A manufacturing method for forming shapes on the surface of flexible sheet material.

Abstract

The objective is to provide a manufacturing method for forming geometric shapes on the surface of a flexible sheet material. [Solution] In the first manufacturing method, a design is first printed on a heat transfer material, then a covering film is prepared and bonded to the heat transfer material, the figure is cut out from the bonded heat transfer material and covering film, and the figure is heat-pressed onto a flexible sheet material. In the second manufacturing method, a design is first printed on a heat transfer material, the figure is cut out from the heat transfer material, the figure is heat-pressed onto a flexible sheet material, a covering film is prepared, a figure film is cut out from the covering film, and the figure film is bonded onto the figure. Since the figure and its design formed by the manufacturing method of the present invention are covered with the covering film, the integrity of the figure and the colors of the design can be maintained.

Description

Technical Field

[0001] The present invention relates to a method for forming a figure, and particularly to a manufacturing method for forming a figure on the surface of a flexible sheet material.

Background Art

[0002] Currently, in the DIY market, printable heat transfer vinyl is commercially available and can be purchased by consumers. After printing and cutting out a figure on the heat transfer film, the figure can be adhered to clothing by heat treatment. This makes it possible to give clothing a unique pattern and create a unique impression that differentiates from others.

[0003] Manufacturers of heat transfer films produce a variety of heat transfer films with different colors, backgrounds, patterns, etc. to increase consumers' willingness to buy, and display and sell them in stores and the like.

[0004] However, there are multiple problems in manufacturing a variety of heat transfer films. For example, the more diverse the types of heat transfer films, the greater the inventory and storage space, and the occurrence of leftovers and unpopular products increases the cost burden on manufacturers. In addition, with the increase in the types of production, the environmental load increases, which has an unfavorable impact on the global environment.

[0005] Furthermore, regarding printable heat transfer films sold in the DIY market, general consumers use home printers from Epson or HP to print dye-based inks onto the heat transfer film to form designs, or use laser printers to print toners onto the heat transfer film to form designs. In designs formed by heat-pressing heat transfer film onto the surface of clothing, the ink or toner does not adhere sufficiently to the fabric fibers and has low resistance to washing. As a result, after two to three washes, the ink or toner on the design peels off, bleeds, or spreads, causing the design to become incomplete or damaged. In addition, color fading occurs, and the vividness of the colors gradually decreases. Home printers are designed for printing on paper and are not suitable for printing on clothing. Therefore, if the design is incomplete and the colors are not vibrant, consumers will stop wearing the clothing, and it is difficult to completely remove the design from the clothing. As a result, the design is damaged and the appearance is significantly impaired, forcing the clothing to be discarded, leading to waste of resources. [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] One objective of the present invention is to provide a method for forming a figure on the surface of a flexible sheet material, which enables consumers to create a figure with a design through DIY, has a simple design for the product used to create the figure, significantly reduces inventory, and contributes to reducing environmental impact.

[0007] One object of the present invention is to provide a method for forming a figure on the surface of a flexible sheet material, wherein the figure and its design are resistant to washing and maintain the integrity of the shape and the vividness of the colors. [Means for solving the problem]

[0008] The manufacturing method for forming a figure on the surface of a flexible sheet material, provided by the present invention, includes the following steps: Step 1: Prepare a printable thermal transfer material having a printing layer and a heat-adhesive layer, and print a design onto the printing layer. Step 2 involves preparing a covering film comprising a transparent or translucent surface film layer and a second adhesive layer, adhering the covering film to the printing layer of the heat transfer material using the second adhesive layer, and covering the design. Step 3 involves cutting out a figure from the bonded heat transfer material and the coating film, and discarding the parts other than the figure (the cut-out figure includes the laminated printing layer, the heat bonding layer, the surface film layer, and the second adhesive layer), and Step 4 involves heat-pressing the cut-out shape onto a flexible sheet material, bonding the shape to the flexible sheet material via the heat-bonding layer, and covering the cut-out shape with the surface film layer.

[0009] Preferably, step 4 of the present manufacturing method includes preparing a transfer film, transferring the cut-out figure onto the transfer film, placing the transfer film containing the figure onto the flexible sheet material and performing a heat-sealing procedure to bond the figure to the flexible sheet material, and then removing the transfer film.

[0010] Preferably, in step 3 of the manufacturing method, the cutting depth of the figure is such that it penetrates the surface film layer, the second adhesive layer, the printing layer, and the heat-bonding layer.

[0011] Another method for forming a figure on the surface of a flexible sheet material, provided by the present invention, comprises the following steps: Step 1: Prepare a printable thermal transfer material having a printing layer and a heat-adhesive layer, and print a design onto the printing layer of the thermal transfer material. Step 2: Cut out the shape from the heat transfer material and remove the parts other than the shape. Step 3: The cut-out shape is heat-pressed onto the flexible sheet material and bonded to the flexible sheet material via the heat-bonding layer. Step 4 involves preparing a coating film comprising a transparent or translucent surface film layer and a second adhesive layer, and cutting out a graphic film from the coating film that is identical or substantially identical in shape to the graphic, and Step 5: The graphic film is bonded to the graphic using the second adhesive layer, so that the surface film layer of the graphic film covers the graphic.

[0012] Preferably, step 3 of the present manufacturing method includes preparing a transfer film, transferring the cut-out figure onto the transfer film, placing the transfer film containing the figure onto the flexible sheet material and performing a heat-sealing procedure to bond the figure to the flexible sheet material, and then removing the transfer film.

[0013] Preferably, in step 2 of this manufacturing method, the cutting depth of the figure is such that it penetrates the printed layer and the heat-bonded layer, and in step 4, after cutting the figure film from the coating film, the portion other than the figure film is discarded.

[0014] By using either of the two manufacturing methods described above, consumers can DIY create patterns and designs on the surface of flexible sheet materials, and the shape, pattern, style, and color of the patterns and designs can be freely designed or determined by the consumer. The surface film layer covers the patterns and designs, providing them with water-wash resistance and maintaining the integrity of the patterns and the vividness of the colors. Manufacturers only need to produce a small number of types of coating films in addition to the heat transfer material, which significantly reduces production burden and product inventory.

[0015] Preferably, the thermal transfer material includes a carrier layer, and the printing layer and the thermal adhesive layer are separated and provided on the carrier layer.

[0016] Preferably, the coating film includes a release layer, the surface film layer and the second adhesive layer are provided on the release layer, and the surface film layer is located between the release layer and the second adhesive layer.

[0017] Preferably, one surface of the release layer is an embossed uneven surface having an uneven pattern, the surface of the surface film layer contacts the embossed uneven surface, and an uneven pattern is formed on the surface.

[0018] Preferably, one surface of the surface film layer of the coating film is bonded to the second adhesive layer, and the other surface is a pattern surface having a convex pattern or a pattern forming a laser effect, and the pattern forming the laser effect can form an effect such as a surface effect processed by laser or a 2D / 3D effect.

[0019] Preferably, the coating film includes a zinc sulfide layer bonded to one surface of the surface film layer, and the zinc sulfide layer imparts an iridescent effect to the light reflected by the surface film layer.

[0020] Preferably, the coating film includes a metal layer bonded to one surface of the surface film layer, and due to the partial bonding with the metal layer, the surface film layer forms a locally transparent and locally opaque foil-stamped film.

[0021] Preferably, pearl powder or lame powder or phosphorescent powder is added to the surface film layer of the coating film. The pearl powder imparts an iridescent effect to the surface film layer. The lame powder imparts a metallic luster to the surface film layer. The phosphorescent powder imparts a phosphorescent effect to the surface film layer.

[0022] Preferably, minute optical members such as minute convex lenses, minute concave lenses, minute convex or concave water droplet-shaped members are provided on one surface of the surface film layer, so that the surface film layer produces light reflection and refraction effects.

[0023] Preferably, the surface film layer is a transparent or translucent reflective layer provided with a reflective member capable of reflecting light.

[0024] Preferably, the second adhesive layer of the coating film is a hot melt adhesive layer that exhibits adhesiveness upon heating.

[0025] The object, features, and effects of the present invention can be understood from the following description of the preferred embodiments and the drawings.

Brief Description of the Drawings

[0026] [Figure 1] It is a schematic cross-sectional view of the thermal transfer material used in the manufacturing method of the present invention. [Figure 2] It is a schematic cross-sectional view of the coating film used in the manufacturing method of the present invention. [Figure 3] It is a schematic cross-sectional view of the coating film according to multiple embodiments of the present invention (the release layer is omitted in the figure). [Figure 4] It is a schematic cross-sectional view of the coating film according to multiple embodiments of the present invention (the release layer is omitted in the figure). [Figure 4A] It is a schematic top view of FIG. 4. [Figure 5] It is a schematic cross-sectional view of the coating film according to multiple embodiments of the present invention (the release layer is omitted in the figure). [Figure 6] It is a schematic cross-sectional view of the coating film according to multiple embodiments of the present invention (the release layer is omitted in the figure). [Figure 7] It is a schematic cross-sectional view of the coating film according to two other embodiments of the present invention. [Figure 8] It is a schematic cross-sectional view of the coating film according to two other embodiments of the present invention. [Figure 9] It is a diagram showing the steps and products of a manufacturing method for forming a figure on the surface of a flexible sheet material according to the first preferred embodiment of the present invention. [Figure 10] It is a diagram showing the steps and products of a manufacturing method for forming a figure on the surface of a flexible sheet material according to the first preferred embodiment of the present invention. [Figure 11] It is a diagram showing the steps and products of a manufacturing method for forming a figure on the surface of a flexible sheet material according to the first preferred embodiment of the present invention. [Figure 12]This figure shows the process and product of a manufacturing method for forming a figure on the surface of a flexible sheet material according to a first preferred embodiment of the present invention. [Figure 13] This figure shows the process and product of a manufacturing method for forming a figure on the surface of a flexible sheet material according to a first preferred embodiment of the present invention. [Figure 14] This figure shows the process and product of a manufacturing method for forming a figure on the surface of a flexible sheet material according to a first preferred embodiment of the present invention. [Figure 15] This figure shows the process and product of a manufacturing method for forming a figure on the surface of a flexible sheet material according to a first preferred embodiment of the present invention. [Figure 16] This figure shows the process and product of a manufacturing method for forming a figure on the surface of a flexible sheet material according to a first preferred embodiment of the present invention. [Figure 17] Figure 16 is a schematic cross-sectional view of the product (a flexible sheet with a shape molded onto its surface). [Figure 17A] This is a schematic cross-sectional view of another product manufactured according to a first preferred embodiment of the present invention. [Figure 18] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 19] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 20] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 21] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 22] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 23] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 24] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 25] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 26] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 27] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 28] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 29] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 30] This figure shows the steps and product of a manufacturing method according to a second preferred embodiment of the present invention. [Figure 31] Figure 30 is a schematic cross-sectional view of the product (a flexible sheet with a shape molded onto its surface). [Figure 32] This figure shows another product manufactured using the manufacturing method of the present invention. [Figure 33] This figure shows other products of the present invention. [Figure 34] This figure shows other products of the present invention. [Figure 35] This figure shows other products of the present invention. [Figure 36] This figure shows other products of the present invention. [Modes for carrying out the invention]

[0027] This invention discloses manufacturing methods according to two preferred embodiments. Through the printable heat transfer materials and coating films disclosed herein, and the manufacturing process, consumers can DIY mold patterns onto various flexible sheet materials. The flexible sheet material may be fabric, leather, plastic film, rubber sheet, or other flexible material. The fabric may be various woven or nonwoven fabrics, and may be fabrics used for clothing, garments, bags, or pouches, for example (but not limited to), various men's and women's clothing, trousers, socks, shoes, headscarves, scarves, bags, backpacks, tote bags, etc. In this specification, fabric is used as an example of a flexible sheet material and a method for molding patterns onto fabric is described, but similar manufacturing methods are applicable to leather, plastic film, and rubber sheet.

[0028] Referring to Figures 1 and 2, these are cross-sectional views of a printable thermal transfer material 10 and a coating film 20 used in the manufacturing method of the present invention. The thermal transfer material 10 comprises a printing layer 12 and a thermal adhesive layer 14 which is a hot melt adhesive layer bonded to one surface (inner surface) of the printing layer 12. The printing layer 12 and the hot melt adhesive layer 14 are provided on a carrier layer 16, and the hot melt adhesive layer 14 is located between the printing layer 12 and the carrier layer 16. A design can be printed on the other surface (outer surface) of the printing layer 12 using ink or toner with an inkjet printer or laser printer. The thermal transfer material 10 according to this embodiment of the present invention is an aqueous thermal transfer material and has an environmentally friendly configuration. The material of the printing layer is not limited to this embodiment. The carrier layer 16 is preferably made of paper or polymer material and has release properties. The printing layer 12 and the hot melt adhesive layer 14 can be peeled off integrally from the carrier layer 16.

[0029] The coating film 20 is a special film material provided in the present invention, comprising a surface film layer 22 and a second adhesive layer 24 bonded to one surface of the surface film layer 22, the other surface 221 of the surface film layer 22 bonded to a release layer 26. The release layer 26 is made of PET (Polyethylene terephthalate) or CPP (Cast Polypropylene) material, and may be made of paper. The surface film layer 22 is a transparent or translucent layered body, and may be made of a polymer thin film such as a PU film, but is not limited thereto. As shown in Figure 2, the surface film layer 22 is formed by coating liquid PU onto the release layer 26. The second adhesive layer 24 is preferably a heat-activated adhesive layer that exhibits adhesive properties upon heating. In a preferred embodiment of the present invention, the adhesive layer 24 may be a transparent hot-melt adhesive made of a material such as PP (Polypropylene), TPE (Thermoplastic elastomer), TPU (Thermoplastic polyurethane), PES (Polyethersulfone), or EVA (Ethylene Vinyl Acetate), and is provided on the other surface of the surface film layer 22 by a coating or bonding method.

[0030] Refer to Figure 2. An embossed surface 261 having a pattern may be formed on one surface of the release layer 26. Preferably, the pattern consists of multiple types of patterns, for example, fine uneven shapes. The uneven pattern may be regular or irregular, and may include, but is not limited to, dotted or striped patterns. After the surface film layer 22 is applied to the embossed surface 261 and molded, the surface in contact with the embossed surface 261 is treated or specially made to become a patterned surface 221 having an embossed pattern 222, the pattern 222 of which mirrors the embossed surface 261. The surface film layer 22 and the adhesive layer 24 can be peeled off integrally from the release layer 26.

[0031] As an alternative, the pattern 222 on the patterned surface 221 of the surface film layer 22 has an appearance similar to a transparent laser-processed surface. That is, the patterned surface 221 exhibits a laser-treated surface effect or a 2D / 3D visual effect. The pattern 222 can be formed via the embossed uneven surface 261 of the release layer 26.

[0032] Referring to Figure 3, as an alternative example, a zinc sulfide layer 27 is applied to one surface of the surface film layer 22 of the coating film 20A, thereby imparting an iridescent effect to the surface film layer 22, that is, the light reflected from the surface film material exhibits a variety of colors. The zinc sulfide layer 27 is positioned between the surface film layer 22 and the adhesive layer 24.

[0033] Referring to Figure 4, as an alternative example, a metal layer 28 is provided on one surface of the surface film layer 22 of the coating film 20B. The metal layer 28 may be a chrome-plated layer, an aluminum-plated layer, or another suitable metal layer, and is provided on one surface of the surface film layer 22 by plating or coating, and is positioned between the surface film layer 22 and the adhesive layer 24, thereby forming a foil-stamped film on the surface film layer 22. Referring to Figure 4A, this is a schematic top view of the coating film 20B, showing only the surface film layer 22 and the metal layer 28. The metal layer 28 is provided only on a portion of the surface of the surface film layer 22 and does not cover the entire surface film layer 22, so the portion of the surface film layer 22 not covered by the metal layer 28 remains transparent or translucent, ensuring the visibility of the design on the heat transfer material. The metal layer 28 may be regular or irregular, and may include shapes such as dots or stripes. Figure 4A shows an example of the shape of the metal layer 28, but it is not limited to this example.

[0034] Referring to Figure 5, as an alternative example, 1 to 5% by weight of an additive 29 may be mixed into the surface film layer 22C of the coating film 20C, and the additive 29 may be pearl powder, glitter powder (colored fine aluminum foil), or phosphorescent powder (phosphorescent particles). The pearl powder imparts an iridescent effect to the surface film layer 22C, the glitter powder imparts a metallic luster to the surface film layer 22C, and different shades of metallic luster can be obtained depending on the color of the glitter powder. The phosphorescent powder imparts a phosphorescent effect to the surface film layer 22C, making it possible to emit light at night.

[0035] Referring to Figure 6, as an alternative example, a fine optical structure is formed on the patterned surface 221 of the surface film layer 22D of the coating film 20D, and minute optical members are provided. For example, minute convex lenses 223 or concave lenses, or minute droplet-shaped members (hereinafter abbreviated as "small droplets") are provided, and preferably these convex lenses 223, concave lenses, or small droplets are formed by the embossed uneven surface 261 of the release layer 26. Each convex lens 223 has a structure that is convex outward and protrudes from the surface of the surface film layer 22. Each concave lens has a structure that is concave inward and is formed recessed from the patterned surface 221 of the surface film layer. Each small droplet may have a structure that is convex outward or concave inward. The convex lenses 223, concave lenses, or small droplets produce light reflection and refraction effects on the surface of the surface film layer 22D.

[0036] As an alternative example, the surface film layer of the coating film is a transparent or translucent reflective material. In the coating film 20E shown in Figure 7, a transparent or translucent reflective layer 25 is used as the surface film layer 22E, and the reflective layer 25 is a layer made up of tiny glass microspheres, and one surface of the glass microsphere layer 25 is bonded to the second adhesive layer 24 by a transparent adhesive or adhesive 251. A release layer 26 is provided on the other surface of the glass microsphere layer. The surface film layer 22E and the second adhesive layer 24 can be integrally separated from the release layer 26.

[0037] As an alternative example, referring to Figure 8, the coating film 20F comprises a transparent or translucent surface film layer 22F, a second adhesive layer 24, and a release layer 26. The surface film layer 22F comprises a glass microsphere layer 25, a transparent or translucent adhesive or adhesive 251, and a zinc sulfide layer 252. The zinc sulfide layer 252 is applied to or coated on one surface of the glass microsphere layer 25 and is located between the glass microsphere layer 25 and the second adhesive layer 24. The adhesive 251 is a TPU, PUR (Polyurethane Reactive), or acrylic hot melt adhesive. The surface film layer 22F can reflect light, and the zinc sulfide layer 252 imparts an iridescent effect to the reflected light. The surface film layer 22F and the second adhesive layer 24 can be integrally separated from the release layer 26.

[0038] In the embodiments disclosed herein, the surface film layers 22, 22F having zinc sulfide layers 27, 252 and the surface film layer 22C to which pearl powder or glitter powder is added are translucent film materials. The surface film layer 22 shown in Figure 2, the surface film layer 22 having a metal layer shown in Figure 4, and the surface film layers 22D, 22E shown in Figures 6 and 7 may be transparent or translucent film materials.

[0039] (First Preferred Embodiment) Figures 9 to 16 show a method for forming a pattern on a fabric surface in a first preferred embodiment of the present invention, which includes the following steps. The coating layer 20 and surface film layer 22 described below include the coating layer and surface film layer shown in each embodiment of Figures 2 to 8.

[0040] Step 1: Prepare the printable heat transfer material 10 shown in Figure 1, and print the design 32 onto the heat transfer material 10.

[0041] Computer printing is a printing technology that can be easily implemented even in ordinary households. Figure 9 (including Figures 9A to 9C) shows how a consumer prints a design 32 on the printing layer 12 of the thermal transfer material 10 using ink or toner with an Epson or HP home printer 30. The design 32 can consist of various figures such as people, animals, non-people, non-animals, letters, or non-letters, and can be expressed in one color or multiple colors, with multiple colors being particularly preferred. Figures 9A to 9C show three different designs 32. Figure 9A is a design of a non-animal with feathers, Figure 9B is a design of a fish, and Figure 9C is a design of a person. Consumers can freely design and print the patterns, styles, and colors of the design 32. The ink that can be printed on the printing layer 12 may be dye ink or sublimation ink (also called thermal sublimation ink).

[0042] Step 2: Prepare the covering film 20 shown in Figure 2, and bond the covering film onto the printing layer 12 of the printing paper 10 to cover the design 32.

[0043] Referring to Figure 10 (including Figures 10A to 10C), the covering film 20 is placed on the heat transfer material 10, and the covering film 20 is bonded to the printing layer 12 of the heat transfer material 10 by the second adhesive layer 24, covering the design 32. The adhesive layer 24 is a hot melt adhesive that becomes adhesive when heated, so consumers can heat the covering film 20 and the heat transfer material 10 using an ironing appliance at home, such as an electric iron or the heat press machine 34 shown in Figures 10A and 10B, so that the covering film 20 is bonded to the printing layer 12 via the second adhesive layer (hot melt adhesive) 24, covering and protecting the design 32. After the coating film 20 and the heat transfer material 10 are bonded together, the release layer 26 of the coating film 20 is peeled off, leaving only the surface film layer 22 of the coating film 20 on the printing layer 12 of the heat transfer material 10, covering the design 32 and preventing the design 32 from coming into contact with the outside.

[0044] Step 3: Cut out the shape from the bonded heat transfer material and the covering film.

[0045] The heat transfer material 10 and the surface film layer 22 of the coating film 20, bonded together in step 2, form a laminated film material 40 (see Figure 12). Next, referring to Figure 11 (including Figures 11A to 11C), a shape is cut out from the laminated film material 40. Consumers can cut it using a home cutting machine 42, such as a CRICUT cutting machine, as shown in Figure 11A. Alternatively, as shown in Figure 11B, the shape can be cut out manually from the laminated film material 40 using cutting tools such as a utility knife or scissors. The home cutting machine 42 cuts the shape under computer control, and the bird shape shown in Figure 13 is a shape 45 cut out by the cutting machine 42 in Figure 11A. Referring to Figure 12, the cutting depth D of the blade of the cutting machine 42 is the depth to penetrate the surface film layer 22, the second adhesive layer 24, the printed layer 12 on which the design 32 is printed, and the hot melt adhesive layer 14. Figure 11B shows an example of cutting out a fish shape 45 with scissors. Figure 11C shows how a cutting machine 42 cuts out a shape from a laminated film material 40, and the cutting machine 42 cuts out a rectangular shape 45 along the outline of the design 32.

[0046] Step 4: Remove the parts other than the figure 45 (waste material), leaving only the cut-out figure.

[0047] Referring to Figure 13, the parts other than the figure 45 are peeled off, that is, the waste material 46 that does not belong to the figure 45 is removed, leaving only the figure 45. The figure 45 formed by cutting includes the hot melt adhesive layer 14, the printed layer 12 on which the design 32 is printed, the second adhesive layer 24, and the surface film layer 22, all of the same shape and laminated from bottom to top.

[0048] Step 5: The cut-out figure is heat-pressed onto the fabric, the inner surface of the cut-out design is bonded to the fabric with the hot-melt adhesive layer, and the surface film layer covers the outer surface of the cut-out design.

[0049] Referring to Figure 14, a transfer film 52 is prepared, and the cut-out figure 45 is transferred onto the transfer film 52. When the figure 45 is transferred to the transfer film 52, it is separated from the carrier layer 16 of the heat transfer material. As described above, the printing layer 12 and the hot melt adhesive layer 14 can be easily separated from the carrier layer 16, so the figure 45 (including the laminated surface film layer 22, the second adhesive layer 24, the printing layer 12, and the hot melt adhesive layer 14) is adhered or attached to the transfer film 52 after being separated from the carrier layer 16.

[0050] Next, as shown in Figure 15 (including Figures 15A and 15B), the transfer film 52 containing the figure 45 is placed on the fabric 55, and the hot melt adhesive layer 14 of the figure 45 is brought into contact with the fabric 55. Then, the transfer film 52 and the figure 45 are heated with an electric iron or a heat press 34, the hot melt adhesive layer 14 is heated and develops adhesion, and the figure 45 is adhered to the surface of the fabric 55 (see Figures 16 and 17). The design 32 of the figure 45 is covered by the surface film layer 22, that is, the design 32 is isolated by the surface film layer 22.

[0051] Figure 17A is a cross-sectional view of a product manufactured by the manufacturing method according to the first preferred embodiment. When the surface film layer 22 is the surface film layer (22E, 22F) shown in Figure 7 or Figure 8, it has a reflective function. During the day, the surface film layer 22 does not reflect light, but at night, the glass microsphere layer 25 of the surface film layer 22 reflects light, imparting a reflective effect to the design 32.

[0052] (Second Preferred Embodiment) Figures 18 to 30 show a method for forming a pattern on a fabric surface in a second preferred embodiment of the present invention, which includes the following steps. The coating layer 20 and surface film layer 22 described below include the coating layer and surface film layer shown in each embodiment of Figures 2 to 8.

[0053] Step 1: Prepare the printable heat transfer material 10 shown in Figure 1, and print the design 32 onto the heat transfer material 10.

[0054] As shown in Figure 18, a design 32 is computer-printed onto the printing layer 12 of the thermal transfer material 10 using a home printer 30. The design 32 can consist of various figures such as people, animals, non-people, non-animals, letters, or non-letters. This process is the same as the printing process shown in Figures 9A to 9C, so a detailed explanation is omitted.

[0055] Referring to Figure 19, after the printing of the design 32 is completed, the design 32 can be heated with an electric iron or a heat press 34 to dry the ink of the design and fix it in place.

[0056] Step 2: Cut out the figure 60 from the heat transfer material, remove the parts other than the figure, and leave only the figure 60.

[0057] As shown in Figure 11B, the shape can be cut out from the heat transfer material 10 manually using a utility knife or scissors, or, as shown in Figure 20A or Figure 20B, the shape 60 can be cut out from the heat transfer material 10 using a household cutting machine 42 under computer control. The cutting depth D of the shape 60 is the depth that penetrates the printed layer 12 and the hot melt adhesive layer 14 (see Figure 21).

[0058] Next, as shown in Figure 22, the parts other than the figure 60 are peeled off and the waste material 62 is removed, leaving only the figure 60 on the carrier layer 16. At this time, the figure 60 includes the printed layer 12 on which the design 32 is printed and the hot melt adhesive layer 14.

[0059] Step 3: The cut-out shape 60 is heat-pressed onto the fabric and bonded to the fabric via the hot-melt adhesive layer.

[0060] Please refer to Figure 23 (including Figures 23A and 23B). A transfer film 52 is prepared, and the cut-out figure 60 is transferred onto the transfer film 52. After the figure 60 is transferred to the transfer film 52, it is separated from the carrier layer 16 of the heat transfer material 10.

[0061] Next, as shown in Figure 24 (including Figures 24A and 24B), the transfer film 52 containing the figure 60 is placed on the fabric 55, the hot melt adhesive layer 14 of the figure 60 is brought into contact with the fabric 55, and then the transfer film 52 and the figure 60 are heated with an electric iron or a heat press machine 34, the hot melt adhesive layer 14 is heated and develops adhesive properties, and the figure 60 is adhered to the surface of the fabric 55.

[0062] Step 4: Prepare the covering film 20 shown in Figure 2, cut out a graphic film 70 from the covering film that is the same as or substantially the same as the graphic 60 in shape to cover the graphic 60, and remove the waste material 72 other than the graphic film 70.

[0063] The covering film 20 shown in Figure 2 is taken, and the graphic film 70 is cut out from the covering film 20 by hand or by a household cutting machine 42 shown in Figure 25. Figure 26 shows the graphic film 70. The shape of the graphic film 70 is the same as or substantially the same as the shape of the graphic 60. By using computer cutting, that is, a computer-controlled cutting machine 42, it is possible to cut out a graphic film 70 that matches the shape of the graphic 60. On the other hand, by hand, it is possible to obtain a graphic film 70 that is substantially the same shape as the graphic 60. It is desirable that the graphic film 70 completely covers the graphic 60.

[0064] Next, as shown in Figure 26 (including Figures 26A and 26B), the portion other than the graphic film 70, i.e., the waste material 72, is removed so that only the cut graphic film 70 remains on the covering film 20. The graphic film 70 includes a laminated surface film layer 22 and a second adhesive layer 24. As is clear from Figures 25 and 26, a fine uneven pattern 222 is formed on the surface of the surface film layer 22, so that the surface film layer 22 is a translucent film material. Note that the pattern 222 shown in Figures 25 and 26 is just an example and does not limit the present invention.

[0065] Step 5: The graphic film 70 is bonded to the graphic 60 via the second adhesive layer 24, so that the surface film layer 22 of the graphic film covers the graphic 60, that is, covers the outer surface of the graphic 60.

[0066] Please refer to Figure 27. Take the transfer film 52 and transfer the graphic film 70 to the transfer film 52. The graphic film 70 is separated from the release layer 26 of the coating film. At this time, the graphic film 70 is composed of the surface film layer 22 and the second adhesive layer 24 of the coating film 20 and is attached to or bonded to the transfer film 52. Figure 27 shows the state in which the graphic film 70 has been transferred to the transfer film 52.

[0067] Next, as shown in Figure 27, the graphic film 70 is aligned with the graphic 60 on the fabric 55, and as shown in Figure 28, the transfer film 52 and the graphic film 70 are heated with an electric iron or a heat press 34 so that the second adhesive layer (hot melt adhesive) 24 becomes adhesive, and the graphic film 70 is adhered to the surface of the graphic 60. Finally, as shown in Figure 29 (including Figures 29A and 29B), the transfer film 52 is peeled off and the graphic 60 and the graphic film 70 are adhered to the fabric 55, thereby completing the manufacturing method of the present invention, and the product is shown in Figures 30 and 31. The graphic 60 and the graphic film 70 are adhered to the surface of the fabric 55, and the graphic film 70 is adhered on the graphic 60, and the printed design 32 on the printing layer 12 is covered and protected by the surface film layer 22, so it is not susceptible to damage. The appearance of the figure 60 and the design 32 is given a visual pattern effect formed by the pattern 222 of the surface film layer 22.

[0068] Figure 32 shows another product obtained by the manufacturing method of the present invention, which can be manufactured by the manufacturing method of the first or second preferred embodiment. After manufacturing, a figure 45(60) with a design 32 is formed on the fabric 55, and the design 32 of the figure is covered with a surface film layer 22. Since the surface film layer 22 of this product contains glitter powder, a metallic luster effect is imparted to the surface of the figure 45(60).

[0069] Figures 33 to 36 show another product obtained by the manufacturing method of the present invention, in which a figure 45 having multiple peacock patterns 32 is formed on a fabric 55, and the surface film layer of each figure 45 has a different surface effect. As shown in Figure 34, the surface film layer of figure 45A has a striped pattern, and the structure of figure 45B is the same as that shown in Figure 17A, and the surface film layer is a reflective film layer and comprises a glass microsphere layer 25 as shown in Figure 7 or Figure 8. As shown in Figures 33 and 35, when figure 45B is not reflective, the pattern of the figure can be seen. At night or in a dimly lit place, when light is shone on figure 45B (see Figure 36), the surface film layer of figure 45B reflects the light, exhibiting an effect that improves safety.

[0070] According to the manufacturing method provided by the present invention, a figure with a design 32 can be formed on fabric such as clothing or trousers. The figure and its design are protected and isolated by the surface film layer 22, so that the figure is not damaged, and the ink or toner used in the design 32 does not bleed, spread, or peel off, thus maintaining the integrity of the figure and its design on the fabric and preserving the vividness of the design's colors. In tests conducted by the inventors, even after washing the fabric 20 times in 60°C water and drying it, the figure and its design remained in perfect condition, the colors remained bright and vivid, and no damage or fading was observed.

[0071] By forming a pattern 222 on the patterned surface 221 of the surface film layer, a pattern effect, such as the pattern shown in Figure 30, or a 2D / 3D visual effect can be imparted to the design 32. By coating the surface film layer 22 with a zinc sulfide layer or a metal layer, it is possible to impart a rainbow effect or a foil stamping effect to the design 32. The metal layer is not arranged across the entire surface film layer 22, allowing it to be displayed without impairing the visibility of the design 32. By adding pearl powder, glitter powder, or phosphorescent powder to the surface film layer 22, a rainbow effect, metallic luster, or phosphorescent effect can also be imparted to the design. Through the various effects described above, the aesthetic appeal and visual impression of the design are improved.

[0072] In addition to heat transfer materials, the present invention only requires the production of a small number of coating films 20 with specifications, namely, a surface film layer having a surface film layer, a sulfide layer, a metal layer, pearl powder, glitter powder, and phosphorescent powder, regardless of whether or not embossing is present. Because there are few types of coating films to be produced, businesses can avoid complexity in product variety, maintain less inventory, reduce manufacturing and inventory costs, and are also environmentally friendly.

[0073] The manufacturing method of the present invention enables consumers to mold figures and designs onto flexible sheet materials in a DIY manner while maintaining the integrity of the figures and designs. For manufacturers, the manufacturing method of the present invention allows for a significant reduction in the number of product types, thereby reducing manufacturing and development costs. [Explanation of Symbols]

[0074] 10 Thermal transfer materials 12 printing layer 14. Hot melt adhesive layer 16 Career Level 20 (20A~20F) Covering film 22(22C~22F) Surface film layer 222 patterns 223 Convex lens 24. Second adhesive layer 25 Reflective layer 26. Delamination layer 252, 27 Zinc sulfide layer 28 Metal layer 29 Additives 30 Printers 32 designs 34. Heat-pressing press machine 40. Multilayer film materials 42 Cutting Machines 45, 45A, 45B, 60 Shapes 46, 72 waste materials 52 Transfer film 55 Fabric 70 graphic film D Cutting depth

Claims

1. Step 1 involves preparing a printable heat transfer material having a printing layer and a heat-adhesive layer, and printing a design onto the printing layer of the printable heat transfer material. Step 2 involves preparing a covering film comprising a transparent or translucent surface film layer and a second adhesive layer, adhering the covering film to the printing layer of the heat transfer material with the second adhesive layer, and covering the design. Step 3: Cut out a figure from the heat transfer material and the coating film which have a design and are bonded together, remove the parts other than the figure, and leave the cut-out figure which includes the printed layer of the laminated printable heat transfer material, the heat adhesive layer, the surface film layer of the coating film and the second adhesive layer. Step 4 involves heat-pressing the cut-out shape onto a flexible sheet material, bonding the shape to the flexible sheet material via the heat-bonding layer, and the surface film layer covering the cut-out shape. A manufacturing method for forming shapes on the surface of a flexible sheet material, including [specific example].

2. The manufacturing method according to claim 1, wherein the cutting depth of the figure is the depth that penetrates the surface film layer, the second adhesive layer which is a hot melt adhesive layer, the printing layer and the heat bonding layer.

3. Step 1 involves preparing a printable thermal transfer material having a printing layer and a heat-adhesive layer, and printing a design onto the printing layer of the thermal transfer material. Step 2 involves cutting out a figure from the heat transfer material having a design and removing parts other than the figure, Step 3 involves heat-pressing the cut-out shape onto the flexible sheet material and bonding it to the flexible sheet material via the heat-bonding layer, Step 4 involves preparing a covering film comprising a transparent or translucent surface film layer and a second adhesive layer, and cutting out a graphic film from the covering film that can cover the graphic, Step 5 involves adhering the graphic film to the graphic using the second adhesive layer, so that the surface film layer of the graphic film covers the graphic. A manufacturing method for forming shapes on the surface of a flexible sheet material, including [specific example].

4. The method for manufacturing according to claim 1, 2, or 3, wherein the thermal transfer material includes a carrier layer, and the printing layer and the heat-adhesive layer are separated and provided on the carrier layer.

5. The manufacturing method according to claim 1, 2, or 3, wherein the coating film includes a release layer, the surface film layer and the second adhesive layer are provided on the release layer, and the surface film layer is located between the release layer and the second adhesive layer.

6. The manufacturing method according to claim 5, wherein one surface of the release layer is an embossed uneven surface having an uneven pattern, the surface of the surface film layer is in contact with the embossed uneven surface, and an uneven pattern is formed on the surface.

7. The manufacturing method according to claim 1 or 3, wherein one surface of the surface film layer of the coating film is bonded to the second adhesive layer, and the other surface is a patterned surface having a pattern.

8. The manufacturing method according to claim 7, wherein the pattern of the preceding surface film layer is an uneven pattern or a pattern that forms a laser effect.

9. The manufacturing method according to claim 1 or 3, wherein the coating film includes a zinc sulfide layer bonded to one surface of the surface film layer.

10. The manufacturing method according to claim 1 or 3, wherein the coating film includes a metal layer bonded to one surface of the surface film layer, and the metal layer is not arranged over the entire surface film layer.

11. The manufacturing method according to claim 1 or 3, wherein pearl powder, glitter powder, or phosphorescent powder is added to the surface film layer of the coating film.

12. The manufacturing method according to claim 1 or 3, wherein a minute optical element, such as a minute convex lens, a minute concave lens, or a minute convex or concave droplet-shaped member, is provided on one surface of the surface film layer.

13. The manufacturing method according to claim 1 or 3, wherein the surface film layer is a transparent or translucent reflective layer comprising a reflective member.

14. The manufacturing method according to claim 1 or 3, wherein step 3 includes the steps of preparing a transfer film, transferring the cut-out figure to the transfer film, placing the transfer film containing the figure on the flexible sheet material and performing a heat-pressing procedure to bond the figure to the flexible sheet material, and then removing the transfer film.

15. The manufacturing method according to claim 3, wherein in step 2, the cutting depth of the figure is such that it penetrates the printing layer and the heat-bonding layer, the second adhesive layer of the coating film is a hot-melt adhesive layer, and in step 4, after cutting out the figure film from the coating film, the portion other than the figure film is discarded.

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