Transfer foil sheet, method for manufacturing the same, and manufacturing apparatus.

Abstract

The goal is to enable the transfer of foil of any shape without the need for a transfer mold and independently of the toner image. [Solution] The present invention provides a heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer, and a step of overlapping the heat transfer sheet and the foil sheet with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet, An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, A method for manufacturing a transfer foil sheet, comprising a transfer foil sheet forming step, which involves peeling off the heat transfer sheet or the foil sheet from the heat transfer sheet or the foil sheet on which the predetermined image has been printed, to form a transfer foil sheet.

Description

Technical Field

[0001] The present invention relates to a transfer foil sheet, a method for manufacturing the same, and a manufacturing apparatus.

Background Art

[0002] One of the methods for decorating message cards, greeting cards, labels (seals), wrapping containers, etc. is "foil stamping". Foil stamping is a processing method in which a pattern or character formed of a metal foil such as a gold foil or a silver foil is attached to the surface of a decoration object, and a method called a hot stamping method has been used hitherto.

[0003] In the hot stamping method, a metal transfer die having convex or concave portions in the shape of a pattern or character to be expressed by a metal foil, and a metal foil sheet having a base film and a metal foil layer formed thereon are used. The metal foil sheet is applied to the surface of the decoration object, and after the metal foil sheet is pressure-bonded to the decoration object with the transfer die and heated, the base film is peeled off, so that a metal foil having a predetermined shape is extracted from the metal foil sheet and transferred to the decoration object.

[0004] In the hot stamping method, a transfer die is produced for each pattern or character to be foil-stamped. Since it takes time and cost to produce the transfer die, the hot stamping method is not suitable for small-lot products or products with a short delivery time from receiving an order to the delivery date.

[0005] On the other hand, there is a method of transferring a metal foil to a toner image formed by printing using a toner containing an adhesive component (Patent Document 1). In this method, a toner image is printed on the surface of a decoration object by an electrophotographic method, and a metal foil sheet is overlaid on the printed surface of the decoration object and pressurized and heated. As a result, the adhesive component contained in the toner image melts and the metal foil adheres, so that the metal foil having the shape of the toner image can be transferred to the decoration object by peeling off the base film from the metal foil sheet.

Prior Art Documents

Patent Documents

[0006] [Patent Document 1] Japanese Patent Publication No. 2014-043049 [Overview of the project] [Problems that the invention aims to solve]

[0007] The method described in Patent Document 1 does not require a transfer mold for each design or character to be foil-stamped, thus reducing the cost of foil stamping and allowing for the production of small-lot products and products with short lead times.

[0008] However, with this method, the metallic foil is transferred to the entire toner image. Therefore, when decorating printed materials with designs or text using foil stamping, it was necessary to prepare both regular toner without adhesive components and toner with adhesive components, and to print using each toner separately.

[0009] The problem that this invention aims to solve is to enable the transfer of foil of any shape without using a transfer mold and independently of the toner image. [Means for solving the problem]

[0010] The method for manufacturing a transfer foil sheet according to the present invention, which was developed to solve the above problems, A heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer are prepared, and the heat transfer sheet and the foil sheet are placed on top of each other with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet. An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, The method includes a transfer foil sheet forming step, in which the heat transfer sheet and the foil sheet are peeled off to form a transfer foil sheet, thereby forming a transfer foil sheet.

[0011] In this invention, "foil" refers to a thin sheet made of metal such as gold, silver, copper, or tin, and can be formed by vapor-depositing a metal material onto a sheet-like substrate (second substrate) or by thinly rolling a metal material on the substrate. A typical example of foil formed by vapor-depositing a metal material is aluminum vapor-deposited foil. Normally, foil is formed from one type of metal material, but it can also be formed from an alloy made of two or more types of metals. Furthermore, foil in which a layer called a topcoat is formed over the entire surface for the purpose of protecting the surface of the foil or coloring the foil may also be included in the "foil" of this invention.

[0012] Furthermore, in this invention, "thermal printer" refers to a known printing device that prints on an object using a ribbon called a thermal transfer ribbon or ink ribbon. Therefore, the thermal transfer sheet corresponds to the thermal transfer ribbon or ink ribbon, etc.

[0013] In the above method for manufacturing a transfer foil sheet, printing a predetermined image onto the stacked heat transfer sheet and foil sheet from the first substrate side of the heat transfer sheet using a thermal printer means printing a predetermined image onto the stacked heat transfer sheet and foil sheet with the first substrate side of the heat transfer sheet facing upwards using a thermal printer. More specifically, it means heating the portion of the heat transfer sheet corresponding to the predetermined image with a thermal head to adhere the portion of the heat transfer layer corresponding to the predetermined image to the adhesive layer of the foil sheet.

[0014] When the portion of the heat transfer layer corresponding to the predetermined image is adhered to the adhesive layer of the foil sheet and fixed, and then the heat transfer sheet is peeled off the foil sheet, or the foil sheet is peeled off the heat transfer sheet, the adhesive layer that is fixed to the heat transfer layer and the foil layer formed on top of the adhesive layer of the foil sheet peel off from the second substrate, while the remaining adhesive layer and foil layer remain on the second substrate side. As a result, a transfer foil sheet is obtained having a foil layer and adhesive layer in a shape excluding the shape corresponding to the predetermined image. By using such a transfer foil sheet, a foil layer and adhesive layer in a shape excluding the predetermined image can be transferred to an object to be decorated. The time from when the heat transfer layer of the heat transfer sheet and the adhesive layer of the foil sheet adhere to each other until they are fixed should be appropriately adjusted according to the ambient temperature, the type of adhesive component contained in the heat transfer layer and the adhesive layer, etc.

[0015] The present invention is also applicable to a transfer foil sheet manufacturing apparatus. That is, the transfer foil sheet manufacturing apparatus according to the present invention is A thermal printer with a thermal head, A transport unit that passes a thermal transfer sheet having a first substrate and a thermal transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate, and an adhesive layer formed on the foil layer, through a thermal printer with the thermal transfer layer of the thermal transfer sheet facing the adhesive layer of the foil sheet, and the thermal transfer sheet and the foil sheet stacked together. A print control unit causes the thermal head to print on the thermal transfer sheet and the foil sheet as they pass through the thermal printer, starting from the first substrate side of the thermal transfer sheet. A sheet peeling section for peeling the thermal transfer sheet or the foil sheet from the thermal transfer sheet and the foil sheet that have passed through the thermal printer, It is equipped with.

[0016] Furthermore, the transfer foil sheet according to the present invention includes a sheet-like base material, a release layer having a predetermined planar shape different from the planar shape of the base material formed on the base material, a foil layer having the same planar shape as the release layer formed on the release layer, and an adhesive layer having the same planar shape as the release layer formed on the foil layer. This transfer foil sheet can be manufactured using the above-described method for manufacturing a transfer foil sheet and a transfer foil sheet manufacturing apparatus.

Advantages of the Invention

[0017] According to the present invention, arbitrary patterns or characters can be hot-stamped onto the object to be decorated without using a transfer mold or forming a toner image on the object to be decorated.

Brief Description of the Drawings

[0018] [Figure 1] A diagram showing a schematic configuration of a foil transfer apparatus according to an embodiment of the present invention. [Figure 2] (a) is a schematic cross-sectional view of a thermal transfer sheet, (b) is a schematic cross-sectional view of a foil sheet, and (c) is a schematic cross-sectional view of an object sheet to be decorated. [Figure 3A] Diagrams (1) to (6) for explaining the foil transfer operation. [Figure 3B] Diagrams (7) to (12) for explaining the foil transfer operation. [Figure 4] A diagram showing how a thermal transfer foil sheet and a transfer foil sheet are obtained from a thermal transfer sheet and a foil sheet.

Embodiments for Carrying Out the Invention

[0019] Hereinafter, a method and an apparatus for manufacturing a transfer foil sheet according to the present invention, as well as a transfer foil sheet, a foil transfer method, and a foil transfer apparatus will be described.

[0020] Figure 1 shows a schematic configuration of a foil transfer apparatus according to one embodiment of the present invention. The foil transfer apparatus 100 includes a heat transfer sheet supply roller 11, a heat transfer sheet recovery roller 12, a foil sheet supply roller 21, a foil sheet recovery roller 22, a sheet to be decorated supply roller 31, and a sheet to be decorated recovery roller 32. The heat transfer sheet supply roller 11, the heat transfer sheet recovery roller 12, the foil sheet supply roller 21, and the foil sheet recovery roller 22 correspond to the transport section of the present invention. The foil sheet recovery roller 21 corresponds to the foil sheet recovery section, and the sheet to be decorated recovery roller corresponds to the sheet to be decorated recovery section.

[0021] A long thermal transfer sheet 111 is wound around the thermal transfer sheet supply roller 11. The thermal transfer sheet 111 has the same structure as a general thermal transfer ribbon used in known thermal printers, and for example, as shown in Figure 2(a), it has a long sheet-like base film (corresponding to the substrate of the present invention) 1111 and an ink layer 1112 formed thereon. For example, a PET film can be used as the base film 1111, and an ink mainly composed of wax or resin can be used for the ink layer. The thermal transfer sheet 111 is conveyed with the ink layer 1112 facing downwards.

[0022] The heat transfer sheet 111, which has been drawn from the heat transfer sheet supply roller 11, is wound around the heat transfer sheet recovery roller 12. As the heat transfer sheet recovery roller 12 rotates in the direction indicated by arrow P1, the heat transfer sheet 111 is drawn from the heat transfer sheet supply roller 11, transported along a predetermined transport path in the direction indicated by the white arrow, and then recovered by the heat transfer sheet recovery roller 12.

[0023] Between the thermal transfer sheet supply roller 11 and the thermal transfer sheet recovery roller 12, a thermal printer 41 and two transport rollers 13 and 14 are positioned. The thermal printer 41 has a sensor 411 and a thermal head 412, and a platen roller 413 positioned opposite the thermal head 412. The platen roller 413 rotates in the direction indicated by arrow P5. The sensor 411 detects the temperature of the thermal head 412.

[0024] The transport roller 13 is positioned between the thermal printer 41 and the thermal transfer sheet supply roller 11, and guides the thermal transfer sheet 111 sent from the thermal transfer sheet supply roller 11 between the guide section 412 and the platen roller 413. The transport roller 14 is positioned between the thermal printer 41 and the thermal transfer sheet recovery roller 12. The thermal transfer sheet 111 that has passed between the thermal head 412 and the platen roller 413 is guided by the transport roller 14 toward the thermal transfer sheet recovery roller 12, and then wound around the roller 12. In this embodiment, the thermal transfer sheet supply roller 11 and the thermal transfer sheet recovery roller 12 are located at approximately the same height, the transport roller 13 is located slightly below them, and the thermal head 412, platen roller 413, and transport roller 14 are located further below at approximately the same height.

[0025] A long foil sheet 211 is wound around the foil sheet supply roller 21. As shown in Figure 2(b), the foil sheet 211 has a sheet-like base film (corresponding to the substrate of the present invention) 2111, and a release layer 2112, a metal foil layer 2113, and an adhesive layer 2114 formed sequentially on it. The foil sheet 211 is conveyed with the adhesive layer 2114 facing upwards.

[0026] The foil sheet 211, which has been drawn from the foil sheet supply roller 21, is wound around the foil sheet recovery roller 22. As the foil sheet recovery roller 22 rotates in the direction indicated by arrow P2, the foil sheet 211 is drawn from the foil sheet supply roller 21, transported along a predetermined transport path in the direction indicated by the white arrow, and then recovered by the foil sheet recovery roller 22.

[0027] The foil sheet supply roller 21 is located on the same side as the thermal transfer sheet supply roller 11 with respect to the thermal printer 41, and is positioned below the roller 11. The foil sheet recovery roller 22 is located below the foil sheet supply roller 21. Five transport rollers 23 to 27 are positioned between the foil sheet supply roller 21 and the foil sheet recovery roller 22.

[0028] The transport roller 23 is positioned between the foil sheet supply roller 21 and the platen roller 413 of the thermal printer 41, and guides the foil sheet 211 sent from the foil sheet supply roller 21 between the guide section 412 and the platen roller 413. As a result, the thermal transfer sheet 111 and the foil sheet 211 pass between the guide section 412 and the platen roller 413 with their ink layer 1112 and adhesive layer 2114 facing each other.

[0029] The transport roller 24 is positioned between the platen roller 413 and the transport roller 14, and the peeling bar 51 is positioned between the transport roller 24 and the transport roller 14. The transport roller 25 is positioned at a predetermined location on the foil sheet recovery roller 22 side of the peeling bar 51. The heat transfer sheet 111 and the foil sheet 211 that have passed between the guide section 412 and the platen roller 413 are guided to the peeling bar 51 by the transport roller 24, and then the foil sheet 211 (more precisely, a sheet from which a part of the metal foil layer has been removed from the foil sheet 211; hereafter referred to as the transfer foil sheet 212) proceeds to the transport roller 25 via the peeling bar 51. Meanwhile, the heat transfer sheet 111 (more precisely, a sheet to which the metal foil layer removed from the foil sheet 211 is attached, as will be described in more detail later; hereafter referred to as the heat transfer foil sheet 112) moves toward the transport roller 14 via the peeling bar 51, and is then collected by the heat transfer sheet recovery roller 12 via the transport roller 14. At this time, the transport roller 24, peeling bar 51, and transport roller 25 are arranged so that the foil sheet 70 bends at a predetermined acute angle (0° to 45°) before and after the peeling bar 51.

[0030] A long sheet to be decorated 311 is wound around the sheet supply roller 31. As shown in Figure 2(c), the sheet to be decorated 311 has a long backing sheet 3111 and labels (seals) 3112 attached to the backing sheet 3111 at predetermined intervals. A release film is attached to the surface of the backing sheet 3111, and the labels 3112 are attached to its adhesive surface in a way that allows them to be peeled off.

[0031] The sheet to be decorated 311, which has been drawn from the sheet to be decorated supply roller 31, is wound around the sheet to be decorated retrieval roller 32. When the sheet to be decorated supply roller 31 rotates in the direction indicated by arrow P3, the sheet to be decorated 311 wound around the roller 31 is discharged, and when the sheet to be decorated retrieval roller 32 rotates in the direction indicated by arrow P4, the sheet to be decorated 311 is retrieved.

[0032] Between the sheet to be decorated supply roller 31 and the sheet to be decorated recovery roller 32, there are three transport rollers 33-35, two mark detection units 36 and 37 for detecting registration marks on the sheet to be decorated, and a foil transfer unit 61. Also, between the foil transfer unit 61 and the transport roller 25, there is a mark detection unit 38 for detecting registration marks on the transfer foil sheet 212.

[0033] The foil transfer section 61 has a pair of pressing rollers 62 and 63 and one peeling roller 64. One of the pressing rollers 62 and 63 (in this embodiment, pressing roller 63) has a heater built inside and functions as a heating roller. Hereinafter, to distinguish it from pressing roller 62, pressing roller 63 will be referred to as heating roller 63.

[0034] The foil transfer section 61 is positioned on the transport path of the transfer foil sheet 212, with the pressing roller 62 and heating roller 63 positioned between the transport roller 25 and the transport roller 26, and the peeling roller 64 positioned between the transport roller 26 and the transport roller 27.

[0035] The mark detection units 36 and 37 are positioned between the sheet supply roller 31 and the pressing roller 62. The transport roller 33 is positioned between the pressing roller 62 and the mark detection unit 37. On the other hand, the transport rollers 34 and 35 are positioned between the peeling roller 64 and the sheet collection roller 32. In this embodiment, the transport roller 34 is positioned such that its upper end is at approximately the same height as the lower end of the peeling roller 64, and the transport roller 35 is positioned such that its lower end is at approximately the same height as the lower end of the sheet to be decorated recovery roller 32. The transport roller 27 and the foil sheet recovery roller 22 are positioned at a height between the transport roller 34 and the transport roller 35.

[0036] The transfer foil sheet 212, guided by the transport roller 25, is passed between the pressing roller 62 and the heating roller 63. The sheet to be decorated 311, sent from the sheet to be decorated supply roller 31, is guided by the transport roller 33 between the pressing roller 62 and the heating roller 63, and passes between the pressing roller 62 and the heating roller 63 while overlapping with the transfer foil sheet 212. After that, the transfer foil sheet 212 and the sheet to be decorated 311 proceed to the peeling roller 64 via the transport roller 26, where the sheet to be decorated 311 (hereinafter referred to as the decorated sheet 312), to which the metal foil layer of the transfer foil sheet 212 is attached, has its direction of travel changed by approximately 90 degrees by the peeling roller 64, and is then guided sequentially by the transport rollers 34 and 35 toward the sheet to be decorated recovery roller 32, where it is recovered. Meanwhile, the transfer foil sheet 212, after the metal foil layer has been removed, has its direction of travel changed by approximately 90 degrees by the transport roller 27, and is then recovered by the foil sheet recovery roller 22.

[0037] The foil transfer apparatus 100 with the above configuration includes a control unit 101, and under the control of the control unit 101, the thermal transfer sheet recovery roller 12, the foil sheet recovery roller 22, the sheet to be decorated supply roller 31, the thermal printer 41 (thermal head 412, platen roller 413), the foil transfer unit 61, and the mark detection units 36-38 operate. The control unit 101 also functions as the printing control unit of the present invention.

[0038] Next, the foil transfer operation by the foil transfer apparatus 100 will be described in detail with reference to Figures 3A, 3B, and 4. Figure 3A(1) shows the foil transfer device 100 in its initial state. In the initial state, the nip section (guide section 412 and platen roller 413, pressing roller 62 and heating roller 63) inside the foil transfer device 100 is open, and the peeling bar 51 is in the retracted position. In this state, the heat transfer sheet 111 is pulled out from the heat transfer sheet supply roller 11, and its end is wound around the heat transfer sheet recovery roller 12. Also, the foil sheet 211 is pulled out from the foil sheet supply roller 21, and its end is wound around the foil sheet recovery roller 22. Furthermore, the sheet to be decorated 311 is pulled out from the sheet to be decorated supply roller 31 until its leading edge reaches the unwinding position SL0 in front of the mark detection unit 36.

[0039] As described above, after the heat transfer sheet 111, foil sheet 211, and sheet to be decorated 311 are set in a predetermined state, the nip section (guide section 412 and platen roller 413, pressing roller 62 and heating roller 63) inside the foil transfer device 100 is closed, and the peeling bar 51 is moved to the peeling position. As a result, the foil transfer device 100 is in the state shown in (2) of Figure 3A. Note that the movement of the nip section from the open state to the closed state, and the movement of the peeling bar 51 from the retracted position to the peeling position may be performed manually by the user or by the control unit 101.

[0040] When the user performs a predetermined operation in the above state and instructs the execution of the foil transfer process, the heat transfer sheet recovery roller 12, the foil sheet recovery roller 22, the sheet to be decorated supply roller 31, and the platen roller 413 start rotating under the control of the control unit 101. As a result, the heat transfer sheet 111 and the foil sheet 211 are transported, and the sheet to be decorated 311 is delivered. As a result, after passing between the guide unit 412 and the platen roller 413, the heat transfer sheet 111 and the foil sheet 211 are transported with the ink layer 1112 and the adhesive layer 2114 in close contact, as shown in Figure 4.

[0041] Furthermore, when the mark detection unit 36 ​​detects the first registration mark on the sheet to be decorated 311 being fed from the sheet to be decorated sheet supply roller 31, the control unit 101 drives the thermal head 412 of the thermal printer 41 to bring the thermal head 412 into contact with the heat transfer sheet 111 and the foil sheet 211 at an appropriate timing. At this time, the heat source (not shown) of the thermal head 412 is turned on / off based on the detection result of the sensor 411, and the thermal head 412 is adjusted to a predetermined temperature. As a result, heat is applied to predetermined areas of the heat transfer sheet 111 and the foil sheet 211, and the ink layer 1112 of that area and the adhesive layer 2114 of the foil sheet 211 adhere to each other. The shape of the area to which heat is applied by contact with the thermal head 412 (hereinafter referred to as the heated area) is predetermined.

[0042] A registration mark is provided on each of the multiple labels 3112 attached to the backing sheet 3111. The control unit 101 drives the thermal head 412 of the thermal printer 41 each time the mark detection unit 36 ​​detects a registration mark on the sheet 311 to be decorated. In Figure 3A (2) and subsequent figures, circles are marked on the heating areas of the heat transfer sheet and foil sheet, and on the registration mark locations on the sheet 311 to be decorated.

[0043] The thermal transfer sheet 111 and foil sheet 211, having passed between the thermal head 412 and platen roller 412 of the thermal printer 41, are guided to the release bar 51 by the transport roller 24. After this, the foil sheet 211 proceeds to the transport roller 25 via the release bar 51, and the thermal transfer sheet 111 proceeds to the transport roller 14 via the release bar 51. The foil sheet 70 is bent at an acute angle before and after the release bar 51, while the thermal transfer sheet 111 moves straight. Since the ink layer 1112 and adhesive layer 2114 are bonded in the heated area of ​​the thermal transfer sheet 111 and foil sheet 211, the release layer 2112 in the heated area of ​​the foil sheet 211 is peeled off from the base film 2111 when bent by the release bar 51, and the adhesive layer 2114, metal foil layer 2113, and release layer 2112 are transferred to the thermal transfer sheet 111.

[0044] Therefore, the heat transfer sheet recovery roller 12 recovers the heat transfer foil sheet 112, on which the adhesive layer 2114, metal foil layer 2113, and release layer 2112 in the shape of the heated area have been transferred to the heat transfer sheet 111.

[0045] In this embodiment, the sheet peeling section is composed of a thermal transfer sheet recovery roller 12, a transport roller 14, a peeling bar 51, transport rollers 24 and 25, a foil sheet recovery roller 22, and the like.

[0046] Figure 4 schematically shows the relationship between the thermal transfer sheet 111 and foil sheet 211 as they pass through the thermal printer 41, and the thermal transfer foil sheet 112 and transfer foil sheet 212 after they have passed through the release bar 51. As shown in Figure 4(A), just before passing between the thermal head 412 and platen roller 413 of the thermal printer 41, the thermal transfer sheet 111 and foil sheet 211 are in a state where the ink layer 1112 and the adhesive layer 2114 are in close contact and overlapping. At this time, the ink layer 1112 and the adhesive layer 2114 are not adhered to each other.

[0047] Figure 4(B) shows the thermal transfer sheet 111 and foil sheet 211 after passing between the thermal head 412 and platen roller 413 (not shown) of the thermal printer 41. When the thermal head 412 contacts the heated areas of both sheets 111 and 211, the base film 1111, ink layer 1112, adhesive layer 2114, metal foil layer 2113, release layer 2112, and base film 2111 in those areas are heated. As a result, the thermoplastic resin contained in the ink layer 1112 and adhesive layer 2114 melts and the ink layer 1112 and adhesive layer 2114 adhere to each other. Although it is stated here that the ink layer 1112, adhesive layer 2114, metal foil layer 2113, release layer 2112, and base film 2111 are heated, it is not necessary for the other layers to be heated as long as at least the ink layer 1112 and adhesive layer 2114 are heated.

[0048] Figure 4(C) shows the heat transfer foil sheet 112 and the transfer foil sheet 212 after the release bar 51. The heat transfer foil sheet 112 has a structure in which the adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 of the heated area of ​​the foil sheet 211 are attached to the heat transfer sheet 111, while the transfer foil sheet 212 has a structure in which the adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 of the heated area are removed from the foil sheet 211. The shape of the metal foil layer 2113 remaining on the transfer foil sheet 212 corresponds to the shape that will be foil-stamped onto the label 3112 (foil stamping shape). In other words, if the foil stamping shape is a positive shape, the shape of the heated area will be a negative shape.

[0049] The reason why the heat transfer foil sheet 112 and the transfer foil sheet 212 have the above structure is thought to be as follows. In this embodiment, the foil sheet 70 is bent at a predetermined acute angle before and after the peeling bar 51, and the heat transfer sheet 111 is moved in a straight line. As a result, the foil sheet 211 is peeled off from the heat transfer sheet 111 and the foil sheet 211, in which a portion of the ink layer 1112 and the adhesive layer 2114 are adhered. This causes peeling at the boundary between the release layer 2112 and the base film 2111, and the adhesive layer 2114, metal foil layer 2113 and release layer 2112 of the heated area of ​​the foil sheet 211 adhere to the heat transfer foil sheet 112, while the transfer foil sheet 212 has a structure in which the adhesive layer 2114, metal foil layer 2113 and release layer 2112 of the heated area have been removed from the foil sheet 211. In other words, in the area of ​​the transfer foil sheet 212 that has the metal foil layer 2113, etc., the base film 2111 will be exposed in the region where the portion corresponding to the heating area has been removed from the foil sheet 211.

[0050] In contrast, the thermal transfer sheet 111 and foil sheet 211, in which a portion of the ink layer 1112 and adhesive layer 2114 are adhered, can be configured such that the foil sheet 211 is moved in a straight line and the thermal transfer sheet 111 is bent at a predetermined acute angle. In this configuration, the thermal transfer sheet 111 is peeled off from the thermal transfer sheet 111 and foil sheet 211, in which a portion of the ink layer 1112 and adhesive layer 2114 are adhered, and peels off at the boundary between the release layer 2112 and the metal foil layer base film 2111, or within the release layer 2112. Thus, the reason why the location of peeling of the release layer changes depending on whether the thermal transfer sheet 111 or the foil sheet 211 is peeled off is presumed to be due to the composition of the release layer 2112, the material of the base film 2111, etc.

[0051] Meanwhile, the transfer foil sheet 212, from which the adhesive layer 2114, metal foil layer 2113, and release layer 2112 in the shape of the heating region have been removed, moves from the peeling bar 51 through the transport roller 25 to the area between the pressing roller 62 and the heating roller 63. At this time, the registration mark of the transfer foil sheet 212 is detected by the mark detection unit 38 just before it reaches the area between the pressing roller 62 and the heating roller 63. Furthermore, as the sheets to be decorated 311 are successively fed from the sheet to be decorated supply roller 31, the registration mark of each label 3112 is detected by the mark detection unit 36 ​​and then by the mark detection unit 37 (as shown in (3) of Figure 3A).

[0052] When the mark detection unit 37 and the mark detection unit 38 detect a registration mark, the control unit 101 moves the pressing roller 62 after a predetermined time has elapsed since the detection and presses it against the heating roller 63. At the same time, the sheet to be decorated 311 and the transfer foil sheet 212 enter between the pressing roller 62 and the heating roller 63 with their registration marks almost aligned, and are conveyed while being heated and pressurized by the pressing roller 62 and the heating roller 63 (as shown in (4) of Figure 3A). As a result, the thermoplastic resin contained in the adhesive layer 2114 of the transfer foil sheet 212 (i.e., the adhesive layer 2114 in the area excluding the heating region) melts and adheres to the surface of the label 3112 on the sheet to be decorated 311.

[0053] The mark detection unit 37 and the mark detection unit 38 are controlled to detect the register mark almost simultaneously, and the thermal head 412 and the sheet to be decorated supply roller 31 are controlled accordingly. However, if there is a timing difference in the detection of the register mark by the two detection units 37 and 38, the control unit 101 adjusts the contact timing of the thermal head 412 to eliminate the time difference.

[0054] As the registration marks of the sheet to be decorated 311 and the transfer foil sheet 212, which are being conveyed by passing between the pressing roller 62 and the heating roller 63, pass through the peeling roller 64, the sheet to be decorated 311 is guided along the peeling roller 64 to the conveying roller 34 (as shown in (5) of Figure 3A). This peels off the adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 from the transfer foil sheet 212 and transfers them to the surface of the label 3112 on the sheet to be decorated 311. Subsequently, the sheet to be decorated 311, with the adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 transferred to the label 3112, is collected by the sheet to be decorated retrieval roller 32 via the conveying roller 34 and the conveying roller 35. Meanwhile, the transfer foil sheet 212 (i.e., the base film) after the adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 have been peeled off is collected by the foil sheet recovery roller 22 via the transport roller (as shown in Figure 3A (6) and Figure 3B (7)).

[0055] The above operation continues until any of the heat transfer sheets 111, foil sheets 211, or sheets to be decorated 311 are used up. Typically, heat transfer sheets 111 and foil sheets 211 that are sufficiently longer than the sheets to be decorated 311 are set on the heat transfer sheet supply roller 11 and foil sheet supply roller 21, and the foil transfer device stops and the foil transfer operation ends when the sheets to be decorated 311 are used up. Figures 3B (8) to (12) and 3C (13) and (14) show the state of the foil transfer device 100 from when all of the sheets to be decorated 311 that were wound around the sheets to be decorated supply roller 31 have been fed out until they are collected by the sheets to be decorated recovery roller 32.

[0056] As shown in Figures 3B(8) and (9), when the rear end of the sheet to be decorated 311 detaches from the sheet to be decorated supply roller 31 and the time range during which the mark detection unit 36 ​​does not detect a registration mark exceeds a predetermined threshold, the control unit 101 separates the guide unit 412 and the platen roller 413 and moves the peeling bar 51 to the retracted position. It also stops the rotation of the heat transfer sheet recovery roller 12. Then, when the transfer of the adhesive layer 2114, metal foil layer 2113, and release layer 2112 to the last label 3112 of the sheet to be decorated 311 is completed (Figure 3B(10)), and the end of the sheet to be decorated 311 passes between the pressing roller 62 and the heating roller 63, the control unit 101 separates the pressing roller 62 and the heating roller 63 (Figure 3B(11)). This prevents unnecessary heat from being applied to the transfer foil sheet 212. Then, when the rear end of the sheet to be decorated 311 passes the transport roller 34, the control unit 101 stops the rotation of the foil sheet recovery roller 22, and then stops the rotation of the roller 32 when the entire sheet to be decorated 311 has been wound onto the sheet recovery roller 32 (Figure 3B (12)). With this, all foil transfer operations are completed.

[0057] As described above, according to this embodiment, a transfer foil sheet 212 having a foil-stamped adhesive layer 2114, a metal foil layer 2113, and a release layer 2112 is prepared, and this transfer foil sheet 212 is pressed onto the sheet 311 to be decorated and heated to transfer the foil-stamped adhesive layer 2114, the metal foil layer 2113, and the release layer 2112 to the label 3112. Therefore, foil stamping of a predetermined shape can be performed without using a transfer mold or printing a toner image using a toner containing an adhesive component.

[0058] In the above embodiment, the process of manufacturing a transfer foil sheet 212 from the heat transfer sheet 111 and the foil sheet 211, and then using this transfer foil sheet 212 to foil-stamp the label 3112 of the sheet to be decorated 311 to produce the decorated sheet 312, was performed continuously. However, although the foil-stamping method has been described, the process of manufacturing the transfer foil sheet 212 from the heat transfer sheet 111 and the foil sheet 211 (corresponding to the transfer foil manufacturing method of the present invention) and the process of using the transfer foil sheet 212 to foil-stamp the label 3112 of the sheet to be decorated 311 to produce the decorated sheet 312 may be performed independently.

[0059] [Pattern] It will be obvious to those skilled in the art that the exemplary embodiments described above are specific examples of the following embodiments.

[0060] (Section 1) A method for manufacturing a transfer foil sheet according to one aspect of the present invention is: A heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer are prepared, and the heat transfer sheet and the foil sheet are placed on top of each other with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet. An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, The method includes a transfer foil sheet forming step, in which the heat transfer sheet and the foil sheet are peeled off to form a transfer foil sheet, thereby forming a transfer foil sheet.

[0061] In the method for manufacturing a transfer foil sheet according to paragraph 1, a predetermined image is printed onto the stacked heat transfer sheet and foil sheet from the first substrate side of the heat transfer sheet using a thermal printer, thereby bonding the heat transfer layer of the heat transfer sheet to the adhesive layer of the foil sheet. Therefore, when the heat transfer sheet or the foil sheet is peeled off from the heat transfer sheet and foil sheet, the foil layer and adhesive layer in the shape corresponding to the predetermined image are transferred to the heat transfer sheet, and a transfer foil sheet having the foil layer and adhesive layer in the shape excluding the predetermined image is obtained. By bringing the adhesive layer of such a transfer foil sheet into contact with the surface of an object to be decorated and heating and pressurizing the transfer foil sheet, the foil layer and adhesive layer in the shape excluding the predetermined image can be transferred to the object to be decorated without using a transfer mold or forming a toner image on the object to be decorated.

[0062] (Paragraph 2) The method for manufacturing a transfer foil sheet relating to Paragraph 2 is the method for manufacturing a transfer foil sheet relating to Paragraph 1, The foil sheet is provided with a release layer between the second substrate and the foil layer.

[0063] According to the above configuration, when the heat transfer sheet or foil sheet is peeled off after a predetermined image has been printed on it, the adhesive layer and foil layer in the shape corresponding to the predetermined image are easily peeled off from the second substrate, and the adhesive layer and foil layer can be reliably transferred to the heat transfer sheet.

[0064] In the above method, the location where the adhesive layer and foil layer, which have a shape corresponding to a predetermined image, peel off from the second substrate may be at the boundary between the foil layer and the release layer, at the boundary between the release layer and the second substrate, or within the release layer. If peeling occurs at the boundary between the foil layer and the release layer, the adhesive layer and the foil layer are transferred to the heat transfer sheet; if peeling occurs at the boundary between the release layer and the second substrate, the adhesive layer, the foil layer, and the release layer are transferred to the heat transfer sheet; and if peeling occurs within the release layer, the adhesive layer, the foil layer, and a portion of the release layer are transferred to the heat transfer sheet. The location of peeling can be adjusted by the adhesive strength between the release layer and the second substrate, the adhesive strength between the release layer and the foil layer, the adhesive strength between the release layer and the second substrate, the composition of the release layer, and whether to peel off the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet.

[0065] (Paragraph 3) The method for manufacturing a transfer foil sheet relating to Paragraph 3 is the method for manufacturing a transfer foil sheet relating to Paragraph 2, The release layer of the foil sheet is configured to peel off at the boundary with the second substrate when the foil sheet is peeled off from the heat transfer sheet on which the predetermined image is printed and from the foil sheet, and to peel off at the boundary with the foil layer when the heat transfer sheet is peeled off from the heat transfer sheet on which the predetermined image is printed and from the foil sheet.

[0066] According to the above configuration, by making the sheet peeled off from the heat transfer sheet and the foil sheet on which the predetermined image is printed the heat transfer sheet or the foil sheet, the surface of the transfer foil sheet that is exposed in the region where there is no foil layer and adhesive layer can be made to be the surface of the second substrate or the surface of the release layer. The surface of the transfer foil sheet that is exposed in the region where there is no foil layer and adhesive layer is the surface that comes into contact with the surface of the object to be decorated when the transfer foil sheet is applied to the object to be decorated and heated and pressed. Therefore, the texture of the surface of the object to be decorated that comes into contact with the exposed surface can be made different depending on whether the exposed surface is the surface of the second substrate or the surface of the release layer.

[0067] (Article 4) The transfer foil sheet relating to Article 4 is The material comprises a sheet-like substrate, a release layer formed on the substrate having a predetermined planar shape different from the planar shape of the substrate, a foil layer formed on the release layer having the same planar shape as the release layer, and an adhesive layer formed on the foil layer having the same planar shape as the release layer. Such transfer foils can be obtained by the method for manufacturing transfer foil sheets described in paragraphs 1 to 3 above.

[0068] (Article 5) The foil transfer method relating to Article 5 is: A heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer are prepared, and the heat transfer sheet and the foil sheet are placed on top of each other with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet. An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, A transfer foil sheet forming step involves peeling the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet on which the predetermined image is printed to form a transfer foil sheet, The process involves placing the transfer foil sheet with its adhesive layer facing the decorative surface of the object to be decorated, pressing the transfer foil sheet onto the object to be decorated, and then heating the transfer foil sheet. A peeling step of peeling the transfer foil sheet from the surface to be decorated, It holds.

[0069] In the present invention, the "object to be decorated" is an object onto which a foil image is transferred using a transfer foil sheet. Typically, this is a short or long sheet of paper such as a single sheet or continuous sheet, but a sheet-like object made of various materials other than paper, such as metal, plastic, or wood, can also be used as the object to be decorated. Furthermore, any object with a smooth surface to be decorated, such as a flat, curved, or spherical surface, can be used as the object to be decorated, regardless of its shape other than a sheet.

[0070] (Paragraph 6) The foil transfer method relating to Paragraph 6 is the foil transfer method relating to Paragraph 5, In the transfer foil sheet forming step, when the foil sheet is peeled off from the heat transfer sheet and the foil sheet on which the predetermined image is printed, it is configured to peel off at the boundary between the release layer and the second substrate, and when the heat transfer sheet is peeled off from the heat transfer sheet and the foil sheet on which the predetermined image is printed, it is configured to peel off at the boundary between the release layer and the foil layer.

[0071] (Paragraph 7) The transfer sheet manufacturing apparatus relating to Paragraph 7 is A thermal printer with a thermal head, A transport unit that passes a thermal transfer sheet having a first substrate and a thermal transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate, and an adhesive layer formed on the foil layer, through a thermal printer with the thermal transfer layer of the thermal transfer sheet facing the adhesive layer of the foil sheet, and the thermal transfer sheet and the foil sheet stacked together. A print control unit causes the thermal head to print on the thermal transfer sheet and the foil sheet as they pass through the thermal printer, starting from the first substrate side of the thermal transfer sheet. A sheet peeling section for peeling the thermal transfer sheet or the foil sheet from the thermal transfer sheet and the foil sheet that have passed through the thermal printer, It is equipped with.

[0072] (Paragraph 8) The foil transfer apparatus relating to Paragraph 8 is A thermal printer with a thermal head, A transport unit that passes a thermal transfer sheet having a first substrate and a thermal transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate, and an adhesive layer formed on the foil layer, through a thermal printer with the thermal transfer layer of the thermal transfer sheet facing the adhesive layer of the foil sheet, and the thermal transfer sheet and the foil sheet stacked together. A print control unit causes the thermal head to print on the thermal transfer sheet and the foil sheet as they pass through the thermal printer, starting from the first substrate side of the thermal transfer sheet. A sheet peeling section that peels off the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet that have passed through the thermal printer to obtain a transfer foil sheet, A foil transfer unit that places the transfer foil sheet on top of the object to be decorated so that its adhesive layer faces the surface to be decorated, and presses it against the surface to be decorated and heats it, A foil sheet recovery unit for peeling and recovering the transfer foil sheet from the surface to be decorated, A decorative object recovery unit for recovering the decorative object after the transfer foil sheet has been peeled off the decorative surface, It is equipped with. [Explanation of Symbols]

[0073] 100… Foil transfer device 101... Control Unit 11…Thermal transfer sheet supply roller 111... Heat transfer sheet 1111...Base film 1112... Ink layer 112… Heat transfer foil sheet 12… Heat transfer sheet recovery roller 21… Foil sheet supply roller 211… Foil sheet 2111…Base film 2112…Release layer 2113...Metal foil layer 2114...adhesive layer 212…Transfer foil sheet 22... Foil sheet collection roller 31…Decoration target sheet supply roller 311…Decorative sheet 3111…Backing sheet 3112… Label 312… Decorative sheet 32... Decorative sheet collection roller 36... Mark detection unit 37... Mark detection unit 38... Mark detection unit 41… Thermal printer 411...Sensor 412... Thermal head 413... Platen Roller 51... Peeling bar 61… Foil transfer section 62...Pressure roller 63...Heating roller 64... Stripping roller 70… Foil sheet

Claims

1. A heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer are prepared, and the heat transfer sheet and the foil sheet are placed on top of each other with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet. An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, A transfer foil sheet forming step involves peeling the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet on which the predetermined image is printed to form a transfer foil sheet. A method for manufacturing a transfer foil sheet having the following characteristics.

2. The method for manufacturing a transfer foil sheet according to claim 1, wherein the foil sheet comprises a release layer between the second substrate and the foil layer.

3. When the foil sheet is peeled from the heat transfer sheet on which the predetermined image is printed and the foil sheet, the release layer of the foil sheet peels off at the boundary with the second substrate, and when the heat transfer sheet is peeled from the heat transfer sheet on which the predetermined image is printed and the foil sheet, the release layer of the foil sheet peels off at the boundary with the foil layer. A method for manufacturing a transfer foil sheet according to claim 2.

4. A transfer foil sheet comprising a sheet-like base material, a release layer formed on the base material having a predetermined planar shape different from the planar shape of the base material, a foil layer formed on the release layer having the same planar shape as the release layer, and an adhesive layer formed on the foil layer having the same planar shape as the release layer.

5. A heat transfer sheet having a first substrate and a heat transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate and an adhesive layer formed on the foil layer are prepared, and the heat transfer sheet and the foil sheet are placed on top of each other with the heat transfer layer of the heat transfer sheet facing the adhesive layer of the foil sheet. An image printing step in which a predetermined image is printed on the stacked thermal transfer sheet and foil sheet from the first substrate side of the thermal transfer sheet using a thermal printer, A transfer foil sheet forming step involves peeling the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet on which the predetermined image is printed to form a transfer foil sheet, The process involves placing the transfer foil sheet with its adhesive layer facing the decorative surface of the object to be decorated, pressing the transfer foil sheet onto the object to be decorated, and then heating the transfer foil sheet. A peeling step of peeling the transfer foil sheet from the surface to be decorated, A foil transfer method having the following characteristics.

6. In the foil transfer method according to claim 5, A foil transfer method configured such that, in the transfer foil sheet forming step, when the foil sheet is peeled off from the heat transfer sheet and the foil sheet on which the predetermined image is printed, it peels off at the boundary between the release layer and the second substrate, and when the heat transfer sheet is peeled off from the heat transfer sheet and the foil sheet on which the predetermined image is printed, it peels off at the boundary between the release layer and the foil layer.

7. A thermal printer with a thermal head, A transport unit that passes a thermal transfer sheet having a first substrate and a thermal transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate, and an adhesive layer formed on the foil layer, through a thermal printer with the thermal transfer layer of the thermal transfer sheet facing the adhesive layer of the foil sheet, and the thermal transfer sheet and the foil sheet stacked together. A print control unit causes the thermal head to print on the thermal transfer sheet and the foil sheet as they pass through the thermal printer, starting from the first substrate side of the thermal transfer sheet. A sheet peeling section for peeling the thermal transfer sheet or the foil sheet from the thermal transfer sheet and the foil sheet that have passed through the thermal printer, A transfer foil sheet manufacturing apparatus equipped with the following features.

8. A thermal printer with a thermal head, A transport unit that passes a thermal transfer sheet having a first substrate and a thermal transfer layer formed on the first substrate, and a foil sheet having a second substrate, a foil layer formed on the second substrate, and an adhesive layer formed on the foil layer, through a thermal printer with the thermal transfer layer of the thermal transfer sheet facing the adhesive layer of the foil sheet, and the thermal transfer sheet and the foil sheet stacked together. A print control unit causes the thermal head to print on the thermal transfer sheet and the foil sheet as they pass through the thermal printer, starting from the first substrate side of the thermal transfer sheet. A sheet peeling section that peels off the heat transfer sheet or the foil sheet from the heat transfer sheet and the foil sheet that have passed through the thermal printer to obtain a transfer foil sheet, A foil transfer unit that places the transfer foil sheet on top of the object to be decorated so that its adhesive layer faces the surface to be decorated, and presses it against the surface to be decorated and heats it, A foil sheet recovery unit for peeling and recovering the transfer foil sheet from the surface to be decorated, A decorative object recovery unit for recovering the decorative object after the transfer foil sheet has been peeled off the decorative surface, A foil transfer apparatus equipped with the following features.

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