JPH11170786A - Method and apparatus for transferring curved surface - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently manufacture a decorative material having three- dimensional protrusion and recess surface. SOLUTION: A decorative material is obtained by opposing a transfer layer side of a transfer sheet S having a support and a transfer layer at a protrusion and recess surface of a base material B to be transferred having the protrusion and recess surface, colliding solid particles P ejected from an ejector 1 with the support side of the sheet S, bringing the sheet S into pressure contact with the material B by its collision pressure, eliminating a static electricity charged at the support of the sheet S and the particles P retained on a support by an electric eliminator 3 of a static eliminating means, removing the particles P retained on the support of the sheet S by a removing unit 4 of a solid particle removing means, and then releasing the support of the sheet S. Since no solid particles remain on the support of the sheet after using, no problem occurs in the case of discarding the support.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate for housing exterior and interior materials, furniture, home electric appliances and the like, and in particular, to a method for transferring a curved surface for manufacturing a decorative plate having a decorative uneven surface, and a method for transferring the same. The present invention relates to a curved surface transfer device to be used.

[0002]

2. Description of the Related Art Conventionally, decorative boards having a decoration such as a picture on the surface of a base material by a direct printing method, a laminating method, a transferring method or the like have been used for various purposes. In this case, if the surface of the base material is flat, there is no problem since the pattern decoration can be easily performed, but the pattern decoration is applied to the uneven surface by a special device.

[0003] For example, a columnar shape such as a window frame or a surface border material, in which the base material decoration surface is two-dimensionally uneven (a shape having a curvature only in one direction (a direction perpendicular to the generating line or the height direction) like a cylinder) One of the curved surface decoration techniques applicable in the case of
No. 5895 has proposed this. That is, the technique of the publication is a surface decoration method by a laminating method, in which a front cover sheet coated with an adhesive is supplied on one side, and one base material is horizontally conveyed at a speed synchronized with the supply speed of the front cover sheet. While maintaining the state in which the ends of the facing sheet are not adhered by a large number of holding jigs, the adhesive-applied surface side of the facing sheet is pressed stepwise on the base material for each small area, and the facing sheet is placed on the base material. It is to be stuck on the surface by heating. This method is called a lapping method.

A curved surface decoration technique applicable to the case where the surface unevenness is a three-dimensional unevenness such as an embossed shape (ie, a shape having a curvature in two directions like a hemispherical surface) is disclosed in, for example, Japanese Patent Application Laid-Open No. 5-139097. There is a proposal in the gazette. That is, the technique of the publication is a surface decoration method by a transfer method, in which a transfer sheet having a structure in which a thermoplastic resin film is used as a support of the transfer sheet, and a release layer, a pattern layer, and an adhesive layer are sequentially provided on the support. Is placed on a substrate having an uneven surface, and pressed from the back surface of the support with a heat roller made of rubber having a rubber hardness of 60 ° or less, and a pattern is transferred to obtain a decorative plate. Further, a foamed layer which foams by heat during transfer is provided between the support and the release layer, and the foaming is also utilized to follow the uneven surface of the substrate.

[0005]

However, of the conventional methods as described above, the technique disclosed in Japanese Patent Publication No. 61-5895 can only handle two-dimensional curved surfaces.
The technique proposed in Japanese Patent Application Laid-Open No. 5-139097 can cope with a three-dimensional curved surface. However, in order to follow the surface unevenness by utilizing elastic deformation of a rotating heat roller by rubber, a shallow embossed shape is required. Is not applicable to large surface irregularities. In addition, the soft rubber roller is liable to be worn by the corners of the unevenness of the transfer substrate. Further, in a configuration in which a foam layer is provided on the transfer sheet, the transfer sheet becomes too complicated and expensive. In addition, there is a problem that the substrate is limited to a flat substrate as a whole.

Therefore, the present invention can provide a decorative material which can be transferred to a large three-dimensional uneven surface and has excellent surface decorativeness.
Further, it is an object of the present invention to provide a curved surface transfer method which does not require a jig having a special shape and which does not need to be replaced due to wear of a component such as a rubber roller, and a curved surface transfer device used therefor.

[0007]

In order to solve the above-mentioned problems, a curved surface transfer method according to the present invention employs a transfer sheet comprising a support and a transfer layer on an uneven surface side of a transfer-receiving substrate having an uneven surface. The transfer layer side of the transfer sheet is opposed, solid particles collide with the support side of the transfer sheet, and the pressure of the transfer sheet is pressed against the uneven surface of the substrate to be transferred using the collision pressure. After adhering to the material, the static electricity charged on the support of the transfer sheet and the solid particles remaining on the support is removed, and the solid particles remaining on the support of the transfer sheet are removed. The support of the sheet was peeled off and the transfer layer was transferred to the substrate to be transferred.

Further, the curved surface transfer device of the present invention is an apparatus used for carrying out the above-mentioned curved surface transfer method, wherein at least (1) a solid particle ejecting means for ejecting solid particles; A base material transporting means for transporting the base material to a position opposed to the solid particle ejection means, (3) a transfer sheet supply means for positioning the transfer sheet between the solid particle ejection means and the substrate to be transferred, and (4) A static electricity removing means for removing static electricity charged on the support and the solid particles remaining on the support; and (5) a solid particle removing means for removing solid particles remaining on the support. Is done.

[0009]

FIG. 1 is a conceptual diagram showing one embodiment of the present invention. In the figure, an ejector 1 as a solid particle ejecting means is shown.
From which solid particles P are ejected substantially vertically downward,
It is ejected toward the transfer sheet S running below. The substrate B to be transferred has a flat plate envelope shape, and the substrate transfer device 2 including a drive roller row or the like as a substrate transfer means in a state in which the concave and convex surface which is the transfer surface is directed upward. Conveyed from right to left in the figure. Then, the transfer sheet S including the support and the transfer layer is supplied such that the transfer layer side faces the uneven surface side of the base material B to be transferred below.

The solid particles P ejected from the ejector 1 collide with the support of the transfer sheet S, and a part of the solid particles P having collided with the transfer sheet S falls downward from both ends in the width direction of the transfer sheet S. While falling, the remaining part remains on the transfer sheet S, and is conveyed to the downstream side together with the transferred base material B (and the transfer sheet S closely adhered thereto). In the example shown in FIG. 1, first, the static eliminator 3 as the static eliminator is used.
As a result, the support of the transfer sheet S and the solid particles P remaining on the transfer sheet S are neutralized, and thereafter, the residual solid particles P are removed by the remover 4 which is a solid particle removing means.

In FIG. 1, a static electricity elimination device 3 of a photoionization type is employed as static electricity elimination means. This static eliminator 3
X-rays having a photoquantity of 9.5 KeV are irradiated to the atmosphere around the object to be neutralized, and air molecules (such as nitrogen molecules) are ionized into a pair of a cation and an anion by the photons of the X-rays. Static electricity is removed by neutralizing the electric charge (the dashed arrow in the figure represents X-rays). This photoionization method uses an equal amount of anions and cations, and ions that have not been used to neutralize a charged object disappear by recombination. Charging of the opposite sign) does not occur. Further, since it is not necessary to blow the generated ions to the charged object, there is an advantage that a blowing device does not need to be provided. Further, a higher ion concentration is obtained as compared with the corona discharge method, and the charge removal (charge neutralization) efficiency is high.

As the means for removing static electricity, the following methods may be used instead of the photoionization method.

[0013] Corona discharge method. This applies an AC high voltage to the needle electrode, causing a discharge between the needle electrode and the ground electrode, causing a positive or negative corona on the needle electrode, and generating cations or anions from the corona toward the charged object. It is a method of spraying. A method of irradiating radiation (α rays, β rays, etc.) from a radioactive isotope to the atmosphere near a charged object to ionize it. For example, radioactive isotopes such as ⁹⁰ Sr, ⁹⁰ Y, and ²⁰⁴ Tl are used. A method in which a grounded rod-shaped, comb-shaped, string-shaped, or wire-shaped electrode is brought into contact with a charged object, and the charged charge is discharged to the ground side.

The timing of static electricity removal may be any time after the transfer sheet S is made to follow the transfer-side surface of the base material B to be transferred along the surface shape thereof by applying the collision pressure of the solid particles P and is adhered. . For example, as shown in FIG. 1, the static electricity removing means may be arranged before the solid particle removing means, or both may be reversed. When the static electricity removing means is arranged before the solid particle removing means, the solid particles P remaining on the support of the transfer sheet S after the transfer are not firmly fixed to the support by electrostatic attraction. The residual solid particles are easily and reliably removed by the removing means. Also,
When the static electricity removing means is arranged after the solid particle removing means,
The solid particles P once removed from the support by the solid particle removing means can be prevented from re-adhering to the support. Further, static electricity removing means may be provided before and after the solid particle removing means. In this case, the respective effects described above are exhibited. Alternatively, the static electricity removal and the solid particle removal may be performed at the same time by a method (means) such as removal of the solid particles by wind pressure of ionic wind or removal of the solid particles by a grounded conductive brush. it can.
In this case, there is an effect that the space and line length of the device can be saved.

In FIG. 1, a gas blowing type remover 4 is employed as a solid particle removing means. Therefore, the transfer sheet S
Is provided on the transfer sheet S on the support side. The remover 4 blows out a pressurized gas such as air from a blower or a compressor (not shown) toward the support of the transfer sheet S, and blows out and removes the solid particles P on the transfer sheet S (arrows in the figure indicate arrows). Gas streamlines are shown). The remover 4 is, specifically, a gas spray nozzle such as a slit nozzle having a rectangular opening or a nozzle having a circular opening, from which gas is ejected, or a fan. The shape of the opening is not particularly limited.
By blowing the gas, even when the surface on which the solid particles P remain remains horizontal and does not fall downward by its own weight, the solid particles P can be blown off and removed. When a gas spraying type remover is used as the solid particle removing means and a method using ions in the air such as a photoionization method is used as the static electricity removing means, depending on the situation, the ion flow may be caused by air current from the remover. Can be disturbed or eliminated to reduce the static electricity removing effect.
As a countermeasure in this case, it is effective to partition the static eliminator 3 and the remover 4 with a wall as shown in FIG. However, the wall is provided with an opening through which the transfer sheet S and the base material B can pass.

FIG. 2 is an explanatory view showing an example of the arrangement of the remover 4 when viewed from above the transfer sheet S. FIG. 1 shows a case where a continuous belt-shaped transfer sheet S is conveyed with its support surface horizontal. The illustrated removers 4a-
4c is a nozzle having a shape such as a slit nozzle so that the gas to be blown out has a band shape. Remover 4a
Is arranged in parallel to the width direction of the transfer sheet, blowing is performed inclining from below vertically toward the downstream side, so that the solid particles P do not flow back to the collision portion of the solid particles P on the upstream side,
The solid particles P on the transfer sheet S are raised. That is, in FIG. 1, the removal unit and the collision unit are separated by the separation wall 5, but the solid particles P flow backward from the entrance for transport of the transfer sheet S and the transfer-receiving substrate B to the upstream side, and the solid particles P The collision of P with the transfer sheet S is not disturbed. A plurality (three or more) of the removers 4b and 4c are alternately slanted, and the region where the gas from the remover 4b and the gas from the remover 4c hit the transfer sheet S overlaps in the width direction at the center in the width direction. And are respectively arranged on the left and right in the transport direction.
Further, the blowout directions of the removers 4b and 4c are inclined from the vertically lower side toward the width direction end direction and toward the upstream side direction. Then, the solid particles P are blown off from the center in the width direction of the transfer sheet S toward the end by the removers 4b and 4c, and the solid particles P that have not yet moved to the end are transferred.
Is blown again toward the end by the remover on the downstream side, falls downward from the end, and is removed from the transfer sheet S. Note that the arrangement of the removers (the gas blowing direction, the number of removers, the arrangement direction, and the like) is not limited to this. In addition, although illustration is omitted, two slit nozzles are installed on the upstream side and the downstream side, respectively, such that the longitudinal direction of the nozzles faces the width direction, and the wind direction of the upstream slit faces the downstream direction, and the downstream slit An arrangement in which the wind direction is directed to the upstream side is also possible. When the solid particles adhere to the side surface of the transfer-receiving base material B, a remover may be provided on the side surface or the like, and a gas may be blown to the outer surface to remove the gas.

In the above description, a gas blowing means such as a nozzle is used as a remover for removing solid particles remaining on the transfer sheet. However, a brush is also used to remove solid particles remaining on the transfer sheet. Can be used as a remover. The brush lifts or collects the solid particles on the transfer sheet, but it is difficult to move the solid particles over a longer distance than a gas blower remover, and it is necessary to move the brush itself. However, when the brush is used in combination with the gas blower, the solid particles that have bitten into the support, which are difficult to remove by the gas blower, may be lifted, and more effective solid particle removal may be performed.

The brush may be a flat brush with bristles extending linearly, or a rotating brush with bristles extending radially from a rotation axis. The rotating brush can scatter solid particles that have been raised or raked up. Also,
Inside, circular, oval, like brushes for vacuum cleaners
Alternatively, it may be a suction brush having a rectangular suction opening and furry around the entire circumference. This suction brush can also directly collect the solid particles that have been raised or raked by suction.

If it is intended to remove the solid particles remaining on the transfer sheet by using only the brush, the brushes other than the rotating brush and the suction brush will cause the solid particles on the transfer sheet to move by relative movement between the transfer sheet and the brush. Must be scraped toward the end of the transfer sheet and dropped from the end. In such a relative movement, the brush may be fixed as long as the transfer sheet is conveyed and moved. The brush bristles may be made of synthetic resin such as nylon or polypropylene, or may be made of metal such as brass or iron in addition to animal hair such as pigs, and may be appropriately used depending on hardness, thickness and the like.

These brushes may be used singly as long as they can be sufficiently removed by using a single kind of a single kind. If these brushes cannot be sufficiently removed by using a single brush,
A plurality of single types or a plurality of types may be used. If the desired solid particles can be removed with the brush alone, the brush alone can be used as the remover, and the above-described gas spray remover can be omitted. And the width (continuous strip) or area of the transfer sheet is small. Therefore, as illustrated in FIG. 3, the remover using the rotating brush 4 ′ may be used in combination with the remover 4 using gas blowing. By using them together, solid particles that cannot be removed by the gas blower remover 4, such as solid particles that are attached to the transfer sheet as if they were half-bitten, or the inside of a deep recess or the corner between the recess side surface and the recess bottom surface The solid particles remaining so as to penetrate can be lifted off the transfer sheet by the direct mechanical action of the rotating brush 4 ′. Then, the solid particles after being lifted may be blown off by the remover 4.

Incidentally, an example of the arrangement of the brushes will be described. In FIG. 2, there is an arrangement in which the removers 4b and 4c are replaced with rotary brushes or flat brushes. Rotation direction is solid particles transfer sheet S
It is the direction to fly to the end side. In the case of a brush as well as in the case of the gas spray type remover, solid particles collect at the end of the sheet and fall from the sheet to be removed. In addition, brushes and gas spray type removers may be arranged alternately in the flow direction. In addition,
No brush is installed at the position 4a in FIG. A gas spraying type remover can be installed as it is.
In addition, even when the solid particle removing means is mainly composed of a brush, it is preferable to install a removing chamber described later in order to prevent scattering of the solid particles.

The collision space in which the solid particles collide with the transfer sheet is filled with the solid particles, and the solid particles that collide with the transfer sheet or the like rebound. This not only deteriorates the working environment, but also makes it difficult to recover and reuse the used solid particles.
The same applies to the removal space for blowing off solid particles remaining on the transfer sheet with gas. For this reason, it is practically preferable to isolate these collision space and removal space from the surroundings. Therefore, the isolation method is described in some detail in the following.

In the example shown in FIG. 1, the space in which the solid particles P are ejected from the ejector 1 and collides with the transfer sheet S is defined as a collision space in the chamber 6 in order to prevent the solid particles P from scattering around. And isolated. In this case, the transfer base material B and the transfer sheet S are isolated except for the entrance and exit. The chamber 6 is on the support side of the transfer sheet S (above the drawing).
Space as a minimum collision space. Further, the space on the transfer layer side of the transfer sheet S, that is, on the side of the substrate to be transferred (downward in the drawing) is also separated from the surroundings by the chamber 7 as a collision space. The chamber 6 and the chamber 7 are connected and integrated by continuous walls on the front side and the rear side in the drawing, and the spaces are connected to each other at both ends in the width direction of the transfer sheet S on the side where the continuous band-shaped transfer sheet S is located. . Then, the collision chamber 8 is formed by the chamber 6 and the chamber 7. After all,
In the embodiment of FIG. 1, the space on both the support side and the transfer layer side of the transfer sheet S is used as a collision space, and is separated from the surroundings by a collision chamber 8 including a chamber 6 and a chamber 7. Further, the chamber 7 shown in FIG. 1 also simultaneously isolates a part of a removal space for removing solid particles described later. The transfer sheet S and the transfer base material B to be transferred are accommodated in a collision space separated from the surroundings by a collision chamber 8 composed of a chamber 6 and a chamber 7, and in FIG. Is done. As a result, the collision chamber 8
The solid particles P colliding with the transfer sheet S and the solid particles P colliding with the transfer sheet S are prevented from scattering into a space such as a surrounding working environment. The solid particles P collected below the chamber 7 on the side of the substrate B to be transferred can be collected and reused.

In FIG. 2, the space for removing the solid particles P remaining on the transfer sheet S by the remover 4 is such that the solid particles P moving on the transfer sheet S are scattered around by being blown off. In order to prevent this, the space on the support side of the transfer sheet S is isolated from the surroundings as a removal space. That is, the separating means for preventing the solid particles P from scattering to the surroundings, and the separating means for separating the jetting space from the surroundings are separated from each other at least in the space on the support side of the transfer sheet S. In the second chamber 6 'as a second isolating means, which is an isolating means for forming the transfer material, the isolation is provided except for the entrance and exit of the transfer-receiving substrate B and the transfer sheet S used for removing solid particles. Further, in an extension of the chamber 7,
The space on the side of the substrate to be transferred (below the drawing) is also isolated from the surroundings as a removal space. Similarly to the relationship between the chambers 6 and 7, the second chamber 6 'and the chamber 7 are connected and integrated by continuous walls on the near side and the far side in the drawing. Are connected to each other at both ends in the width direction of the transfer sheet S. And the second
The removal chamber 9 is formed by the chamber 6 ′ and the chamber 7. After all, in the embodiment of FIG. 1, similarly to the collision chamber 8, the space on both the support side and the transfer layer side of the transfer sheet S is set as the removal space, and the surroundings are removed by the removal chamber 9 including the second chamber 6 ′ and the chamber 7. Isolated. That is, the chamber 7 on the transfer substrate side is a part of the collision chamber 8 and also a part of the removal chamber 9. In other words, the upstream portion of the chamber 7 is a collision chamber, and the downstream portion is a removal chamber. In other words, the lower space on the side of the substrate to be transferred is the chamber 6.
The second chamber 6 ′ is separated into a collision space and a removal space by a lower extension surface of the isolation wall 5 that isolates the second chamber 6 ′ from the second chamber 6 ′. Then, the removal chamber 9 including the second chamber 6 'and the chamber 7
In the removal space isolated from the surroundings, the solid particles P
A transfer sheet S and a transfer-receiving substrate B to be removed are accommodated, and in the same figure, a static eliminator 3 and a remover 4 are accommodated. As a result, the transfer sheet S is removed by the removal chamber 9.
When the solid particles P remaining thereon are blown off and removed, the solid particles P are prevented from scattering into a space such as a surrounding working environment. The solid particles P collected below the chamber 7 on the side of the substrate to be transferred can be collected and reused.

When separating the collision space and the removal space from the surroundings,
As illustrated in FIG. 1, the chamber 7 on the substrate to be transferred is also used as the collision chamber 8 and the removal chamber 9, and the collision space and the removal space are each integrated with the space on the substrate to be transferred. This makes it easier to collect and reuse the solid particles collected below the chamber 7. As will be described later (see FIG. 14), when a drain tube is used for collecting solid particles, it is only necessary to connect the drain tube below one chamber 7, and the structure of the apparatus can be simplified.

In FIG. 1, the transfer sheet support-side chamber 6 and the second chamber 6 'have a structure in which they are connected by the same separation wall 5, but each chamber separates its internal space from the surroundings. Chamber 6 and second
The chamber 6 'may be separated.

FIG. 4 shows another example of a method of isolating the collision space and the removal space from the surroundings. In the example shown in FIG. 4, the chamber on the side of the substrate to be transferred is a collision chamber and a removal chamber, each of which is separated into a chamber 7a and a chamber 7b. With such a configuration, it is easy to independently control the internal pressures of the collision chamber 8a including the chamber 6 and the chamber 7a and the removal chamber 9a including the second chamber 6 ′ and the chamber 7b.
The control of the internal air pressure is, as will be described later, in order to prevent the solid particles P flying in the chamber from leaking from the entrance of the transfer sheet S and the base material B to be transferred, in order to prevent the inside from being negative pressure than the outside. That is. In the removal chamber, gas blown out from the remover flows in, and it is necessary to exhaust more than this amount of gas. On the other hand, if an impeller is used as the solid particle ejection means in the collision chamber, the gas inflow amount is small. Therefore, if the exhaust of the collision chamber is made independent of the removal chamber, the negative pressure control can be ideally performed.

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

[Substrate to be Transferred] The substrate to be used in the present invention may have a flat surface to be transferred. Of course, the present invention shows its true value only when the surface to be transferred has an uneven surface. In particular, the substrate to be transferred has three-dimensional irregularities. A conventional pressing jig (see JP-B-61-5895 described above) and a transfer roller made of rubber (see JP-A-5-139097 described above) essentially have the directionality of the rotating shaft. , The applicable surface irregularities are limited. That is, the former is limited to two-dimensional irregularities having a curvature only in one axial direction, and the latter is capable of transferring to three-dimensional irregularities having a curvature in two axial directions, but the three-dimensional shape can be changed in any direction. Cannot be applied homogeneously. For example, unless the longitudinal direction of the wood grain conduit pattern is parallel to the feed direction of the transfer sheet, it cannot be successfully transferred to the concave portion of the conduit. Moreover, in the latter case, the shape of the base material is practically limited to a flat plate shape, and otherwise, it is impossible unless a transfer roller having a special shape tailored to each base material shape is used.

However, in the present invention, as will be described later, since the collision pressure of a group of solid particles that behave fluidly is used, the planar direction of the pressure application region is essentially required for the three-dimensional shape of the surface irregularities. Do not have. (This directionality is the direction of the temporal position change of a point on the transfer-receiving substrate to which pressure is applied.) Therefore, a shape having irregularities in the transfer direction of the transfer sheet or the transfer-receiving substrate is considered. The substrate to be transferred may be used. In other words, it means that the present invention can be applied to two-dimensional unevenness having unevenness only in one direction such as only the feed direction or width direction, and three-dimensional unevenness having unevenness in two directions such as both the feed direction and the width direction. In addition, the point that the collision pressure of the solid particle group does not have directionality is that the ejector that ejects the solid particles is placed so that the single sheet transfer sheet is placed on the substrate to be transferred and pressed and adhered one by one. This can be easily understood by considering how the area to which the collision pressure is applied moves by moving or transferring the transfer sheet and the base material to be transferred while fixing the ejector.

The substrate to be transferred is not limited to a flat plate material (having an envelope shape) as a whole, but may be a substrate having two-dimensional irregularities that are convex or concave in an arc shape and are curved in the feeding direction or width direction. Alternatively, the curved surface may have finer three-dimensional surface irregularities. In the present invention, whether to transfer the two-dimensional unevenness having a circular cross section or the like of the base material to be transferred, for example, in the width direction or in the feed direction is arbitrary in consideration of workability and the like. Can be.

It is also possible to use a substrate to be transferred having an irregular surface having fine irregularities superimposed on large irregularities, or a substrate having a surface to be transferred to the bottom of the concave portion or the inner surface of the concave portion of the irregular surface. . The large irregularities and the fine irregularities are, for example, as shown in FIG.
1, 402 and fine irregularities 403 on the convex portions 402
The large uneven shape has a step of 1 to 10 m.
m, the width of the concave portion is 1 to 10 mm, and the width of the convex portion is 5 mm or more. The fine uneven shape is smaller than the large uneven shape in both the step and the width. Is about 0.1 to 5 mm, the width of the concave portion and the width of the convex portion are 0.1 mm or more, and is ２ of the width of the convex portion having a large irregular shape.
Less than about.

Specific examples of the uneven pattern of the decorative material, which is composed of a combination of large and small irregularities and fine irregularities and has three-dimensional surface irregularities, include joints and grooves as large irregularities. It has a two-dimensional array pattern of tiles, bricks, stones, etc., and has fine irregularities on the spray painted surface such as stucco, lysine etc., unevenness of stone surface such as granite cleavage surface and travertine marble board Etc., such as stone-grained uneven pattern, or large-sized uneven pattern, such as siding pattern, groove, stirrup, sane, etc., siding pattern, floating wood grain pattern, and uneven pattern with conduit grooves, hairline, etc. as fine unevenness on it Is mentioned.

Each of the surfaces constituting the uneven surface may be any plane only, only a curved surface, or a combination of a plane and a curved surface. Therefore, the curved surface on the transfer-receiving substrate of the present invention also means an uneven surface having no curved surface composed of only a plurality of flat surfaces, such as a tooth profile of a clog. Further, the curvature referred to in the present invention is:
The case of an infinite curvature (curvature radius = 0) that is angular like a periphery of a side or a vertex of a cube is also included. In addition, in order to make the surface of the transfer-receiving substrate have desired irregularities, press working, embossing, extrusion, cutting, molding, or the like may be used.

The material of the substrate to be transferred is arbitrary.
If it is a board material, a non-porcelain ceramic board such as a calcium silicate board, an extruded cement board, an ALC (lightweight foamed concrete) board, a GRC (glass fiber reinforced concrete) board, a wood veneer, a wood plywood, a particle board, or a wooden board Wood plates such as medium density fiberboard (MDF), metal plates such as iron, aluminum and copper, ceramics such as ceramics and glass,
A resin molded product such as polypropylene, ABS resin, and phenol resin may be used. When a liquid is used as the solid particle accelerating fluid and solid particles are ejected together with the liquid as described later, those which are insoluble and non-absorbable in the liquid are preferable. For example, a metal plate, a resin molded product, ceramics such as ceramics and glass, and the like are used.

Further, an easy-adhesion primer for assisting the adhesion with the adhesive or a sealer for sealing and sealing fine irregularities and porosity of the surface is applied to the surface of the substrate to be transferred in advance. You may keep it. A resin such as an isocyanate, a two-part curable urethane resin, an epoxy resin, an acrylic resin, or a vinyl acetate resin is applied as an easy-adhesion primer or a sealer.

[Transfer Sheet] The transfer sheet is composed of a support and a transfer layer which transfers and transfers. The transfer layer comprises at least a decorative layer. Further, the adhesive may be formed on the transfer sheet as an adhesive layer that becomes a part of the transfer layer.
When a liquid is used as the solid particle accelerating fluid and solid particles are ejected together with the liquid, a support or a transfer layer that is insoluble in the liquid is used. For example, when the liquid is water, it may be appropriately selected and used from the materials used as general transfer sheets, except for the water-soluble resin.

(Support) As a support for the transfer sheet,
If the substrate to be transferred is a two-dimensional uneven surface, paper having no stretchability (however, if the solid particle accelerating fluid is a liquid, select one that is insoluble in the liquid). In order to apply the present invention to a three-dimensional uneven surface that exhibits its true value, a stretchable support is used at least at the time of transfer. Due to the extensibility, the transfer sheet can adhere to and transfer to the inside of the concave portion on the surface of the substrate to be transferred when the collision pressure of the solid particles is applied. The stretchability of the entire transfer sheet is mainly governed by the stretchability of the support. Therefore, the support has
In addition to a conventionally known thermoplastic resin film, a rubber film that can be stretched even at room temperature can be used. In the case of a thermoplastic resin film, there is almost no stretchability when forming a transfer layer such as a decorative layer, and during transfer, sufficient stretchability is exhibited by heating, and after cooling, the deformed shape is maintained, and the shape is restored by elasticity. A transfer sheet that can be used in the present invention can be easily prepared as a transfer sheet that does not cause the problem, similarly to a conventionally known ordinary transfer sheet.

As a specific example of the support, a biaxially stretched polyethylene terephthalate film, which has been widely used in the past, can exhibit necessary and sufficient stretchability by setting heating conditions, collision pressure conditions, and the like, depending on the surface unevenness. It is possible to perform a curved surface transfer, but it is possible to develop a stretch at low temperature and low pressure, for example, a copolymer polyester film such as polybutylene terephthalate or terephthalate isophthalate copolymer, a polypropylene film, a polyethylene film. Also, low-stretch or non-stretch films such as polyolefin films such as polymethylpentene films, polyvinyl chloride resin films and nylon films, and rubber (elastomer) films such as natural rubber, synthetic rubber, urethane elastomer and olefin elastomer are preferable. Di body. The thickness of the support is usually 20 to 100 μm.

When a liquid is used as the fluid for accelerating the solid particles, it is also possible to use a resin film which swells but is insoluble in the liquid in contact with the liquid during transfer. An example of such a swellable and insoluble resin film is disclosed in Japanese Patent Application Laid-Open No.
JP-A-150208, JP-B-61-3276, etc., are polyvinyl alcohol-based films having an average degree of polymerization of 300 to 3000 and a degree of saponification of 65 to 9
A film having a thickness of 7 mol% and a thickness of 20 to 100 μm is typical.

The support may be provided, if necessary, with a release layer on the transfer layer side 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.

If an uneven pattern is provided on the surface of the support that is in contact with the transfer layer, the uneven pattern can be formed on the surface of the transfer layer after transfer. The uneven pattern is, for example,
There are hairline, line-shaped groove, uneven pattern of cleavage face of granite, wood grain conduit groove, wood grain ring pattern, cloth texture surface texture, skin squeezing, characters, geometric pattern and so on. The formation of the concavo-convex pattern is performed by embossing, sandblasting, or hairline processing the resin sheet of the support by hot pressing, or forming the ink (2) using a resin having a releasing property as a binder on the support. Liquid-cured urethane, silicone resin, melamine resin, polyfunctional acrylate or methacrylate monomer or prepolymer that crosslinks with ultraviolet light or electron beam, etc. There is a method in which a layer is provided to provide a support having a shaping layer. The shaping layer has the function of the release layer.

(Transfer Layer) The transfer layer of the transfer sheet is composed of at least a decorative layer, and a release layer, an adhesive layer and the like may be a component of the transfer layer as appropriate. In the configuration having the adhesive layer, it is possible to omit applying the adhesive to one or both of the transfer sheet and the substrate to be transferred at the time of transfer.

The decorative layer is formed by a known layer such as gravure printing, silk screen printing, or offset printing, and a pattern layer obtained by printing a pattern or the like with a material, or a metal such as aluminum, chromium, gold, or silver by a known vapor deposition method. A metal thin film layer or the like formed on the target or on the entire surface, which is used according to the application. As the pattern, according to the surface irregularities of the substrate to be transferred,
A wood pattern, a stone pattern, a cloth pattern, a tile pattern, a brick pattern, a leather pattern, a character, a geometric pattern, a solid pattern, and the like are used. 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. A single material such as an acrylic resin, a vinyl chloride-vinyl acetate copolymer, a polyester resin, a cellulosic resin, a polyurethane resin, a fluororesin, or the like, or a mixture containing these is used for the binder. 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 release layer is provided between the support or the release layer and the decorative layer to adjust the releasability between the decorative layer and the surface of the decorative layer after transfer. This is the same as a conventionally known transfer sheet. The release layer is transferred to the transfer-receiving substrate together with the decorative layer during transfer, and covers the surface of the decorative layer.

As a means for easily removing air remaining between the transfer sheet and the substrate to be transferred at the time of transfer, a large number of small holes are formed in the transfer sheet as necessary to penetrate all layers of the transfer sheet. You may.

[Adhesive] The adhesive is used as an adhesive layer constituting a transfer layer of a transfer sheet or an adhesive layer on a substrate to be transferred.
Apply by online coating or offline coating before or immediately before transfer. When applied to a substrate to be transferred, the adhesive layer of the transfer sheet transfer layer can be omitted. The adhesive to be used may be appropriately selected depending on the application, required physical properties, and the like. When a liquid is used as the solid particle accelerating fluid, an adhesive that is insoluble in the liquid is selected.

As the adhesive, for example, a heat-sensitive adhesive,
Moisture-curable heat-sensitive adhesives, hot-melt adhesives, moisture-curable hot-melt adhesives, two-component curable adhesives, ionizing radiation-curable adhesives, water-based adhesives, or pressure-sensitive adhesives with adhesives Various adhesives can be used. When water is used for the solid particle accelerating fluid, a moisture-curable adhesive or an aqueous adhesive should be avoided.

As the heat-sensitive adhesive, any of a heat-sealing adhesive using a thermoplastic resin and a thermosetting adhesive using a thermosetting resin can be used. However, from the point that bonding is completed in a short time, a heat-fusion type (heat-sensitive adhesive)
Is preferred. The adhesive may be diluted with a solvent or without a solvent, or may be a liquid or a solid at room temperature, and may be used as appropriate. In the case of an adhesive other than a pressure-sensitive adhesive exhibiting tackiness, a transfer layer can be formed with only a single adhesive layer. If a coloring agent such as a pigment is added to the adhesive layer, it can be said that the entire layer is a decorative layer composed of a solid ink layer. Examples of the heat-sensitive adhesive include polyvinyl acetate resin, vinyl chloride-vinyl acetate copolymer, acrylic resin, thermoplastic polyester resin, thermoplastic urethane resin, polyamide resin obtained by condensation polymerization of dimer acid and ethylenediamine, and the like. A conventionally known adhesive can be used. As the thermosetting adhesive, a phenol resin, a urea resin, a diallyl phthalate resin, a thermosetting urethane resin, an epoxy resin, or the like can be used.

The moisture-curable heat-sensitive adhesive is also a kind of heat-sensitive adhesive. The moisture-curable heat-sensitive adhesive is
Since the curing reaction proceeds with the moisture in the air when left naturally, it is applied immediately before transfer from the viewpoint of work stability. Immediately after transfer, the moisture-curing heat-sensitive adhesive has the same adhesive strength as a normal heat-melting adhesive, but the cross-linking / curing reaction gradually proceeds with the moisture in the air when allowed to stand naturally. It is excellent in heat resistance without creep deformation and heat melting, and a large adhesive strength can be 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 a relative humidity of 50% RH or more and a temperature of 10%.
° C or higher. When the temperature and the relative humidity are both higher, the curing is completed in a shorter time. The standard curing completion time is usually about 10 hours in an atmosphere of 20 ° C. and 60% RH.

The moisture-curable heat-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 one or more isocyanate groups at both molecular terminals, and is a solid thermoplastic resin at room temperature. Isocyanate groups react with each other due to moisture in the air to cause a chain extension reaction, and as a result, a reactant having a urea bond in a molecular chain is generated,
The urea bond further reacts with the isocyanate group at the molecular terminal to cause a biuret bond and branch to cause a crosslinking reaction.

The skeleton structure of the molecular chain of the prepolymer having an isocyanate group at the molecular terminal is arbitrary, and 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. When a urethane bond is present in the molecular chain, the terminal isocyanate group also reacts with the urethane bond to generate an allophanate bond, which also causes a cross-linking reaction.

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

As the moisture-curable heat-sensitive adhesive, in addition to the above-mentioned various polyisocyanate prepolymers,
In order to adjust various physical properties, various auxiliary materials such as a thermoplastic resin, a tackifier, a plasticizer, and a filler can be 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,
A thermoplastic resin such as ethylene-ethyl acrylate (EAA), a tackifier such as terpene-phenol resin, rosin abietate, a filler (enrichment pigment) composed of fine powders such as calcium carbonate, barium sulfate, silica, and alumina; It is a coloring pigment, a curing catalyst, a moisture removing agent, a storage stabilizer, an antioxidant and the like.

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

The above-mentioned prepolymer or monomer specifically has a radical polymerizable unsaturated group such as a (meth) acryloyl group or a (meth) acryloyloxy group, or a cationic polymerizable functional group such as an epoxy group in the molecule. Consisting of a compound having Further, a polyene / thiol prepolymer based on a combination of a polyene and a polythiol is also preferably used. In addition, for example, a (meth) acryloyl group 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, triazine (meth) acrylate and the like can be used. A molecular weight of about 250 to 100,000 is usually used.

Examples of the monomer having a radical polymerizable unsaturated group include monofunctional monomers such as methyl (meth)
There are acrylate, 2-ethylhexyl (meth) acrylate, phenoxyethyl (meth) acrylate and the like.
Also, as polyfunctional monomers, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, trimethylpropane tri (meth)
There are also acrylate, trimethylolpropane ethylene oxide tri (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate and the like.

Examples of the prepolymer having a cationically polymerizable functional group include prepolymers of epoxy resins such as bisphenol epoxy resins and novolak epoxy compounds, and vinyl ether resins such as fatty acid vinyl ethers and aromatic vinyl ethers. .

Examples of thiols 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.

As the ionizing radiation, electromagnetic waves or charged particles having energy capable of crosslinking the molecules in the adhesive are used. Usually, ultraviolet rays or electron beams are used, but visible rays, X-rays, ion beams, or the like can also be used. As the ultraviolet light source, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light, and a metal halide lamp is used. As a wavelength of the ultraviolet light, a wavelength range of 190 to 380 nm is usually mainly used. As the electron beam source, various electron beam accelerators such as Cockcroft-Walton type, Van degraft type, resonance transformer type, insulating core transformer type, or linear type, dynamitron type, high frequency type, etc.
One that irradiates electrons with energy of 1000 keV, preferably 100 to 300 keV is used.

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

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

Further, various additives may be added to the various resins used for the adhesive, if necessary. These additives include, for example, extenders (fillers) composed of fine powders such as calcium carbonate, barium sulfate, silica, and alumina; In this case, the adhesive may be added to prevent the adhesive from flowing into the concave portion from the convex portion.).

To apply the adhesive to a sheet such as a transfer sheet or a substrate to be transferred, a solvent (or dispersion medium) such as water or an organic solvent is used.
In the form of a solution (or dispersion) dissolved (or dispersed) in
Alternatively, a hot-melt thermoplastic composition or a room-temperature liquid uncured resin is applied in the form of a solvent-free resin liquid. As a coating method,
What is necessary is just to apply by the solution coating by gravure roll coat etc. which is a conventionally well-known coating method, or the melt coating (melt coating) method by an applicator etc. When used without adding a diluting solvent, solvent drying is unnecessary. For example, heat-sensitive adhesives can be used as solventless hot-melt adhesives, respectively. In addition, an ionizing radiation-curable adhesive or the like can be applied without a solvent. When used as a hot-melt adhesive, there is no solvent, so solvent drying is unnecessary even immediately before transfer, and high-speed production is possible. The amount of the adhesive applied varies depending on the composition of the adhesive, the type of the substrate to be transferred, and the surface state.
Usually, it is about 10 to ²⁰⁰ g / m ² (solid content).

In the case where the adhesive is used as a hot-melt adhesive, and when the transfer sheet is further modified to follow the irregular shape of the substrate to be transferred and transferred, the support of the transfer sheet is necessarily made of polypropylene. It is necessary to select a material that exhibits thermoplasticity or rubber elasticity at room temperature or in a heated state, such as a thermoplastic resin sheet such as a system resin. However, from a different viewpoint, it is necessary to select a support having low heat resistance. Means that you don't get Therefore, when the adhesive is melt-coated to form a transfer sheet, when the adhesive layer is thickly applied, the support is softened by heat during the melt coating, and the adhesive is heated in an adhesive coating apparatus. The sheet may stick to the applicator roller and may be stretched, distorted, or entangled by dragging.

Therefore, in such a case, the adhesive is not directly melt-coated on the sheet, but the release sheet (separator) is used.
The transfer sheet may be formed by applying an adhesive via the transfer sheet. That is, after heat-melt coating the adhesive on the release sheet with heat resistance and release properties, the release sheet with the applied adhesive,
The sheet to be the transfer sheet was thermally laminated once with a nip roller or the like, and then only the release sheet was peeled off from the sheet with a peeling roller or the like, thereby reducing the heat damage to the sheet and forming the adhesive layer. It can be a transfer sheet. The release sheet does not need to be stretchable. A heat-resistant resin sheet such as a biaxially stretched polyethylene terephthalate sheet, polyethylene naphthalate, polyarylate, or polyimide, or paper is used as a base material. A conventionally known release sheet that has been release-treated by coating with methylpentene or the like can be used. The thickness of the release sheet is usually about 50 to 200 μm.

It should be noted that a heat-melting adhesive was used as the adhesive,
The timing of heating to activate and heat-bond the adhesive may be before applying the collision pressure, during the application of the collision pressure, or before and during the application of the collision pressure. The heating of the adhesive is performed by heating the transfer sheet or the substrate to be transferred. The material to which the adhesive has been applied (the transfer sheet or the substrate to be transferred) may be heated, the material to which the adhesive is not applied may be heated, or both materials may be heated. Good. Also,
For the heating during the application of the collision pressure, heated solid particles or a fluid for accelerating the solid particles may be used as the heating fluid.

On the other hand, if the transfer sheet follows the surface shape of the substrate to be transferred and is formed, and the adhesive is sufficiently activated, the cooling of the adhesive may be promoted by cooling means such as cold air. Cold air is blown from the transfer sheet side or the transfer-receiving substrate side. In addition, cooling solid particles and cooling fluid can also be used as cooling means. The promotion of cooling also prevents the transfer sheet formed following the inside of the concave portion of the concave-convex surface of the transfer-receiving substrate from returning to the case where there is a restoring force after releasing the collision pressure.

[Solid Particles] Solid particles include non-metallic inorganic particles such as glass beads, ceramic beads, calcium carbonate beads, alumina beads, zirconia beads, corundum beads, and alundum beads.
Iron, carbon steel, iron alloys such as stainless steel, aluminum,
Aluminum alloys such as duralumin, titanium, metal particles such as metal beads such as zinc, or fluororesin beads,
Organic particles such as resin beads such as nylon beads, silicone resin beads, urethane resin beads, urea resin beads, phenol resin beads, and crosslinked rubber beads can be used. When water is used as the solid particle acceleration fluid,
As the solid particles, non-metals such as stainless beads, glass beads, ceramic beads, and resin beads that do not cause rust or corrosion by water are preferable. The shape is preferably a spherical shape, but other shapes such as a spheroid, a scale and the like may be used. The particle size of the solid particles is usually 10 to 1000 μm
It is about.

The solid particles can also serve as heating means and cooling means. When heated solid particles are used, the activation of the adhesive by heating and the promotion of the 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 substrate to be transferred may be heated to some extent by another heating method before the application of the collision pressure. For the purpose of promoting cooling after bonding, solid particles having a temperature lower than the temperature of the adhesive at the time of bonding can be used as the cooling solid particles. 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 colliding heated solid particles with cooled solid particles.
In addition, the transfer sheet, the base material to be transferred, the adhesive, etc., which need to be heated by another heating method, are sufficiently heated, and the cooling solid particles are used for the formation, adhesion and cooling of the transfer sheet. It can be done at the same time.

In order to heat or cool the solid particles, when storing the solid particles in a tank such as a hopper,
Electric heater, heating steam,
What is necessary is just to perform by a heating means and a cooling means with a refrigerant | coolant etc. Also,
These means may be provided on the outer wall of the solid particle transport tube, and heating or cooling may be performed in the transport tube. Alternatively, when a fluid is used for accelerating the solid particles, the solid particles can be cooled or heated by heat conduction from the fluid using a cooled or heated fluid. In this case, by causing the fluid to collide with the transfer sheet, the fluid can be used as a heating or cooling unit together with the solid. Alternatively, when the fluid is a liquid and a tank for storing solid particles together with the liquid is used, the solid particles and the liquid may be cooled and heated during storage.

[Application of Impact Pressure by Solid Particles] In order to strike the solid particles against the transfer sheet and apply the impact pressure to press the transfer sheet against the substrate to be transferred, the solid particles are ejected from the solid particle ejection means for ejecting the solid particles. The particles are ejected toward the transfer sheet to apply a collision pressure to the transfer sheet. As the solid particle ejecting means, for example, an ejector using a rotating impeller (see FIGS. 5 to 9) or an ejector using an ejection nozzle (see FIG. 10) is used as a particle accelerator. The ejector using the impeller accelerates and ejects solid particles by rotation of the impeller. An ejector using a blowing nozzle accelerates solid particles with a high-speed fluid flow using solid particle accelerating fluid,
It is transported and ejected together with the 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. A centrifugal blast device accelerates and ejects solid particles by the rotational force of an 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.

As the means for ejecting solid particles, a method of accelerating solid particles by using free fall due to gravity, a method of accelerating magnetic particles by a magnetic field, etc. may be employed other than the blowing nozzle and the impeller. Is also possible. In the case of an impeller, a solid particle ejecting unit using gravity and a magnetic field, the solid particles can be ejected toward the transfer sheet in a vacuum.

[Impeller] FIGS. 5 to 8 are explanatory views showing an example of an impeller which can be used as a particle accelerator of the ejector. This impeller corresponds to a centrifugal blast device used in the blasting field.

In the drawing, the impeller 812 includes a plurality of blades 8.
13 is fixed on both sides by two side plates 814, and the center of rotation is a hollow portion 815 without blades 813. Further, a direction controller 816 is provided inside the hollow portion 815. The direction controller 816 has a hollow cylindrical shape having an opening 817 that is partially open in the circumferential direction.
The rotation axis is the same as the rotation axis 12 and is rotatable independently of the impeller. The direction controller 816 fixes the opening 817 in a predetermined direction when used. Further, a hollow impeller 8 is provided inside the direction controller 816.
Another impeller having the same rotation axis as the twelve rotation axes is included as a sprayer 818 (see FIG. 7). Sprayer 818
Rotates with the outer impeller 812. A rotating shaft 819 is fixed to the center of rotation of the side plate 814. The rotating shaft 819 is rotatably supported by a bearing 820, and is driven and rotated by a rotating power source (not shown) such as an electric motor. The impeller 812 rotates. The rotation shaft 819 is
It 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
Is supplied from a hopper or the like through a transport pipe. Usually, the solid particles P are supplied from above (directly above or obliquely above) the impeller 812. The solid particles P supplied into the sprayer 818 scatter outside by the impeller of the sprayer 818. The scattered solid particles P are emitted only in the direction permitted by the opening 817 of the direction controller 816, and the blades 8 of the outer impeller 812 are discharged.
13 and the blade 813. And feather 8
13, is accelerated by the rotational force of the impeller 812, and is ejected from the impeller 812.

The ejection direction of the solid particles is shown in FIGS.
, But may be horizontal or obliquely downward (not shown). 8 (A) and 8 (B)
8A and 8B are conceptual diagrams of ejection direction control for adjusting the ejection direction of the solid particles P based on the setting of the direction of the opening 817 of the direction controller 816. Fixed in position). Note that the direction controller 816 can also adjust the ejection amount of the solid particles P by adjusting the size of the opening 817 in the circumferential direction and the width direction.

In FIG. 5, the rotating shaft 819 is configured so as to be only outside the side plate 814 and not penetrate to the hollow portion 815. Penetrating to the hollow part 815,
It is also possible to adopt a configuration in which the inside of the hollow cylindrical rotary shaft having an opening for passing through solid particles on the outer periphery is formed as a hollow portion (not shown).

The shape of the blade of the impeller is typically a rectangular flat plate (a rectangular parallelepiped) as shown in FIGS. 5 to 8, but other than this, a curved curved plate, a propeller shape such as a screw propeller, or the like may be used. It is also possible to select according to the application and purpose. The number of blades is usually selected from the range of 2 to 10 blades. Then, by the combination of the shape of the impeller, the number of blades, the rotation speed, the mass and supply speed of the solid particles and the supply direction, the opening size and the direction of the direction controller, the ejection direction of the accelerated solid particles, Jet velocity, projection density,
Adjust the divergence angle etc.

FIG. 9 is an explanatory view showing another example of the impeller. The impeller 812a of FIG.
3a has a structure in which both sides are fixed by two side plates 814a. The solid particles P are supplied from above (directly above or obliquely above) the impeller 812a. In addition, the side plate 814a also regulates the ejection direction in the width direction with respect to the rotation shaft 819a. The ejection direction of the solid particles P is horizontal in the figure, but may be vertically downward or obliquely downward. Then, depending on the combination of the shape of the impeller, the number of blades, the rotation speed, the mass of the solid particles, and the supply speed and the supply direction, the ejection direction of the accelerated solid particles, the ejection speed, the projection density, the ejection diffusion angle, etc. To adjust.

The impellers (812, 812a)
Etc.), if necessary, by opening only the ejection and extraction portion of the solid particles, and by providing an ejection guide (not shown) covering the periphery of the other impeller, the ejection direction of the solid particles can be aligned, The direction of ejecting solid particles can also be controlled. 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 impeller (812, 812a, etc.)
Usually, the diameter is about 5 to 60 cm, the width of the blade is about 5 to 20 cm, the length of the blade is about the diameter of the impeller, and the rotation speed of the impeller is about 500 to 5000 rpm. The ejection speed of solid particles is about 10 to 50 m / s, and the projection density is 10 to 15
It is about 0 kg / m ² .

The material of the blades of the impeller may be appropriately selected from ceramics, metals such as steel, high chromium cast steel, titanium, and titanium alloy according to the type of solid particles. Solid particles are accelerated by contact with the blades, so if metal beads or inorganic particles are used for the solid particles, the particles are hard, so the blades should be made of high-chromium cast steel or ceramic with good wear resistance. . When resin beads are used as the solid particles, steel may be used because they are softer than metal particles.

[Blowing Nozzle] FIG. 10 is an explanatory view of an example of a blowing device 840 using a blowing nozzle as a solid particle blowing means for blowing solid particles together with a fluid. 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 that blows 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 a pressurized tank (not shown) as appropriate is jetted from the internal nozzle 842 to the nozzle opening 843 of the blowing nozzle 844 through the induction chamber 841, At 841, a negative pressure is created by the action of the fluid flow flowing at a high speed, the solid particles are introduced into the fluid flow by the negative pressure and mixed, and the solid particles are accelerated and conveyed by the fluid flow. And is ejected together with the fluid flow.

Note 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, there are a hollow cylindrical shape, a polygonal column shape, a conical shape, a polygonal pyramid shape, a fish tail shape and the like. The blowing nozzle may have a single opening, or may have an inside partitioned into a honeycomb shape. Fluid pressure is spraying pressure, usually 0.1-100 kg / cm
^{About 2} . The flow velocity of the fluid flow is usually 1 to 20 for the liquid flow.
m / sec, and about 5 to 80 m / sec for air flow.

The material of the ejector such as the induction chamber and the nozzle may be appropriately selected from ceramics, steel, titanium, titanium alloy and the like according to the type of solid particles and 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,
Uses titanium alloy, synthetic resin, and ceramic. However,
If the surface is waterproofed, steel or the like may be used.

Since the solid particles pass along the inner wall of the ejector, when metal beads or inorganic particles are used for the solid particles, the particles are hard. Good. When resin beads are used as the solid particles, stainless steel may be used because they are softer than metal particles.

[Fluid] The fluid is used 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 is a solid particle acceleration fluid that accelerates the solid particles. Either a gas or a liquid can be used as the fluid, but usually a gas that is easy to handle is used. The gas is typically air, but may be carbon dioxide, nitrogen or the like. On the other hand, the liquid is not necessarily limited, but is nonflammable,
Water is one of the preferred materials because of its ease of drying, non-toxicity, low cost, and availability. In addition, nonflammable liquids such as chlorofluorocarbon, glycerin and silicone oil can be used. Liquids (as well as gases) can collide with the solid particles along with the transfer sheet. Naturally, liquid has a higher density than gas, so 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 at a constant velocity collision, the collision pressure is higher than that of gas and a practical collision pressure can be obtained. (Since the density difference from the solid particles is small, it is easy to transport the solid particles.) Therefore, in the case of a liquid, besides the collision pressure of the solid particles, the collision pressure of the liquid can be used as the transfer pressure. A transfer pressure can be applied, and as a result, a large effect can be obtained by molding the transfer sheet by following the surface irregularities of the substrate to be transferred. 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. Also, 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.

[Impacting pressure application mode] Although only one jetting device can be used depending on the area of the impacting pressure application region, if the required area is large, a plurality of jetting devices are used to impinge on the transfer sheet. The region may have a desired shape. For example, a plurality of rows are arranged in a straight line in the width direction orthogonal to the feeding direction of the transfer sheet and the transfer-receiving base material, and a wide and band-shaped collision region is formed in the width direction. Or,
Even if the ejectors 32 are arranged in a zigzag pattern as shown in FIG. 11A or the ejectors 32 are arranged in a line as shown in FIG. May be arranged so as to collide on the upstream side. In the arrangement shown in FIG. 11B, the pressing of the transfer sheet against the transfer base material by the collision pressure starts from the center in the width direction, and is gradually pressed toward both ends in the width direction. With this configuration, it is possible to prevent the transfer sheet from adhering to the transfer-receiving substrate while air is held in the central portion in the width direction. When a plurality of the ejectors 32 are arranged in the width direction as shown in FIGS.
It is preferable that the pressurizing regions of the individual ejectors 32 partially overlap each other and are arranged so that pressurization can be performed without fail over the entire width. FIG. 11B shows an example of such an array,
In the figure, a dotted line portion is a pressing area. In order to lengthen the time for applying the collision pressure, a multistage arrangement in which the ejectors are arranged in two or more rows in the feed direction of the transfer sheet and the substrate to be transferred is preferable.

Further, it is not always necessary to make the collision pressure all uniform in the collision area. For example, FIG. 12 shows that the central portion in the width direction orthogonal to the transfer direction of the transfer sheet has the maximum collision pressure,
It is a graph which shows the example of a setting of the mountain-shaped pressure distribution which a collision pressure falls as it goes to both ends in the width direction. This setting is from high pressure (center in the figure) to low pressure (sides in the figure)
To help the pressing progress in a stepwise manner.
However, in the case of a pressure distribution as shown in FIG. 12, the impact pressure on the transfer-receiving substrate is such that the transfer onto the desired uneven surface can be completely performed, and the transfer sheet is distorted due to excessive pressure, and the transfer-receiving substrate Adjust so that it all falls within the proper pressure range where deformation, breakage, etc. do not occur. In the curved surface transfer method using a rubber transfer roller, if the diameter of the center portion of the transfer roller is increased, the center portion can be strengthened in terms of pressure. Pressure is applied in contact and transfer sheet transfer cannot be made uniform. The collision pressure is adjusted by controlling the speed of the solid particles colliding from the ejector with the transfer sheet, the number of solid particles colliding per unit time, 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,
Adjust the number of revolutions 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 ejector with respect to substrate to be transferred]
In the case of an ejector using an impeller, the ejection direction of solid particles does not spread in principle in a direction parallel to the impeller rotation axis.
It tends to spread in a direction orthogonal to the rotation axis. On the other hand, in the case of the blowing nozzle, the spread of the ejected solid particles is smaller than that in the case of the ejector using the impeller, and even if it spreads, it is usually uniform and isotropic in any direction. The arrangement of the ejectors may be determined in consideration of such characteristics of the ejectors. However, when the size of the desired collision area cannot be obtained with one ejector, a plurality of ejectors may be used.

When a plurality of ejectors are arranged on the surface to be transferred of the substrate to be transferred, each ejector is parallel to the substrate to be transferred, and the ejection direction of each ejector is the same as that of the substrate to be transferred. Basically, the arrangement is in the line direction. Such a parallel arrangement
This is because the solid particles are caused to collide perpendicularly to the envelope surface of the transfer-receiving surface of the transfer-receiving substrate, and the collision pressure can be basically and effectively used to the maximum. Therefore, for example, as shown in FIG. 13, if the envelope surface (the cross-sectional shape perpendicular to the transport direction) of the transfer-receiving surface of the transfer-receiving substrate B is a cylindrical convex curved surface having a circular shape, the plurality of ejectors 32 may be used. And the direction of the ejector is set so that the direction of the ejector is close to the individual collision surface (tangential plane of the convex curved surface) which each ejector 32 mainly serves so that the solid particles collide almost perpendicularly. It is good to arrange in the direction of the normal to the envelope surface. As described above, the ejection device may be arranged so that the ejection direction of the ejection device is adjusted so that the solid particles collide as vertically as possible in accordance with the uneven shape of the target substrate to be transferred. However, the direction of the ejector need not necessarily be perpendicular to the side surface of the transfer sheet support.
Further, a large number of ejectors may be provided, and some ejectors may be stopped depending on the substrate to be transferred.

[One Form of Continuous Transfer Using Chamber] When solid particles are actually used, it is preferable that the solid particles be recycled without being scattered in the surrounding atmosphere. Therefore, next, as one embodiment of the present invention, an embodiment of a curved surface transfer apparatus that performs continuous transfer while preventing scattering of solid particles and circulating reuse by using a chamber will be described with reference to FIG.

The curved surface transfer apparatus shown in FIG. 14 is an apparatus that uses a long transfer sheet S to successively and successively transfer a decorative layer and the like onto a flat transfer substrate B having an uneven surface. The apparatus includes a substrate transporting device 10 including a row of rotating rollers for transporting a substrate to be transferred B, a transfer sheet supply device 20 for supplying a transfer sheet S, and solid particles P in a chamber 33.
Is ejected from an ejector 32 which is a solid particle ejecting means to collide with the support side of the transfer sheet S to sequentially apply an impact pressure,
Impact pressure applying unit 3 for pressing transfer sheet S against transfer-receiving substrate B
0 is provided. The ejector 32 uses, for example, the above-described impeller.

The chamber 33 serves as a collision space except for the entrance of the transfer sheet S and the transfer base material B, and the transfer sheet S and the transfer base material B exposed to the collision pressure, and at least the opening of the jetting device 32. Is covered from the outside to prevent the solid particles P from leaking into the external working atmosphere. For this reason,
The inside of the chamber 33 is preferably set at a lower pressure (negative pressure) than the outside. The chamber 33 is a collision chamber that separates the space above the support side of the transfer sheet S and the space below the transfer substrate side from the surroundings as a collision space. In addition, a small chamber 71 described later is used as a second chamber to isolate a minimum removal space on the transfer sheet support side from the surroundings. Further, the transfer substrate side of the small chamber 71 has an integral structure that is also connected to the transfer substrate side of the chamber 33, and the removal chamber is formed by the small chamber 71 and a part of the lower part of the chamber 33. Is configured. In the small chamber 71, as a solid particle removing means, a solid particle remover 70 comprising a slit-shaped nozzle for blowing air toward the solid particles remaining on the transfer sheet on the transfer sheet support side in the chamber 71. Is provided.
In the small chamber 71, a static eliminator 80 as static elimination means is provided upstream of the solid particle remover 70.

[0099] The substrate transporting device 10 as the substrate transporting means includes:
It is composed of a row of driving rotary rollers for conveyance, an endless conveyor belt, and the like. Note that the substrate transporting unit transports the substrate to be transferred B at least to a position facing the ejector 32, and then further transports the substrate B to a position facing the static eliminator 80 and the remover 70. Then, the peeling roller 60
The substrate B to be transferred is conveyed to this position.

The sheet supply device 20 serving as a sheet supply means
Is composed of a sheet feeding device 21, a sheet supporting device 22, a sheet discharging device 23, and other guide rollers. In addition,
The sheet supply means supplies the transfer sheet S to at least the ejection device 3
2, the apparatus further includes a static eliminator 80, a remover 70, and a peeling roller 60.
Through the sheet discharge device 23.

The collision pressure application unit 30 as the collision pressure application means
Is a hopper 31 for storing and supplying the solid particles P to the ejector 32, the ejector 32, the chamber 33, and the solid particles P after the collision.
A return pipe to the hopper 31, a separation device 35 for separating the solid particles P from the gas, a vacuum pump 36 for sucking and exhausting the carrier gas of the collected solid particles, and the like.

The solid particle remover 70 of FIG. 14 adopting the gas blowing method is a rectangular slit-shaped nozzle having a long opening, and blows out air from a blower that sucks ambient air at room temperature. The blown air blows off solid particles remaining on the transfer sheet. Remover 7
The arrangement of 0 is an arrangement as exemplified in FIG.

The static eliminator 80 as the static eliminator is the above-described static elimination type static eliminator, and is disposed upstream of the solid particle remover 70.

The curved surface transfer apparatus of the present invention includes at least the solid particle ejecting means, the substrate conveying means, the transfer sheet conveying means, the gas spraying method, the solid particle removing means such as a brush, and the static electricity removing means as described above. The apparatus shown in the figure is a sheet heating apparatus 4 for heating the transfer sheet S.
0 on the upstream side of the jetting device 32 in the chamber 33, and the substrate heating device 41 for heating the substrate to be transferred B on the upstream side outside the chamber 33. The base material coating device 50 for performing appropriate operations and the like is located on the upstream side of the substrate heating device 41, the peeling roller 60 is located on the downstream side outside the small chamber 71, and the preliminary adhesion between the transfer sheet S and the base material B to be transferred. The apparatus is also provided with a suction / exhaust device 90 and the like for promoting the operation.

First, in the apparatus shown in FIG. 14, the plate-shaped substrate to be transferred B is transported one by one by the substrate transporting device 10 and the adhesive is applied to the entire surface or only the convex portions by the substrate coating device 50. Apply to the part. If the adhesive contains a solvent, the substrate to be transferred B and the adhesive are heated by the next substrate heating device 41, and the evaporated components are evaporated and dried. Note that a plurality of the base material coating devices 50 and the base material heating devices 41 may be connected to each other, and the undercoating or the sealer coating before the undercoating may be performed simultaneously with the transfer before the adhesive is applied. Then, the substrate to be transferred B
Is heated by the heating device 41, and then conveyed and supplied into the chamber 33 of the collision pressure applying unit 30.

The transfer sheet S is tensioned by a sheet feeding device 20 including a sheet feeding device 21, a sheet supporting device 22, a sheet discharging device 23, etc., and is unwound from a feeding roll set in the sheet feeding device 21. After entering the chamber 33 of the collision applying unit 30 via the guide roller.
When the adhesive is applied to the transfer sheet S at the time of transfer, the transfer sheet S is transferred from the sheet feeding device 21 to the collision pressure applying unit 30.
When the adhesive is applied by an adhesive coating device (not shown) while the solvent is supplied, and the solvent is required to be further dried, it is dried by a drying device (not shown). To the unit 30.

Further, as shown in FIG. 14 (B), when the transfer sheet S enters the chamber 33, both ends in the width direction are sandwiched by the sheet supporting device 22 (not shown in FIG. 14 (A)). Transferred substrate B transported on the layer side surface
Is transferred at a constant speed in parallel with the transferred base material B with a slight gap above the transferred base material B so as to face the transfer base material B, and is subjected to an impact pressure to receive the transferred base material B. Until they are brought into contact with each other, they are conveyed while maintaining the gap between them.

The sheet supporting device 22 is composed of a belt or the like which rotates in accordance with the transfer of the transfer sheet S while sandwiching both ends of the transfer sheet S having a width larger than the width of the base material B to be transferred. Here, since the envelope surface of the transfer-receiving substrate B is substantially in the shape of a flat plate,
The complete contact of the transfer sheet S with the transfer base material B by the impact pressure is made earlier at the center in the width direction and later near both ends in the width direction. This is one of measures for preventing air from remaining between the base material B to be transferred and the transfer sheet S (particularly in the vicinity of the center thereof) and not being closely attached. When transferring the transfer sheet S in the vicinity of the base material B at a constant speed, whether the transfer sheet S is slightly separated from the base material B or transferred as a contact state is determined by the surface of the base material B. The selection is made by appropriately considering the shape of the irregularities, the preheating temperature of the transfer-receiving substrate B, the thermal deformability of the transfer sheet S, the collision pressure of the solid particles P, the activation temperature of the adhesive, and the like.

The transfer sheet S is heated by the sheet heating device 40 such as heater heating, infrared heating, dielectric heating, induction heating, hot air heating, etc., before being nipped and conveyed by the sheet support device 22 and receiving the collision pressure. And softened, and easily stretched when a collision pressure is applied. In the figure, the sheet heating device 40 is provided in the chamber. Therefore, in the case of hot air heating, it is better to reduce the air volume. This is because air enters the chamber 33, hinders maintenance of a negative pressure in the chamber 33 as described later, and agitates the solid particles P. Note that the transfer sheet S is also indirectly heated by the transferred substrate B that is heated by the substrate heating device 41 and supplied to the collision pressure applying unit. The heating by the sheet heating device 40 can be omitted when the preheating of the transfer sheet S is unnecessary.

On the other hand, the solid particles P are supplied from the hopper 31 to the ejector 32 in the chamber 33, where they are accelerated by the impeller as shown in FIGS. I do. Then, the transfer sheet S is exposed to the collision of the solid particles P ejected from the ejector 32. The amount of change in the momentum of the solid particles P per unit time at the time of collision is the collision pressure that presses the transfer sheet S against the transfer substrate B. Here, since the envelope surface of the transfer base material B is substantially flat, the solid particles P are mainly made to collide with the support side of the transfer sheet S substantially vertically, and the transfer base material B and the transfer sheet S are conveyed. The entire width of the collision is defined as a collision area. Then, as the transfer base material B and the transfer sheet S are transported, the entire region in the longitudinal direction is sequentially exposed to the collision pressure. In addition, the sheet supporting device 22 uses the solid particles P to transfer the transfer sheet S
Of the transfer sheet S and the base material B to be transferred from both ends in the width direction are prevented.

Then, the transfer sheet S is pressed against the substrate B to be transferred by the solid particle collision pressure, and the transfer sheet S is also extended and deformed into the concave portion on the uneven surface of the substrate B to be transferred.
The transfer layer is formed following the uneven surface shape of the base material B to be transferred, and the activated adhesive makes the transfer layer adhere to the base material B. The base material B to which the transfer sheet S is in close contact is cooled by cooling or the like before the impact pressure is released and before the transfer sheet S goes out of the small chamber 71 as the next removal chamber via the chamber 33.

On the other hand, a part of the solid particles P that have been subjected to the collision with the transfer sheet S fall to the lower part of the chamber 33 bypassing the side surface of the sheet supporting device 22. Further, after the remaining portion is transported to the downstream side while being placed on the transfer sheet support, it enters the small chamber 71 which is separated from the chamber 33 only in the upper portion of the substrate transfer device 10 by a separate chamber. And there, first, the static eliminator 80 as the static elimination means.
As a result, the support and the remaining solid particles thereon are neutralized (neutralized), and thereafter, air is blown from the slit nozzle-shaped solid particle remover 70 onto the transfer sheet S and the base material B to be transferred. Solid particles P remaining on S
From the end of the transfer sheet to the lower part of the small chamber 71. Further, since air at room temperature is used as the air blown out from the remover 70, the substrate B and the transfer sheet S are simultaneously removed from the transfer sheet S at the same time as the solid particles are removed by the air.
Is cooled to a temperature at which it can be peeled off.

Solid particles P collected at the lower part of the chamber 33
Is sucked from there by the drain pipe 34 and collected in the original hopper 31. Further, the air in the chamber 33 is also sucked together with the solid particles P by the drain pipe 34 for the recovery and transfer of the solid particles P, and transferred to the solid particle P separation device 35 together with the airflow above the hopper 31. In the separation device 35, as shown in the drawing, the solid particles P conveyed by a gas flow are discharged into the device cavity in the horizontal direction, and the solid particles P having a high density with respect to the gas fall downward by their own weight, and the gas remains as it is. The remaining solid particles P which flow horizontally and are going to move with the airflow by the filter are filtered, and then discharged out of the system by the vacuum pump 36. In this way, the solid particles P are transferred from the chamber entrance through which the transfer sheet S and the transfer-receiving substrate B enter and exit.
Avoid spilling with air.

In order to prevent the solid particles P from flowing out of the chambers 33 and 71 and to prevent the solid particles P from flowing back from the chamber 33 to the hopper 31, the pressure inside the chambers 33 and 71 may be set lower than the outside. The pressure regulation of this chamber
The amount of gas discharged from the vacuum pump 36, the amount of gas flowing out of the chamber due to the amount of gas exhausted by connecting an air blower (not shown), and the like to the solid particles P from the ejector 32.
Together with the amount of gas entering the chamber (especially in the case of an ejector such as a blowing nozzle using gas as a solid particle accelerating fluid),
Further, the balance between the amount of gas entering the chamber from the remover 70 that blows out the gas and the amount of gas entering the chamber by connecting a blower (not shown) as appropriate to the chamber (particularly, in the case of an ejector using an impeller), etc. It is done by adjusting.

After the transfer target substrate B and the transfer sheet S that have come into close contact with each other, after leaving the small chamber 71, the support of the transfer sheet S is peeled off from the transfer substrate B by the release roller 60. As a result, a decorative material D in which a decorative layer or the like is transferred and formed as a transfer layer of the transfer sheet S on the uneven surface of the base material B to be transferred.
Is obtained. On the other hand, the support of the transfer sheet S after passing through the peeling roller 60 is wound by the sheet discharge device 23 as a discharge roll.

In the case where the blowout nozzle using liquid as the solid particle accelerating fluid is used as the ejector, a dryer is provided upstream or downstream of the cooling device, or also as the cooling device itself, for example. The liquid is dried or blown off by blowing air at room temperature or hot air. When using an ionizing radiation-curable resin as an adhesive or the like to cure the resin, an ionizing radiation irradiating device such as a mercury lamp (ultraviolet light source) is provided between the ejector and the peeling roller to cure the resin.

[Method of heating adhesive or the like when using chamber]
As described above, as an embodiment of the present invention, an example in which solid particles collide in a chamber has been described. However, a heating method for activating an adhesive or improving transfer sheet stretchability when the chamber is used will be further described.

The transfer sheet may be heated by any means. For example, when the transfer sheet is heated before the collision pressure is applied, heater heating, infrared heating, dielectric heating, induction heating, hot air heating, or the like is used. The apparatus shown in FIG. 14 performs heating before applying the collision pressure in order to perform cooling immediately before the ejector 32 so as not to be cooled after heating.
3 is an example in which a sheet heating device 40 is provided in the apparatus 3. However, in the case where the heating is performed in the chamber 33 and hot air heating is used as the heating means (the same applies to the heating of the substrate to be transferred, which will be described later), it is better to reduce the blowing air volume. This is because air is to be introduced into the chamber 33, and the load on the vacuum pump for collecting solid particles is increased, including the case where air is used for accelerating solid particles.

The sheet heating is performed in the chamber 33 as shown in FIG.
If the elongation does not hinder the sheet conveyance, it may be performed outside the chamber 33 or both inside and outside the chamber 33. The heating may be performed from any of the back side, the front side, and the front and back sides of the transfer sheet S. Note that the sheet heating is preferably performed after the sheet supporting device 22 supports both ends in the width direction. Before that, the sheet is likely to extend in the feed direction or hang down, thereby hindering the transfer.

When a heated solid particle or a fluid for accelerating solid particles is used as the heating means during the application of the collision pressure, the heated fluid can also be used. Further, heating may be performed by dispersing in a gap between the ejectors and providing a heat source. Of course, the heating during and before the application of the collision pressure can be used together, or the heating during the application of the collision pressure alone may be performed.

If the substrate to be transferred is coated with an adhesive or a sealer, and the solvent is dried by heating with a substrate heating device or the like, the substrate to be transferred is heated and then heated. The transfer sheet can also be heated to some extent indirectly from the transfer substrate. Therefore, even if heating of the transfer sheet is necessary, if indirect heating from the substrate to be transferred or heating by the solid particles P or the solid particle accelerating fluid is sufficient, the sheet heating device dedicated to the transfer sheet is omitted. Can also.

Next, the substrate to be transferred may be heated before the collision pressure is applied, during the application of the collision pressure, or before and during the application of the collision pressure. In the case where the transfer sheet is heated to improve the stretchability by heating the transfer-receiving base material, it is possible to prevent the temperature of the heated transfer sheet from lowering. Further, the transfer sheet can be heated from the side of the substrate to be transferred. The substrate to be transferred may be heated outside or inside the chamber, or outside and inside. External and internal heating can be accomplished using long transport distances, even when sufficient preheating is required. If the internal volume of the chamber itself becomes large in order to provide a long substrate heating device inside the chamber, it is better to provide part or all of the substrate heating device outside the chamber and reduce the internal volume of the chamber. However, it is advantageous in terms of handling in consideration of scattering and recovery of solid particles.

The advantage of heating inside the chamber is that heating can be performed immediately before the application of the collision pressure or even during the application of the collision pressure. Particularly, the substrate to be transferred having a large heat capacity can be effectively preheated only in the vicinity of the transfer surface. It is effective when trying. In addition, in the case of a substrate heating device that also has a role of evaporating a solvent or moisture in order to dry the coating and the adhesive by the substrate coating device disposed on the upstream side, it is preferable that the substrate heating device be disposed inside the chamber. Absent. A means for exhausting the evaporated solvent or moisture filled in the chamber is required, and in the case of a solvent, it is necessary to consider explosion-proof measures. It is preferable that the substrate heating device for such a purpose be disposed outside the chamber or, even if disposed inside, a substrate heating device (drying furnace) for evaporation is separately disposed outside. Of course, if the undercoating is performed on a separate line, it is not necessary to use the substrate heating device as a drying device.

As the heating means for the substrate to be transferred, induction heating and dielectric heating can be performed from the inside of the substrate. On the other hand, heater heating, infrared heating and hot air heating are more efficient from the uneven surface side. . The substrate to be transferred may also be heated from the back side. If the substrate to be transferred is heated to just before or during the application of the collision pressure after the substrate to be transferred is conveyed to the opening of the chamber, the heating from the back side of the substrate is also preferable from the viewpoint of the apparatus space. The heating during the application of the collision pressure may be performed by dispersing a heat source in the gap between the ejectors in addition to the heating on the upstream side of the collision pressure application unit (heating through the transfer sheet).

[Forced Cooling of Adhesive] In the case where the adhesive is of the heat-sealing type, if the adhesive is forcibly cooled after the transfer sheet is in close contact with the base material to be transferred, the transferred sheet follows the inside of the concave portion and is formed. It promotes the fixation of the sheet, prevents the transfer sheet from returning to its original shape after the pressure is released when the transfer sheet has a restoring force, and allows the transfer sheet (support) to be separated and removed more quickly. In addition, transfer loss can be prevented and the production speed can be improved. 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 transferred substrate is large, in addition to the cooling solid particles and the cooling fluid, the transferred substrate can be cooled from the back surface by spraying a low-temperature fluid and cooling the rollers and belt conveyor for transferring the substrate. . Alternatively, after the above cooling in the chamber, cooling may be performed by blowing cold 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.

[Air Vent] Before the collision pressure is applied, if the adhesive to be the transfer layer or the adhesive layer on the substrate to be transferred is not activated even if heated, or the time before it is activated If the transfer process can be used, the non-adhesive contact between the transfer substrate and the transfer sheet can be performed, so that the transfer sheet is brought into contact with the uneven surface of the transfer substrate, and the gap between the transfer sheet and the transfer substrate is reduced. It is good to perform "air bleeding" to forcibly bleed air. By performing the air bleeding, it is possible to prevent "air biting" in which the air between the transfer sheet and the transfer-receiving substrate remains at the time of transfer, and further prevent transfer omission due to the air bite. For example, in the apparatus shown in FIG. 14, the air is evacuated by a suction and exhaust device 90 including a suction and exhaust nozzle 91 and a vacuum pump 92. The suction / exhaust nozzles 91 are provided on the transfer layer side of the transfer sheet S, and on both sides adjacent to both sides along the transport direction of the transferred base material B to be transported,
It is sufficient that the air is provided between the transfer sheet S and the transfer base material B by the vacuum pump 92 and exhausted by providing the transfer base material B in the transport direction of the transfer base material B to the position before the shielding means 1. Suction and exhaust nozzle 9
For example, if the outer periphery of the opening 1 is surrounded by a brush and the tip of the brush is brought into contact with the substrate B to be transferred and the transfer sheet S, air can be vented without hindering their transport. Note that the timing of the air release and the preheating of the transfer sheet may be started first, or both may be started at the same time, depending on the speed at which the transfer sheet is preheated and softened, and the degree of softening.
This air release is effective when the transfer surface of the transfer substrate has an uneven surface such as a rock surface tone or a stucco tone.

[Others] The curved surface transfer method and apparatus of the present invention have been described above, but the present invention is not limited to the above-described matters. For example, in the description of the apparatus in FIG. 14, the transfer sheet is pressed against the transfer base material using a long belt-shaped transfer sheet and a single-sheet transfer base material, and fixed while moving and transferring the both integrally. In this embodiment, the solid particle collision pressure is continuously applied by the ejector described above.

The positional relationship between the ejection direction of the solid particles from the ejector and the transfer sheet and the substrate to be transferred is as follows: both are placed on a horizontal plane, and the solid particles are ejected vertically downward from above. It is not limited to. Even if the ejection direction maintains the vertical relationship with the transfer sheet support surface, the transfer sheet may be placed or conveyed on a slope (not shown) or in a vertical plane (FIG. 9B) in addition to the horizontal plane. is there. Further, even when the transfer sheet is in a horizontal plane, the solid particles may be ejected and collided from the bottom upward with the support being on the lower side. Of course, the solid particles may be ejected at an angle to the transfer sheet support surface.

Before applying the collision pressure, the transfer sheet may be preliminarily pressed against the base material by the elastic roller.

When the chamber is filled with an inert gas such as nitrogen and an ionizing radiation curable resin (before curing) is used for the base coat layer of the transfer layer, oxygen, water vapor and the like in the air are used. May be prevented from inhibiting the curing of the resin.

[Cosmetic Materials] Cosmetic materials obtained by the present invention include exterior materials such as outer walls, fences, roofs, gates, and gable plates, architectural interior materials such as wall surfaces and ceilings, window frames, doors, handrails, sills, and Kamoi. Such as fittings,
It can be used in various fields such as a surface material of furniture such as a chest, a cabinet of light electric / OA equipment, or a vehicle interior material such as an automobile.

The surface of the decorative material after transfer may be further coated with a transparent protective layer. As such a transparent protective layer, one or two kinds of fluororesins such as polytetrafluoroethylene and polyvinylidene fluoride, acrylic resins such as polymethyl methacrylate, silicone resins, and urethane resins are used.
Seed or the like as a binder, if necessary, a benzotriazole, an ultraviolet absorber such as ultrafine cerium oxide, a light stabilizer such as a hindered amine radical scavenger,
A paint to which 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.

[0133]

EXAMPLES (Examples) First, a transfer-receiving substrate B having three-dimensional surface irregularities as shown in the plan view of FIG. 15A and the perspective view of the main part of FIG. 15B was prepared. This transferred substrate B
Is a groove-like concave portion 401 having a depth of 1.5 mm and an opening width of 5 mm as large irregularities, and a flat convex portion 40 of a brickwork pattern.
2 and a depth of 0.
Pear-skinned fine irregularities 40 distributed in the range of 1 to 0.5 mm
3 is a 12 mm thick calcium silicate plate having three-dimensional surface irregularities in which these large irregularities and fine irregularities overlap. Then, undercoating and undercoating were performed off-line on the uneven surface by another device.

The transfer sheet has a thickness of 100 μm on the support.
m, using a polypropylene-based thermoplastic elastomer film, on one side of which a gravure printing of a brick-like pattern having cement joints aligned with the concave-convex surface shape of the transferred substrate B as a decorative layer serving as a transfer layer was sequentially performed. I prepared something. As the binder resin of the picture ink, a mixture of an acrylic resin and a vinyl chloride-vinyl acetate copolymer in a ratio of 8: 2 (weight ratio) is used. As the coloring pigment, red-bodied pattern, isoindolinone, carbon black, Titanium white was used.

In this embodiment, an apparatus as shown in FIG. 14, which uses a curved transfer apparatus using an impeller as shown in FIGS. Then, the transfer-receiving base material B is placed on the base material transfer device 10 composed of a transfer roller row with its uneven surface facing upward and transferred, and the base material coating device 50 converts the transfer material from the polyamide resin. After melt-coating the solvent-free hot-melt type heat-sensitive adhesive of 30 g / m ² , the adhesive and the substrate B to be transferred are heated by the substrate heating device 41 and then supplied to the collision pressure applying unit 30. did. On the other hand, the transfer sheet S is transferred by the transfer sheet supply device 20 with its support side facing up.
Further, the joint was supplied to the collision pressure applying unit 30 such that the joint of the pattern and the joint-shaped groove-shaped recess of the transfer-receiving substrate B were aligned (registered). The transfer base material B is the impact pressure applying unit 3
When the transfer sheet S entered the chamber 33 of No. 0, the transfer sheet S was brought close to the base material B to be transferred. Then, both ends in the width direction of the transfer sheet S were sandwiched between the front and back sides by a pair of endless belt-shaped sheet support devices 22. In this state, preheating of the transfer sheet S, activation of the adhesive, and heating of the base material B to be transferred were performed by the sheet heating device 40 using radiant heat from a heating wire heater from the support side of the transfer sheet S.

Next, the solid particles P have an average particle size of 0.4
mm spherical zinc spheres were ejected from the ejector 32 and collided with the support side of the transfer sheet S, so that the transfer sheet S was pressed against the base material B to be transferred. The rotation speed of the impeller of the ejector 32 is 36
At 00 rpm, the ejection speed of the solid particles was 35 m / s. Then, after the transfer sheet S is extended into the joint concave portion of the base material B to be transferred and thermally fused, the transfer sheet S is firstly removed by the static eliminator 80 in the small chamber 71 provided downstream of the chamber 33. The charge on the support and the residual solid particles thereon was neutralized and neutralized. Specifically, the static eliminator 8
As 0, a photoionization system manufactured by Hamamatsu Photonics Co., Ltd. is used, and X-rays of 3 to 9.5 keV are irradiated into the atmosphere to ionize air molecules into an anion-cation pair, and the charges of the ions are charged. Was neutralized. Subsequently, at 20 ° C.
Cold air consisting of (room temperature) air was blown to remove solid particles remaining on the transfer sheet by dropping from the end of the transfer sheet toward the lower part of the chamber, and the adhesive was cooled to a temperature below the bonding temperature. Thereafter, the peeling roller 60
Then, the support of the transfer sheet was peeled off from the base material B to form a decorative material D. In the decorative material, the pattern was transferred by the transfer sheet following the concave side surface of the large irregularities of the surface irregularities. Further, no solid particles were adhered to the support of the peeled transfer sheet, including the inside of the concave portion formed in the concave shape of the transfer-receiving substrate. Further, an emulsion paint of polyvinylidene fluoride containing 0.5% by weight of a benzotriazole-based ultraviolet absorber is applied to a dry thickness of 10 μm on the surface of the transfer layer of the decorative material to form a transparent protective layer, and the transparent protective layer is formed. A layered cosmetic material was obtained.

(Comparative Example) In the example, the static eliminator 80 was used.
The solid particles were removed without operating. Other conditions were the same as those of the example. As a result, solid particles which could not be removed and remained adhered were scattered on the separated support.

[0138]

According to the present invention, a decorative material having a large three-dimensional uneven surface decorated can be easily obtained. More specifically, it can be transferred onto the convex portion of the large irregular surface and into the concave portion (the side surface which is the bottom portion or the connecting portion between the convex portion and the bottom portion). For example, even if there is a hairline, satin finish, etc., it is possible to decorate by transfer even in the concave portion of the fine unevenness. In addition, since no solid particles remain on the support of the used transfer sheet, there is no problem in disposing of the support.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram of a curved surface transfer device according to the present invention.

FIG. 2 is an explanatory view showing an example of an arrangement of a remover as a solid particle removing means.

FIG. 3 is an explanatory view showing another example of the solid particle removing means.

FIG. 4 is an explanatory diagram showing another example of a method of isolating a collision space and a removal space from the surroundings.

FIG. 5 is a perspective view showing an example of an ejector using an impeller.

FIG. 6 is a front view of the ejector of FIG. 5;

FIG. 7 is an explanatory view of the inside of the ejector of FIG. 5;

FIG. 8 is an explanatory diagram for adjusting a jetting direction by the jetting device of FIG. 5;

FIG. 9 shows another example of an ejector using an impeller.
(A) is a front view, (B) is a side view.

FIG. 10 is a cross-sectional view showing an example of an ejector using an ejection nozzle.

11A and 11B are diagrams illustrating an example of an arrangement state of the ejectors, in which FIG. 11A is an arrangement diagram in a staggered lattice state, and FIG. It is an arrangement view of the state where it shifted.

FIG. 12 is an explanatory diagram showing an example of setting a pressure distribution in the width direction of the collision pressure.

FIG. 13 is a side view showing an example of the direction of the ejector when viewed from the flow direction.

14A and 14B are diagrams illustrating an example of a curved surface transfer apparatus capable of performing the curved surface transfer method of the present invention, wherein FIG. 14A is a schematic diagram viewed from a side in a substrate transport direction, and FIG. Is a schematic view of a portion viewed from a substrate transport direction.

FIGS. 15A and 15B are explanatory views showing an example of three-dimensional surface irregularities of a transfer-receiving base material, wherein FIG. 15A is a plan view and FIG.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 ejector 2 substrate transport device 3 static eliminator 4 remover 5 partition wall 6 chamber 6 ′ second chamber 7 chamber 8 collision chamber 9 removal chamber 10 substrate transport device (substrate transport unit) 20 sheet feeding unit 21 sheet sending Apparatus 22 Sheet support device 23 Sheet discharge device 24 Guide roller 30 Impact pressure applying means 31 Hopper 32 Ejector (Solid particle ejection means) 33 Chamber 34 Drain pipe 35 Separation device 36 Vacuum pump 40 Sheet heating device 41 Substrate heating device 50 Material coating device 60 Separation roller 70 Cooling device 71 Small chamber 90 Suction / exhaust device 91 Suction / exhaust nozzle 92 Vacuum pump 401 Groove-shaped concave portion 402 Flat convex portion 403 Fine irregularity 812, 812a Impeller 813, 813a Blade 814, 814a Side plate 815 Hollow part 816 Direction controller 8 17 Opening 818 Sprayer 819, 819a Rotating shaft 820 Bearing 840 Blower using blowout nozzle 841 Induction chamber 842 Internal nozzle 843 Nozzle opening 844 Nozzle S Transfer sheet B Transfer substrate P Solid particle D Cosmetic material

Claims (2)

[Claims] 1. A transfer sheet comprising a support and a transfer layer, wherein the transfer layer side of a transfer sheet comprising a support and a transfer layer is opposed to the uneven surface side of the transfer-receiving base material having the uneven surface, and solid particles collide with the support side of the transfer sheet. Utilizing the collision pressure, the transfer sheet is pressed against the uneven surface of the transfer substrate, and the transfer layer adheres to the transfer substrate, and then the transfer sheet support and the solid particles remaining on the support After removing the static electricity charged on the transfer sheet and removing the solid particles remaining on the support of the transfer sheet, the transfer layer is transferred to the substrate to be transferred by peeling and removing the support of the transfer sheet. Characterized surface transfer method. 2. The transfer layer side of a transfer sheet comprising a support and a transfer layer is opposed to the uneven surface side of the substrate to be transferred having the uneven surface, and solid particles are caused to collide with the support side of the transfer sheet. Utilizing the collision pressure, the transfer sheet is pressed against the uneven surface of the transfer substrate, and the transfer layer adheres to the transfer substrate, and then the transfer sheet support and the solid particles remaining on the support After removing static electricity charged on the transfer sheet and removing solid particles remaining on the transfer sheet support, a method of transferring the transfer layer to the substrate to be transferred by peeling and removing the support of the transfer sheet is used. An apparatus used for carrying out the method, wherein at least (1) solid particle ejecting means for ejecting solid particles, and (2) substrate transfer for conveying a substrate to be transferred to a position facing the solid particle ejecting means. (3) transferring the transfer sheet to the solid particle ejecting means; A transfer sheet supply means positioned between the transfer base material, (4) a static electricity removing means for removing static electricity charged on the support and the solid particles remaining on the support, and (5) a transfer sheet supply means. And a solid particle removing means for removing remaining solid particles.