. 17, a cylindrical shape in which the envelope surface (the cross-sectional shape perpendicular to the conveyance direction) of the transfer surface of the base material B becomes circular , A plurality of ejectors 9 are prepared, and the ejectors are arranged so that the solid particles collide substantially perpendicularly with an individual collision surface (tangential plane of the convex surface) which each ejector mainly serves. It is preferable that the direction is normal to the envelope surface of the adjacent substrate surface. In this manner, the ejector may be arranged so that the ejecting direction of the ejector is such that the solid particles collide as vertically as possible according to the uneven shape of the target substrate. However, the direction of the ejector need not necessarily be perpendicular to the side surface of the transfer sheet support. Further, a large number of ejectors may be provided, and some ejectors may be stopped depending on the base material to be manufactured.

Application of practical transfer pressure by solid particle collision pressure
How to : When actually transferring using solid particles, it is preferable that the solid particles are circulated and reused without being scattered in the surrounding atmosphere. Therefore, it is preferable that the transfer pressure is applied by causing the solid particles to collide with the transfer sheet in a chamber (isolation chamber) that separates the collision space for pressing the transfer pressure due to the solid particle collision pressure from the surrounding space (see FIG. 18). The separation of the support may be performed immediately after the solid particle collision pressure is released or after a certain interval, provided that the transfer layer adheres to the base material and the support can be peeled without being broken. But it is good. It may be inside or outside the chamber. The transfer sheet is pressed against the base material by the solid particle collision pressure by placing the single transfer sheet on the single base material and transporting the two sheets integrally, while the solid particles are transferred by a fixed ejector. A form in which the collision pressure is continuously applied, or a form in which both are fixed only when the solid particle collision pressure is applied, and only the ejector is moved, or the transfer sheet is in a continuous band form, and is at a speed equal to the conveying speed of the base material. It may be in any form such as a form in which it is transferred and a collision pressure is applied by an ejector having a fixed position. The transfer surface of the substrate (envelope surface)
In addition to applying the collision pressure by colliding solid particles from above in the horizontal and vertical directions, the collision pressure may be applied from below with the transferred surface being vertical or inclined, or with the transferred surface facing downward. . Further, before applying the collision pressure, the transfer sheet may be preliminarily pressed against the base material by the elastic roller.

Preferably, in the case of a transfer sheet made of a thermoplastic resin support, the transfer sheet is preheated and softened by an infrared radiation heater or the like, and preheated in advance when the substrate has a large heat capacity. The solid particles are made to collide with the transfer sheet in a state of being activated by heating. Even in the case of the transfer method using the solid particle collision pressure, similarly to the roller transfer method, the transfer sheet or the base material (and the adhesive layer formed thereon) can be appropriately heated at the time of or before the transfer pressure. . For example, before pressing against the collision pressure, the transfer sheet may be heated by any heating means such as infrared radiation heating or roller heating, and the substrate may be heated by any heating means such as infrared radiation heating. For the heating at the time of pressing with the collision pressure, heated solid particles can be used as the solid particles, or in the case of the ejector using the blowing nozzle, the solid particle acceleration fluid can also use the heated fluid. of course,
Heating before and during pressing of the collision pressure, or heating only during pressing may be used as appropriate. However, if the hot air heating is performed in a chamber that isolates the collision space, gas flows into the chamber and affects the chamber pressure balance, so it is preferable to perform the heating outside the chamber.

In the case where the adhesive is of a heat-sealing type, if the adhesive is forcibly cooled after the transfer sheet is in close contact with the base material, the adhesive follows the inside of the concave portion and promotes the fixation of the formed transfer sheet, thereby facilitating the transfer. Prevents the transfer sheet from returning to its original shape after pressure release when the sheet has a restoring force.
Since the separation and removal of the toner can be performed more quickly, it is possible to prevent transfer omission and improve the production speed. For this purpose, during the application of the collision pressure, the cooling solid particles are used without releasing the collision pressure, or when the solid particle acceleration fluid is used, the cooling fluid is used. It is preferable to cool the adhesive layer using cooling means. When the heat capacity of the base material is large, the base material can be cooled from the back surface by spraying a low-temperature fluid in addition to the cooling solid particles and the cooling fluid, and cooling a base for transporting the base material or a roller or a belt conveyor. 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. Note that the solid particles remaining on the support (particularly in the groove-shaped concave portion) can be blown off and removed using the wind at the time of blowing the cold air.

[Example of Apparatus for Performing Coating Step and Transferring Step] FIG. 18 shows a method of manufacturing a decorative material according to the present invention. A conceptual diagram is shown. In the figure, the transfer method using solid particle collision pressure and the roller transfer method are both illustrated as the transfer step. The base material B is first conveyed to the transfer step and then to the painting step by the base material conveying device 10 such as a conveying tool or a row of driving rotary rollers. Then, in the case of the transfer step using the solid particle collision pressure (upper right half of the drawing), the solid particles P are caused to collide with the support side of the transfer sheet S from the ejector 9. The collision of the solid particles is performed in a chamber 11 isolated from the surrounding space except for the entrance and exit of the transfer sheet and the substrate. The transfer sheet is unwound in a continuous band form from the feed roll 12 and is supplied into the chamber 11 at a speed synchronized with the transfer of the base material so as to contact or approach the base material surface with the guide roller 13, and is supported by the peeling roller 14. The body is peeled off and taken up as a take-up roll 15. In the case of the transfer step by the roller transfer method (lower right half of the drawing), the transfer pressure is applied by the elastic roller R. In the painting process, the painting chambers 20a, 20b, and 20c are installed in this order in FIG. Each of the coating rooms 20a, 20b, and 20c has a coating device 21a, 21b, and 21c for separately painting the top surface with an NC coating device and a mask board, respectively, and sequentially coating the colors a, b, and c in each coating room. Then, separate coating is performed. If the transfer step is not performed, only the painting step is performed. Then, a cosmetic material whose top surface is separately painted can be obtained. If necessary, a decorative material having a decorative layer transferred and formed before painting can be obtained.

[Uses of Cosmetic Materials] Cosmetic materials obtained by the present invention include exterior materials such as siding, exterior walls such as fences, roofs, gates and gable plates, building interior materials such as wall surfaces, ceilings and floors, window frames, door,
Various fields such as handrails, sills, doors and other fixtures, furniture surface materials such as chests of cabinets, cabinets for light electric and OA equipment such as television receivers, vehicle interior materials such as automobiles and trains, and interior materials such as aircraft and ships. Can be used. The shape of the cosmetic material is
It is arbitrary such as a flat plate, a curved plate, a rod-shaped body, and a three-dimensional object.

[0048]

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

(Example 1) First, as a base material B having a plurality of top surfaces partitioned by groove-shaped recesses on its surface, a base material B having a brickwork pattern as shown in the plan view of FIG. ,
A groove-shaped concave portion 1 of a joint having a depth of 1 mm and an opening width of 5 mm;
A 12 mm-thick calcium silicate plate having a top surface portion 2 having a size of 100 mm and a flat surface was prepared. Then, a sealer coating with an acrylic urethane resin and a white undercoat coating with a urethane resin were previously performed on the uneven surface. Then, as a separate coating process, the top surface of the base material was separately coated in three colors of black brown, yellow brown, and red brown by spray coating using a mask board for each color (see FIGS. 1 and 2). . The paint is not applied repeatedly,
As the paint, the above-mentioned concealed colored paint of three colors of black brown, yellow brown and red brown was used. In addition, the coating of each top surface was spread so as to cover the groove-shaped concave portion. Acrylic resin-based (organic solvent-diluted) paints were used for the paints, each of which was made by blending inorganic color pigments such as red iron oxide, graphite, titanium white, and carbon black. Then, the bottom of the groove-shaped concave portion 1 was painted with a brush using a white paint obtained by adding a titanium pigment to an acrylic resin-based binder, thereby obtaining a cosmetic material in which each top surface was painted in a different color. Since the colors of the tops of the decorative materials are different from each other to three colors, it was possible to express a design feeling as if three types of bricks were stacked. In addition, over the entire surface of this cosmetic material,
An emulsion paint of polyvinylidene fluoride containing 0.5% by weight of a benzotriazole-based UV absorber and a matting agent of silica particles is applied to a dry thickness of 50 μm to form an uncolored matte transparent protective layer. And a cosmetic material with a transparent protective layer.

(Example 2) The base material was applied with an adhesive in addition to the sealer coating and the undercoating of the base material used in Example 1. The adhesive was a non-solvent hot-melt heat-sensitive adhesive made of a polyamide resin at 30 g / m ^2.
It was melt coated. The transfer sheet S has a thickness of 100
A gravure-printed brick-like design was prepared as a decorative layer of a transfer layer on one side of a support made of a μm polypropylene thermoplastic elastomer film. The pattern is white,
A gray and black achromatic coarse-grained pattern. The resin of the binder for the picture ink is a mixture of an acrylic resin and a vinyl chloride-vinyl acetate copolymer in a ratio of 8: 2 (weight ratio), and the coloring pigment is carbon black.
Titanium white was used. Then, the decorative layer was transferred to the top surface of the base material using the transfer sheet. Transfer pressure application
A roller transfer method performed by pressing an elastic roller was used. The elastic roller is JI with the surface of the iron core coated with silicone rubber.
The S rubber had a hardness of 60 degrees and was used as a heating roller having a roller surface temperature of 100 ° C. Next, quinacridone, isoindolinone, an acrylic resin binder as a paint,
Three transparent colored paints of black brown, yellow brown and red brown prepared by mixing carbon black are prepared, and each top surface is separately painted in three colors in the same manner as in Example 1 and painted with groove-shaped concave portions. To obtain a cosmetic material. Cosmetic material is as if 3
In addition to being able to express the design feeling of stacking different types of bricks,
By the brick-like pattern by the printing of the decoration layer, the design expression that was impossible only by painting was possible, and the design was further enhanced. In addition, an uncolored matte transparent resin layer was further formed on this decorative material in the same manner as in Example 1 to obtain a decorative material with a transparent protective layer.

(Example 3) In Example 2, the transfer pressure applied in the transfer step was changed to the solid particle collision pressure. Along with this, the base material has a flat top surface portion used in Example 2, and fine unevenness 6 having a satin finish with a depth distributed in a range of 0.1 to 0.5 mm as small unevenness 6. A base material having a top surface portion and a groove-shaped concave portion having a depth of 2 mm and a width of 7 mm was prepared (see FIG. 3). Then, as in Example 2, an adhesive was previously applied on the sealer and the undercoat. The transfer pressure was applied using an apparatus on a production line as shown in the upper part of FIG. 18 and using an ejector using an impeller as shown in FIGS. 9 to 11 as the ejector. The substrate B was preheated to a surface temperature of 100 ° C. with an infrared radiation heater in advance, and then transported by the substrate transport device 10 with its uneven surface facing upward, and supplied into the chamber 11. On the other hand, the transfer sheet S was also supplied from the feed roller 12, approached by the guide roller 13 such that the transfer layer side faced the base material, and supplied into the chamber 11. The transfer sheet was preheated by the heat of the substrate. Then, in the chamber 11, the solid particles P collided against the support side of the transfer sheet from the ejector 9 located above the transfer sheet, and the collision pressure was applied as the transfer pressure.
As the solid particles P, spherical zinc spheres having an average particle diameter of 0.4 mm were used. The rotation speed of the impeller of the ejector is 3600 [rpm
m], and the ejection speed of the solid particles was 35 [m / s].
As a result, the transfer sheet was extended by the collision pressure to follow the inside of the small unevenness on the top surface and was formed. Then, the substrate on which the transfer sheet is in close contact is carried out of the chamber 11 and cooled, and after the support of the transfer sheet is peeled off from the substrate, the decoration layer is transferred to the entire top surface of the substrate having the small irregularities. I was Then, as in Example 2, each top surface portion was separately painted in three colors and painted in the groove-shaped concave portion to obtain a decorative material. The cosmetic material can express the design feeling as if three types of bricks are stacked, and also the design expression that cannot be done by painting alone with the brick-like pattern by printing the decoration layer, and the actual small size on the top part Due to the unevenness, the design became even higher. In addition, an uncolored matte transparent resin layer was further formed on this decorative material in the same manner as in Example 1 to obtain a decorative material with a transparent protective layer.

[0052]

According to the separate coating of the present invention, a decorative material of a design expression in which each top surface of a plurality of top surfaces is arranged in at least two different colors without using a dedicated printing plate or transfer sheet. Can be easily obtained. In addition, since the color scheme for each top surface is handled by painting instead of printing, the shape of the top surface,
Even if the pattern of the surface unevenness design differs depending on the size, arrangement, etc., it can be easily handled. Further, in the embodiment in which the transfer step of first transferring the decorative layer to the base material surface, the decorative layer can provide a design expression such as a printed pattern which cannot be obtained only by painting, so that the design can be further enhanced. In addition, even if the design of the unevenness of the top surface portion and the color arrangement on the top surface portion are different, the color arrangement is handled in the painting process, so that the formation of the decorative layer can be dealt with with a small printing plate or transfer sheet. Accordingly, waste of the printing plate and the transfer sheet can be reduced. When the transfer pressure is applied in the transfer step by pressing the elastic roller, the decoration layer can be easily transferred by a simple transfer device. Further, even if there are irregularities on the top surface, if they are minute irregularities, they can be transferred to the entire surface of the top surface including the inside of the concave portion depending on the shape. As a result, the design can be further improved. Further, when the transfer pressure application in the transfer step is performed by the solid particle collision pressure, in addition to the large irregularities due to the groove-shaped concave portion and the top surface portion, even if there are small irregularities such as fine irregularities on the top surface portion,
The image can be transferred to the entire top surface including the inside of the concave portion. Further, even if there is a height difference between the top surfaces, the transfer can be performed, and if desired, the transfer can be performed even to the inside of the groove-shaped recess. As a result, the decorative layer is transferred to the uneven surface having a shape that cannot be obtained by the conventional transfer method, so that a decorative material having a higher sense can be easily obtained together with the unevenness. In addition, in the transfer method using solid particle collision pressure, the overall (envelope surface) shape of the decorative material is not only a flat plate material but also a tile-like (envelope surface shape) as a whole.
Two-dimensional irregularities or three-dimensional irregularities such as a wavy shape, a convexly or concavely curved shape, a window frame, a sash, and the like are also possible. Further, there is no wear of parts such as the roller due to unevenness of the base material, which may occur in the case of the elastic roller.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram illustrating a separate painting of a top surface portion in a method of manufacturing a decorative material according to the present invention.

FIG. 2 is a conceptual diagram illustrating a mask board (for a color in FIG. 1) as selective shielding means as an embodiment of a method of separately painting a top surface portion.

FIG. 3 is an enlarged perspective view of a main part showing an example of unevenness of a base material.

FIG. 4 is a conceptual diagram illustrating another embodiment of a method for separately painting a top surface.

FIG. 5 is a conceptual diagram illustrating another embodiment of a method of separately painting the top surface.

FIG. 6 is a plan view showing examples of various patterns of an arrangement of a top surface portion.

FIG. 7 is a conceptual diagram illustrating a transfer process using an elastic roller for applying a transfer pressure in the present invention.

FIG. 8 is a conceptual diagram illustrating a transfer step using a solid particle collision pressure to apply a transfer pressure in the present invention.

FIG. 9 is a conceptual diagram (front view) illustrating an example of an ejector using an impeller.

FIG. 10 is a perspective view of an impeller part of FIG. 10;

FIG. 11 is a conceptual diagram illustrating the inside of the impeller of FIG. 10;

FIG. 12 is an explanatory diagram for adjusting the ejection direction with an impeller.

13A and 13B are conceptual diagrams illustrating another example of an ejector using an impeller, wherein FIG. 13A is a front view, and FIG. 13B is a side view.

FIG. 14 is a conceptual diagram illustrating an example of an ejector using an ejection nozzle.

FIG. 15 is a plan view showing various arrangement examples of the ejector. (A) is an arrangement arranged in a houndstooth check pattern, (B) is an arrangement in which the central portion is located on the upstream side, and is shifted toward the downstream side toward both ends.

FIG. 16 is an explanatory diagram in which a collision pressure is provided with a width distribution.

FIG. 17 is a side view showing an example of the direction of the ejector viewed from the flow direction.

FIG. 18 is a conceptual diagram illustrating an example of a production line of a cosmetic material in which a separate coating process is performed after a transfer process using a solid particle collision pressure or an elastic roller in the method for producing a cosmetic material according to the present invention. .

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Groove-shaped recessed part 2 Top part 2a, 2b Top part 3 Opening part 4 Shield part 5 Selection shielding means (mask board) 6 Small unevenness 7 Support body 8 Transfer layer 9 Ejector 10 Substrate conveying device 11 Chamber (collision space) 12 Feeding roll 13 Guide roller 14 Peeling roller 15 Take-up roll 20a-20c Painting room 21a-21c Painting device 812, 812a Impeller 813, 813a Blade 814, 814a Side plate 815 Hollow portion 816 Direction controller 817 Opening portion 818 Spreader 819 819a Rotating shaft 820 Bearing 840 Jetting device using blowing nozzle 841 Induction chamber 842 Internal nozzle 843 Nozzle opening 844 Nozzle B Base material D Cosmetic material F Fluid P Solid particle R Elastic roller R1 Rotating axis R2 Elastic body S Transfer Sheet

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI B44D 5/00 B44D 5/00 (72) Inventor Mitsuyoshi Miyakoshi 1-1-1, Ichigaya-Kagacho, Shinjuku-ku, Tokyo Dai Nippon Printing Co., Ltd. In-company (72) Inventor Reiko Suga 1-1-1, Ichigaya-Kagacho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd.

Claims (4)

[Claims] 1. A base material having irregularities composed of a plurality of top surfaces defined by groove-shaped recesses on its surface is prepared, and at least two different top surfaces of the base material are separated from each other in a separate coating process.
A method of manufacturing cosmetics that can be applied in more than one color. 2. The decorative material according to claim 1, wherein a transfer step of transferring the decorative layer to the surface of the base material is first performed, and then a separate coating step of coating each top surface portion with at least two different colors is performed. Production method. 3. The method for manufacturing a decorative material according to claim 2, wherein the transfer pressure is applied during the transfer step by pressing an elastic roller. 4. The method for producing a decorative material according to claim 2, wherein the transfer pressure is applied in the transfer step by a solid particle collision pressure.