Method for manufacturing transfer foil by composite printing and transfer foil

Abstract

The problem addressed by the present disclosure is to make it possible to manufacture transfer foil with improved designability in multiple designs and multiple color tones at once without plate restrictions even in minimum lots. In this method for manufacturing transfer foil 1, transfer foil in which a release layer 20, a color ink layer 30, a masking layer 40, and an adhesive layer 50 are laminated on one surface of a support sheet 10 in the stated order is manufactured such that the masking layer 40 and the adhesive layer 50 are each formed by screen printing and the color ink layer 30 is formed by digital printing.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a transfer foil and a transfer foil, and more particularly, to a method for manufacturing a transfer foil and a transfer foil that use a combination of screen printing and digital printing.

Background Art

[0002] Conventionally, as a method of decorating the surface of an object to be transferred with patterns, colors, etc., a method using a transfer foil in which transfer layers such as a release layer, a color ink layer, and an adhesive layer are laminated on a support sheet has been used. For such transfer foils, in order to enhance the product image of the decorated object obtained by transfer, etc., it is required to improve the designability.

[0003] The printing method for each layer may be single or a combination of multiple printing methods, and when combining, it is necessary to align the printing positions. If the printing methods are the same rotogravure method, alignment is easy, but since roll-to-roll screen printing is intermittent feeding, it has been difficult to combine with the rotogravure method.

[0004] Further, Patent Document 1 discloses a transfer foil in which a release layer, a polarizing ink layer, a color ink layer, and a heat-sensitive adhesive layer are sequentially laminated on one side of a base film, and as the polarizing ink for forming the polarizing ink layer, 10 to 15% by weight of a pearl pigment is added to a transparent resin, and both sides of the polarizing ink layer are covered with a two-component curable primer. According to this transfer foil, by providing a specific polarizing ink layer, it is said that a true pearl luster can be given to the pattern and a decorative effect superior to that of the pattern by the color ink can be exhibited.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

[0006] The formation of each layer responsible for the design property of such a transfer foil is usually carried out by gravure printing (large lot), screen printing (small to medium lot), etc. However, in reality, production in extremely small lots is often required. Also, in terms of the design aspect, improvement in design property is often sought through a combination of tonal expression characteristic of gravure printing, high concealment expression characteristic of screen printing, functional ink expression, etc. Nevertheless, in the case of a composite transfer foil of gravure printing and screen printing, not only can it not handle extremely small lots, but there are also problems such as issues with printing alignment accuracy, longer delivery times, and cost increases (increase in plate cost, increase in film cost, increase in ink cost), etc., and it was not practical.

[0007] An object of the present disclosure is to provide a method for manufacturing a transfer foil and a transfer foil capable of manufacturing a transfer foil with improved design property without plate constraints, at once with a plurality of designs and a plurality of color tones, even in an extremely small lot.

[0008] A method for manufacturing a transfer foil according to an aspect of the present disclosure is a method for manufacturing a transfer foil in which a release layer, a color ink layer, a concealment layer, and an adhesive layer are laminated in this order on one surface of a support sheet. Each of the concealment layer and the adhesive layer is formed by screen printing, and the color ink layer is formed by digital printing.

[0009] A transfer foil according to an aspect of the present disclosure includes a support sheet, a release layer, a color ink layer, a concealment layer, and an adhesive layer laminated in this order. Each of the concealment layer and the adhesive layer consists of a screen printing layer, and the color ink layer consists of a digital printing layer.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

[0011] Hereinafter, embodiments of the present disclosure will be described. Note that the present disclosure is not limited to the following embodiments. The following embodiments are only a part of various embodiments of the present disclosure, and various modifications can be made according to the design as long as the object of the present disclosure can be achieved.

[0012] The method for manufacturing the transfer foil of the present embodiment is for manufacturing a transfer foil in which a release layer, a color ink layer, a concealment layer, and an adhesive layer are laminated in this order on one surface of a support sheet.

[0013] The inventors have intensively studied a method for enhancing the designability of the transfer foil. As a result, it has been found that by setting the printing methods of the respective layers constituting the transfer foil to a specific combination, the designability can be improved and it is also suitable for extremely small lot production, and the present disclosure has been completed.

[0014] <Method for manufacturing transfer foil> In the method for manufacturing the transfer foil of the present embodiment (hereinafter also referred to as manufacturing method (X)), in a method for manufacturing a transfer foil in which a release layer, a color ink layer, a concealment layer, and an adhesive layer are laminated in this order on one surface of a support sheet, each of the concealment layer and the adhesive layer is formed by screen printing, and the color ink layer is formed by digital printing.

[0015] In manufacturing method (X), other concealment layers and / or anchor layers may be further formed in addition to the above layers. A flow chart showing manufacturing method (X) including the formation of other concealment layers and anchor layers is shown in FIG. 1.

[0016] The manufacturing method (X) shown in the flowchart of FIG. 1 includes a release layer forming step (S1), another concealment layer forming step (S11), a color ink layer forming step (S2), an anchor layer forming step (S12), a concealment layer forming step (S3), and an adhesive layer forming step (S4) in this order.

[0017] In the manufacturing method (X), the shielding layer 40 and the adhesive layer 50 are each formed by screen printing, and the color ink layer 30 is formed by digital printing.

[0018] Figures 2 to 4 are cross-sectional views showing an example of a transfer foil manufactured by the manufacturing method (X). The transfer foil 1 in Figure 2 includes a support sheet 10, a release layer 20, another shielding layer 110, a color ink layer 30, an anchor layer 120, a shielding layer 40, and an adhesive layer 50. The transfer foil 1 in Figure 3 includes a support sheet 10, a release layer 20, a color ink layer 30, an anchor layer 120, a shielding layer 40, and an adhesive layer 50. The transfer foil 1 in Figure 4 includes a support sheet 10, a release layer 20, a color ink layer 30, a shielding layer 40, and an adhesive layer 50.

[0019] The transfer foil 1 in Figure 2 includes another shielding layer 110 between the release layer 20 and the color ink layer 30. Also, an anchor layer 120 is provided between the color ink layer 30 and the shielding layer 40. In the manufacturing method (X), when the transfer foil 1 includes another shielding layer 110, it is preferable to form the other shielding layer 110 by screen printing. Also, when the transfer foil 1 includes an anchor layer 120, it is preferable to form the anchor layer 120 by screen printing.

[0020] In this way, by setting the printing method for each layer constituting the transfer foil to a specific printing method, the design property of the obtained transfer foil can be enhanced. The reason why the manufacturing method (X) has such a configuration and exhibits the effect of improving the design property is, for example, that the advantages of screen printing (high shielding expression, high chroma, expression of gold, silver, pearl, etc.) and the advantages of digital printing (shading expression, thin line expression, gradation expression, photographic image reproducibility, etc.) are effectively combined. Also, since digital printing does not require a plate, it is possible to immediately adjust the shading freely on the data, adjust thin lines and tones at the printing site, and print and confirm or propose multiple types of changed patterns at once.

[0021] In addition, since the manufacturing method (X) combines screen printing and digital printing, it is different from the conventional transfer foil manufacturing method in which each layer is formed by gravure printing or the like and is suitable for mass production, and can suitably respond to the production of extremely small lots. According to such a manufacturing method suitable for extremely small lots, the delivery time can be shortened and the production of a variety of products becomes more possible. Therefore, it becomes easier and can be done earlier to make proposals using various samples and the like. Also, a plate for the color ink layer to be digitally printed is not required, and it is also possible to shorten the conventional plate-making time.

[0022] Furthermore, according to the manufacturing method (X), compared with the conventional transfer foil manufacturing method using gravure printing or the like, a significant cost reduction in plate-making costs can be achieved, the amount of solvent used in manufacturing can also be significantly reduced, and the effect of reducing the environmental load can also be obtained. Also, in ordinary gravure printing and screen printing, when a customer performs color calibration of a new product pattern, it is necessary to perform multiple color proofs, change the plate, and taste the color repeatedly over several days. However, with digital printing, it is possible to make a one-shot decision by showing samples with multiple color adjustments and design adjustments on the spot at once, and the delivery time for launching a new product can be shortened. Hereinafter, each step will be described.

[0023] [Release layer forming step (S1)] In this step (S1), a release layer 20 is formed on one surface of the support sheet 10. The release layer 20 is provided to improve the releasability between the support sheet 10 and the color ink layer 30 or another concealing layer 110, and to improve the transferability of the transfer foil 1 to the object to be transferred.

[0024] The support sheet 10 preferably has flexibility, heat resistance, mechanical strength, chemical resistance, etc. that are difficult to cause softening deformation due to heat pressure in a heat transfer process or the like. Examples of the material of the support sheet 10 include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate, polyvinyl chloride, polycarbonate, poly(meth)acrylate ester, polystyrene, polyethylene, polypropylene, triacetyl cellulose, polyvinyl alcohol, polyimide and other synthetic resins, natural resins, paper, synthetic paper, etc., and composites obtained by combining these. Among these, polyester is preferable, and polyethylene terephthalate is more preferable. The support sheet 10 is preferably subjected to matting treatment with a silicone resin or the like.

[0025] As the support sheet 10, a long sheet is usually used. From the viewpoint of maintaining sufficient flexibility and the like, the thickness of the support sheet 10 is preferably 19 μm or more and 100 μm or less, and more preferably 25 μm or more and 70 μm or less. Further, for example, it is preferable to apply a release agent such as silicone, melamine, alkyd, or UV-curable polyol resin to the surface of the support sheet 10 according to the need for releasability and then use it.

[0026] In step (S1), the method for forming the release layer 20 is not particularly limited, and it can be formed by, for example, screen printing, gravure printing, etc. However, it is preferable to form the release layer 20 by screen printing. "Screen printing" is a type of stencil printing. It is a printing method in which a screen printing plate provided with a fine mesh woven with synthetic fibers such as polyester or metal fibers such as stainless steel is used, and ink is passed through this mesh to perform printing on an object. In screen printing, a screen printing plate with a mesh corresponding to the pattern, thickness, etc. of each layer to be formed is used.

[0027] In step (S1), when forming the release layer 20 by screen printing, the ink used (hereinafter also referred to as ink (S1)) preferably has low adhesion to the support sheet 10 and appropriate adhesion to the color ink layer 30 or other concealing layers 110. Examples of the components of the ink (S1) include vinyl chloride-vinyl acetate resins (vinyl chloride-vinyl acetate resins), urethane resins, acrylic resins, polyester resins, and the like. The ink (S1) may contain a curing agent. From the viewpoint of making the adhesion to the color ink layer 30 or other concealing layers 110 more appropriate, polyester-based ink (S1) is preferred. When the ink (S1) contains a solvent, cyclohexanone, isophorone, high-boiling aromatic solvents, etc. are desirable for screen printing, and toluene, methyl ethyl ketone, ethyl acetate, etc. are desirable for gravure printing. Also, when printing the ink (S1) on the support sheet 10, it is desirable to use additives to improve the leveling property of the ink film and the defoaming property of the ink.

[0028] The release layer 20 formed by step (S1) is usually a layer with a substantially uniform thickness. The thickness of the release layer 20 is, for example, 0.5 μm or more and 5 μm or less, and preferably 0.7 μm or more and 3 μm or less.

[0029] [Other Concealing Layer Forming Step (S11)] In this step (S11), another concealing layer 110 is formed on the surface of the release layer 20. Another concealing layer 110 is provided to conceal the color and pattern of the object to be transferred to improve the design property, or when decoration such as gold, silver, and pearl is required. Examples of the color of another concealing layer 110 include white, black, yellow, red, blue, gold, silver, pearl, etc.

[0030] In this step (S11), the method for forming another concealing layer 110 is not particularly limited, and it can be formed by, for example, screen printing, gravure printing, etc., but it is preferable to form another concealing layer 110 by screen printing.

[0031] In step (S11), when forming another hidden layer 110 by screen printing, the ink used (hereinafter also referred to as ink (S11)) preferably has appropriate adhesion to the color ink layer 30. Examples of the ink (S11) include those obtained by mixing a resin binder with colorants such as pigments and dyes, extender pigments, stabilizers, plasticizers, catalysts, curing agents, antioxidants, ultraviolet absorbers, and the like.

[0032] Examples of the resin binder include butyral resin, polyamide resin, polyethyleneimine resin, sulfonamide resin, polyester polyol resin, petroleum resin, epoxy resin, styrene resin, acrylic resin, vinyl chloride resin, and the like. Examples of the colorant include inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, lead yellow, titanium yellow, red iron oxide, cadmium red, ultramarine blue, cobalt blue, organic pigments or dyes such as quinacridone red, isoindolinone yellow, phthalocyanine blue, metal pigments composed of flaky foil pieces such as aluminum and brass, and pearl pigments composed of flaky foil pieces such as titanium dioxide-coated mica and basic lead carbonate.

[0033] As a component of the ink (S11), a vinyl chloride / polyester-based resin is preferable from the viewpoint of making the adhesion to the color ink layer 30 more appropriate. When the ink (S11) contains a solvent, the solvents used are preferably cyclohexanone, isophorone, high-boiling aromatic solvents, etc. in the case of screen printing.

[0034] Another hidden layer 110 formed by step (S11) is usually a layer with a substantially uniform thickness. The thickness of the other hidden layer 110 is preferably 0.5 μm or more and 5 μm or less per color, and more preferably 0.7 μm or more and 3 μm or less.

[0035] [Color Ink Layer Forming Step (S2)] In this step (S2), the color ink layer 30 is formed on the surface of the release layer 20 or the other hidden layer 110 by digital printing. The color ink layer 30 is a layer that imparts decorations such as patterns and colors to the transfer foil 1.

[0036] "Digital printing" refers to a method of directly printing from digital-based images onto various substrates. Examples of digital printing include inkjet printing, laser printing, etc. "Inkjet printing" is a printing method in which, for example, ink droplets are ejected by using a print head that uses a piezoelectric crystal, and the droplets are deposited on a substrate to reproduce a digital image. "Laser printing" is a printing method in which toner is used, the necessary pixel locations are sensitized by a laser, the toner is once held, and then fixed on a substrate by heat to reproduce a digital image.

[0037] For the digital printing in step (S2), usually, inks or toners of multiple colors such as yellow (Y), magenta (M), cyan (C), black (K), white (W), etc. are used. This ink can be prepared, for example, by mixing pigments such as coloring pigments and fluorescent pigments with a resin binder. Further, this ink may contain a release agent, a softening agent, a surfactant, etc. As the coloring pigment, various known pigments can be used, for example, pigments such as carbon black, azo-based, phthalocyanine-based, quinacridone-based, thioindigo-based, anthraquinone-based, isoindolinone-based pigments, etc. can be mentioned. As the resin binder, for example, those similar to those exemplified as the binder of the ink for forming the other shielding layer 110 can be mentioned.

[0038] It is preferable to use toner for the digital printing in step (S2), and it is more preferable to use a polyester-based toner.

[0039] From the viewpoint of printing speed, laser printing using toner is preferable as digital printing. In the case of laser printing using toner, the thickness of the color ink layer 30 is preferably 3 μm or more and 12 μm or less per color, and more preferably 4 μm or more and 10 μm or less.

[0040] [Anchor layer formation step (S12)] In this step (S12), an anchor layer 120 is formed on the surface of the color ink layer 30. The anchor layer 120 is provided to protect the color ink layer 30 and to closely adhere the color ink layer 30 and the concealment layer 40.

[0041] In this step (S12), the method for forming the anchor layer 120 is not particularly limited. For example, it can be formed by screen printing, gravure printing, etc. However, it is preferable to form the anchor layer 120 by screen printing.

[0042] In step (S12), when the anchor layer 120 is formed by screen printing, the ink used (hereinafter also referred to as ink (S12)) preferably has appropriate adhesion to the color ink layer 30. Examples of the components of the ink (S12) include thermoplastic resins such as vinyl chloride-vinyl acetate resin (vinyl chloride-vinyl acetate resin), urethane resin, polyester resin, vinyl chloride-vinyl acetate / polyester resin, etc. From the viewpoint of making the adhesion to the color ink layer 30 more appropriate, vinyl chloride-vinyl acetate / polyester resin is preferable as the component of the ink (S12). The ink (S12) may contain a curing agent. The ink (S12) usually contains a solvent. Examples of this solvent include aliphatic hydrocarbon solvents, aromatic hydrocarbon solvents, alcohol solvents, glycol solvents, etc. From the viewpoint of suppressing the redissolution of the color ink layer 30, aromatic hydrocarbon solvents are preferable as the solvents contained in the ink (S12).

[0043] The anchor layer 120 formed by step (S12) is usually a layer with a substantially uniform thickness. The thickness of the anchor layer 120 is, for example, 0.5 μm or more and 4.0 μm or less, and preferably 1.0 μm or more and 3.5 μm or less.

[0044] [Concealment layer forming step (S3)] In this step (S3), the concealment layer 40 is formed by screen printing on the surface of the anchor layer 120. The concealment layer 40 is provided to conceal the color and pattern of the object to be transferred to improve the design property, or when decoration such as gold, silver, and pearl is required. Examples of the color of the concealment layer 40 include white, black, yellow, red, blue, gold, silver, pearl, etc.

[0045] The ink used for screen printing in step (S3) (hereinafter also referred to as ink (S3)) preferably has appropriate adhesion to the anchor layer 120 when the transfer foil 1 includes the anchor layer 120, and preferably has appropriate adhesion to the color ink layer 30 when the transfer foil 1 does not include the anchor layer 120. Examples of the components of the ink (S3) include those obtained by mixing a coloring agent such as a pigment or a dye, an extender pigment, a stabilizer, a plasticizer, a catalyst, a curing agent, an antioxidant, an ultraviolet absorber, etc. into a thermoplastic resin binder such as a vinyl chloride-vinyl acetate resin (vinyl chloride-vinyl acetate resin), a urethane resin, a polyester resin, a vinyl chloride-vinyl acetate / polyester resin. The ink (S3) may contain a curing agent. Further, the ink (S3) usually contains a solvent. From the viewpoint of suppressing the redissolution of the color ink layer 30, an aromatic hydrocarbon solvent is preferable as the solvent contained in the ink (S12).

[0046] Examples of the resin binder include those similar to those exemplified as the binder of the ink (S11) for forming the other masking layer 110. Examples of the coloring agent include those similar to those exemplified as the coloring agent of the ink (S11) for forming the other masking layer 110.

[0047] When the transfer foil 1 does not include the anchor layer 120, as the components of the ink (S3), a vinyl chloride-vinyl acetate resin, a polyester resin, and a vinyl chloride-vinyl acetate / polyester resin are preferable, and a vinyl chloride-vinyl acetate / polyester resin is more preferable, from the viewpoint of making the adhesion to the color ink layer 30 more appropriate. From the viewpoint of suppressing the redissolution of the color ink layer 30, an aromatic hydrocarbon solvent is preferable as the solvent contained in the ink (S3).

[0048] The masking layer 40 formed by step (S3) is usually a layer with a uniform thickness. The thickness of the masking layer 40 is preferably 0.5 μm or more and 5 μm or less per color, and more preferably 0.7 μm or more and 3 μm or less.

[0049] [Adhesive layer forming step (S4)] In this step (S4), an adhesive layer 50 is formed on the surface of the hidden layer 40 by screen printing. The adhesive layer 50 is provided for adhesion when transferring from the transfer foil 1 to the object to be transferred.

[0050] The ink used for screen printing in step (S4) (hereinafter also referred to as ink (S4)) preferably has appropriate adhesion to the hidden layer 40, and further preferably has appropriate adhesion to the member to be adhered in the subsequent heat transfer process. The components of the member to be adhered in the heat transfer process are not particularly limited, and examples include organic substances such as plastics and natural materials, and inorganic substances such as glass, metal, and ceramics. For a member containing such components, thermoplastic resin and hot melt adhesive are desirable as the components of the ink (S4). When the ink (S4) contains a solvent, from the viewpoint of suppressing the redissolution of the color ink layer 30, an aromatic hydrocarbon solvent is preferred.

[0051] Examples of thermoplastic adhesives include two-component curable urethane adhesives, polyester urethane adhesives, polyether urethane adhesives, acrylic adhesives, polyester adhesives, polyamide adhesives, polyvinyl acetate adhesives, epoxy adhesives, rubber adhesives, etc. However, in order to make the adhesion to the hidden layer 40 appropriate, for example, vinyl chloride-vinyl acetate resin (vinyl chloride-vinyl acetate resin), urethane resin, polyester resin, vinyl chloride-vinyl acetate / polyester resin, acrylic resin, etc. are preferably used.

[0052] Examples of hot melt adhesives include resins such as ethylene-vinyl acetate, vinyl chloride-vinyl acetate (vinyl chloride-vinyl acetate), polyolefin, polyamide, nylon, polyester, rubber, acrylic, urethane, cellulose, and reactive hot melt. If necessary, a mixture of two or more types can also be used. In particular, it is preferable to mix and use an acrylic resin and a urethane resin.

[0053] The ink (S4) may contain additives such as pigments, dyes, antioxidants, curing agents, catalysts, leveling agents, defoaming agents, thixotropic agents, extender pigments, ultraviolet absorbers, etc.

[0054] From the viewpoint of improving the adhesiveness to the object to be transferred, it is preferable to use a material of the same system as the material constituting the object to be transferred for the ink (S4). As components of the ink (S4), a polyester resin and a vinyl chloride / polyester resin are preferable.

[0055] The adhesive layer 50 formed by the step (S4) is usually a layer with a substantially uniform thickness. The thickness of the adhesive layer 50 is, for example, 0.6 μm or more and 8 μm or less, and preferably 2 μm or more and 5 μm or less.

[0056] <Manufacturing apparatus for transfer foil> Examples of the manufacturing apparatus (hereinafter also referred to as manufacturing apparatus (Y)) that performs the manufacturing method (X) include a combination of a screen printing machine that performs screen printing and a digital printing machine that performs digital printing. The manufacturing apparatus (Y) may be, for example, an apparatus having a screen printing section and a digital printing section, or may be one that enables the manufacturing method (X) to be performed using an existing digital printing machine and an existing digital printing machine. In this case, the apparatus cost can be reduced by using existing apparatuses.

[0057] Screen printing machines usually operate in an intermittent feeding mode. Digital printing machines include, for example, the rotary printing method, the continuous feeding method, etc. As the manufacturing apparatus (Y), it is preferable that the screen printing machine operates in an intermittent feeding mode and the digital printing machine operates in the rotary printing method. In the combination of the rotary printing method and the continuous feeding method, it is difficult to achieve positional accuracy by repeating offline printing multiple times, but with an intermittent feeding screen printing machine, the position can be adjusted and printed offline any number of times. In addition, compared with rotary printing methods such as gravure printing, screen printing machines require less ink usage at the start of printing and have lower plate-making costs, so they are well-suited for small-batch, multi-variety printing in terms of compatibility with digital printing. In this way, the manufacturing apparatus (Y) can better coordinate the screen printing machine and the digital printing machine, and can more easily manufacture the transfer foil 1.

[0058] When the digital printing machine that forms the color ink layer 30 operates in the rotary printing method, during digital printing, the support sheet 10 of the transfer foil being manufactured may expand and contract in both the conveying direction and the width direction, and the shape of the pattern or the like in the color ink layer 30 may be deformed. In preparation for such a case, in the screen printing after the formation of the anchor layer 120 or the concealment layer 40, it is preferable to be able to correct the size, material, and stretchability of the screen printing plate to match this deformation.

[0059] <Transfer foil> As shown in FIGS. 2 to 4, the transfer foil (hereinafter also referred to as transfer foil (Z)) 1 of the present embodiment includes a support sheet 10, a release layer 20, a color ink layer 30, a concealment layer 40, and an adhesive layer 50 laminated in this order. Each of the concealment layer 40 and the adhesive layer 50 is formed of a screen printing layer, and the color ink layer 30 is formed of a digital printing layer.

[0060] The transfer foil (Z) 1 may further include another concealment layer 110 between the release layer 20 and the color ink layer 30, or may further include an anchor layer 120 between the color ink layer 30 and the concealment layer 40. In this case, it is preferable that the other concealment layer 110 is formed of a screen printing layer, and it is preferable that the anchor layer 120 is formed of a screen printing layer.

[0061] Since the transfer foil (Z) 1 has a layer in which the concealment layer 40 and the adhesive layer 50 are formed by screen printing and a layer in which the color ink layer 30 is formed by digital printing, the design property can be improved.

Example

[0062] Hereinafter, the present disclosure will be specifically described by way of examples, but the present disclosure is not limited to only the examples.

[0063] <Manufacture of transfer foil> [Manufacture of transfer foil 1] A transfer foil (coating container specification) was manufactured using a screen printing machine and a digital printing machine. · Support sheet: A polyethylene terephthalate film (thickness 25 μm, with a release treatment applied to the film surface) The paints used for forming each layer are as follows. · Release layer: Polyester resin (thickness: 3 μm) · Color ink layer: Toner (polyester-based) (cyan, magenta, yellow, black, white) · Anchor layer: Polyester resin (thickness: 3 μm) · Concealment layer: Polyester resin (thickness: 3 μm) · Adhesive layer: Polyester resin (thickness: 3 μm)

[0064] [Manufacture of transfer foil 2] A transfer foil (thin shaft specification) was manufactured using a screen printing machine and a digital printing machine. · Support sheet: A polyethylene terephthalate film (thickness 25 μm, with a release treatment applied to the film surface) The paints used for forming each layer are as follows. · Release layer: Vinyl chloride acetate resin (thickness: 3 μm) · Color ink layer: Toner (polyester-based) (cyan, magenta, yellow, black, white) · Anchor layer: Vinyl chloride acetate resin (thickness: 3 μm) · Concealing layer: Vinyl acetate resin (thickness: 3 μm) · Adhesive layer: Vinyl acetate / polyester resin (thickness: 3 μm)

[0065] [Manufacture of transfer foil 3] A transfer foil (specification for molded plastic containers) was manufactured using a screen printing machine and a digital printing machine. · Support sheet: Polyethylene terephthalate film (thickness 25 μm, with a release treatment applied to the film surface) The paints used for forming each layer are as follows. · Release layer: Acrylic resin (thickness: 3 μm) · Color ink layer: Toner (polyester-based) (cyan, magenta, yellow, black, white) · Anchor layer: Vinyl acetate / polyester resin (thickness: 3 μm) · Concealing layer: Vinyl acetate / polyester resin (thickness: 3 μm) · Adhesive layer: Vinyl acetate / polyester resin (thickness: 3 μm)

[0066] [Evaluation] [Manufacturing method] Regarding the manufacturing method of the transfer foil of the present invention, the functionality (adhesion), productivity (printability) of the manufacturing method, and processability (transferability) of the transfer foil were evaluated according to the following methods and criteria. The evaluation results are shown in Table 1 below. · Adhesion: A test of adhesion (cross-cut method) (JIS K5600-5-6 (ISO2409)) was conducted on the color ink layer on the surface of the product obtained using the transfer foil, and regarding adhesion, it was evaluated as A (good): no peeling of the color ink layer was observed, or B (bad): peeling of the color ink layer was observed. · Printability: In mass production printing, it was determined whether good products could be stably printed without defects such as scratches, chips, dirt, smudges, bleeding, unevenness, pinholes, trailing, blocking, etc. Regarding printability, it was evaluated as A (good): printing could be continued without defects, or B (bad): defects occurred and good products could not be continuously printed. · Transferability: Thermal transfer processing (temperature: 180 - 280 °C, pressure: 5 - 40 kgf / cm 2 ) was performed on the members to which adhesion was desired (Manufacturing 1: coating containers, Manufacturing 2: plastic thin shaft parts, Manufacturing 3: plastic containers), and judgments were made regarding transfer defects of patterns, appearance defects such as scratches, chips, dents, and brightness changes, and yield reduction such as a decrease in transfer processing speed. Regarding transferability, it was evaluated as A (good): transfer could be continued without occurrence of defects, or B (bad): transfer defects occurred and good products could not be continuously transferred.

[0067]

Table 1

[0068] As can be seen from the results in Table 1, according to the manufacturing method of the present invention, a transfer foil excellent in functionality and processability can be manufactured with high productivity.

[0069] [Design property] The design property of the transfer foil obtained by the manufacturing method of the present invention was evaluated according to the following criteria in terms of harmonious expression, photographic image reproduction, thin line and small character expression, high concealment expression, and gold, silver, and pearl expression. The same transfer foils obtained by gravure printing or screen printing were also evaluated in the same manner. The evaluation results are shown in Table 2 below.

[0070] · Harmonious expression: In the part of the harmonious expression obtained by transfer, it was evaluated as A (good): there was no color unevenness and a smooth harmonious expression was achieved, or B (bad): color unevenness occurred and it was inferior as a harmonious expression. · Photographic image reproduction: In the part of the photographic image obtained by transfer, it was evaluated as A (good): CMYK overprint dot expression of 175 lines or more was possible and good photographic image reproduction was achieved, or B (bad): only dot expression of less than 175 lines was possible and it was inferior as a photographic image reproduction. ·Fine line and small character expression: In the part of the fine line and small character obtained by transfer, A (good): The fine line was less than 0.2 mm and the small character expression was less than 2 pt, and a good fine line and small character expression was achieved, or B (bad): Only thick lines of 0.2 mm or more and large characters of 2 pt or more could be printed, and the fine line and small character expression was inferior. ·High concealment expression: In the part of the high concealment expression obtained by transfer, A (good): It was not affected by the color of the background when overprinted, and a good high concealment expression was achieved, or B (bad): It was affected by the color of the background when overprinted, and the high concealment expression was inferior. ·Gold, silver, and pearl expression: In the part of the gold, silver, and pearl expression obtained by transfer, A (good): Gold, silver, and pearl inks could be mass-produced and printed, and a good gold, silver, and pearl expression was achieved, or B (bad): Gold, silver, and pearl inks could not be mass-produced and printed, and the gold, silver, and pearl expression was evaluated as inferior.

[0071]

Table 2

[0072] As can be seen from the results in Table 2, the transfer foil obtained by the manufacturing method of the present invention had improved designability compared to conventional transfer foils by gravure printing, screen printing, etc.

[0073] A comparison between the manufacturing method of the transfer foil of the present invention and the prior art is shown below.

[0074]

Table 3

[0075] As can be seen from Table 3, according to this embodiment, it is possible to propose a minimum of one sheet, the manufacturing cost can be reduced to 1 / 3 of gravure printing and 1 / 2 of screen printing, the shortest delivery time can be reduced to 1 / 30 of gravure printing and 1 / 3 of screen printing, and in terms of environmental response, the solvent usage amount can be reduced to 1 / 30 of gravure printing and 1 / 4 of screen printing.

[0076] (Summary) As is clear from the above-described embodiments and examples, the method for manufacturing the transfer foil (1) according to the first aspect is a method for manufacturing a transfer foil (1) in which a release layer (20), a color ink layer (30), a concealing layer (40), and an adhesive layer (50) are laminated in this order on one surface of a support sheet (10). Each of the concealing layer (40) and the adhesive layer (50) is formed by screen printing, and the color ink layer (30) is formed by digital printing.

[0077] According to the first aspect, the high concealment expression of screen printing is excellent, the chroma is high, and printing of colors such as gold, silver, and pearl is possible. Also, the gradation expression, thin line expression, gradation (gradation) expression, photographic image reproducibility, etc. of digital printing are excellent. As a result of these being effectively combined, the designability of the transfer foil (1) can be improved. Further, since this manufacturing method combines screen printing and digital printing, there are no plate restrictions, and it is possible to manufacture transfer foils at once with a plurality of designs and a plurality of color tones, and it is possible to suitably respond to production in extremely small lots.

[0078] In the method for manufacturing the transfer foil (1) according to the second aspect, in the first aspect, an anchor layer (120) is further laminated between the color ink layer (30) and the concealing layer (40), and the anchor layer (120) is formed by screen printing.

[0079] According to the second aspect, the transfer foil (1) can further improve its designability by including an anchor layer (120) that protects the color ink layer (30) and can contain colors such as gold, silver, and pearl.

[0080] In the method for manufacturing the transfer foil (1) according to the third aspect, in the first or second aspect, screen printing is performed by an intermittent feed method, and digital printing is performed by a rotary method.

[0081] According to the third aspect, better cooperation between screen printing and digital printing can be achieved, and the manufacturing of the transfer foil (1) can be performed more easily.

[0082] The transfer foil (1) of the fourth aspect includes a support sheet (10), a release layer (20), a color ink layer (30), a concealment layer (40), and an adhesive layer (50) laminated in this order. Each of the concealment layer (40) and the adhesive layer (50) is formed of a screen printing layer, and the color ink layer (30) is formed of a digital printing layer.

[0083] According to the fourth aspect, as a result of effectively combining the excellent points of screen printing and the excellent points of digital printing, it is possible to obtain a transfer foil (1) with improved design quality.

[0084] In the transfer foil (1) of the fifth aspect, in the fourth aspect, an anchor layer (120) is further provided between the color ink layer (30) and the concealment layer (40), and the anchor layer (120) is formed of a screen printing layer.

[0085] According to the fifth aspect, by further providing the anchor layer (120), the design quality can be further improved.

Explanation of Reference Numerals

[0086] 1 Transfer foil 10 Support sheet 20 Release layer 30 Color ink layer 40 Concealment layer 50 Adhesive layer 110 Another concealment layer 120 Anchor layer

Claims

1. A method for manufacturing a transfer foil in which a release layer, a first concealment layer, a color ink layer, an anchor layer, a second concealment layer, and an adhesive layer are laminated in this order on one side of a support sheet, wherein each of the first concealment layer, the second concealment layer, the anchor layer, and the adhesive layer is formed by screen printing, and the color ink layer is formed by digital printing.

2. The method for manufacturing a transfer foil according to Claim 1, wherein the ink used for the screen printing of the anchor layer contains at least one thermoplastic resin selected from the group consisting of vinyl chloride-vinyl acetate resins, urethane resins, and polyester resins.

3. The method for manufacturing a transfer foil according to Claim 1 or 2, wherein the screen printing is performed by an intermittent feed method and the digital printing is performed by a rotary method.

4. A transfer foil comprising a support sheet, a release layer, a first concealment layer, a color ink layer, an anchor layer, a second concealment layer, and an adhesive layer laminated in this order, wherein each of the first concealment layer, the second concealment layer, the anchor layer, and the adhesive layer consists of a screen printing layer, and the color ink layer consists of a digital printing layer.

5. The transfer foil according to Claim 4, wherein the anchor layer consists of an ink for screen printing containing at least one thermoplastic resin selected from the group consisting of vinyl chloride-vinyl acetate resins, urethane resins, and polyester resins.

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