Transfer foil manufacturing method

Abstract

This disclosure provides a method for efficiently producing a transfer foil that minimizes misalignment between the metallic and colored portions of an object when partially decorating the object with a colored metallic appearance. In this method, a metal foil 40 of a hot stamp foil is thermally transferred onto only the entire surface of the colored layer 10 of an intermediate member 1 opposite the resin layer 20, thereby producing a metal layer 41 disposed on the surface of the colored layer 10 opposite the resin layer 20. This produces a decorative layer 70 that includes the colored layer 10 and the metal layer 41.

Description

[Technical Field]

[0001] The present disclosure relates generally to a method for manufacturing a transfer foil, and more particularly to a method for manufacturing a transfer foil used to partially decorate an object with a colored metallic appearance. [Background technology]

[0002] Patent Document 1 discloses a transfer foil in which a release layer, a polarized ink layer, a colored ink layer, and a heat-sensitive adhesive layer are laminated in this order on one side of a base film. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 7-40651 Summary of the Invention

[0004] The object of the present disclosure is to efficiently manufacture a transfer foil that is less likely to cause misalignment between the metallic portion and the colored portion in the decorated portion when applying partial decoration to an object with a colored metallic appearance.

[0005] A transfer foil manufacturing method according to one aspect of the present disclosure is a method for manufacturing a transfer foil for transferring a decorative layer including a decorative layer to an object. In the method, a hot stamp foil is prepared, which includes a substrate and a metal foil disposed on one side of the substrate. An intermediate member is prepared, which includes a resin layer and a colored layer containing a colorant partially disposed on one side of the resin layer. The metal foil of the hot stamp foil is thermally transferred only to the entire surface of the colored layer of the intermediate member opposite the resin layer side, thereby producing a metal layer disposed on the surface of the colored layer opposite the resin layer side. This produces the decorative layer having the colored layer and the metal layer. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a cross-sectional view of a first intermediate member according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a cross-sectional view showing a state in which a metal layer is thermally transferred from a hot stamp foil to a first intermediate member in the embodiment. [Figure 3] FIG. 3 is a cross-sectional view showing a step of producing a second intermediate member in the embodiment. [Figure 4] FIG. 4 is a cross-sectional view of the transfer foil in the embodiment. [Figure 5] FIG. 5 is a cross-sectional view showing how a decorative layer is transferred from a transfer foil to an object in the embodiment. [Figure 6] FIG. 6 is a cross-sectional view showing how a decorative layer is transferred from a transfer foil to an object in the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] The following embodiments and modifications will be described with reference to the drawings. Note that the following embodiments and modifications are merely a portion of various embodiments of the present disclosure. Furthermore, the following embodiments and modifications can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved. Furthermore, the configurations of the modifications can be combined as appropriate.

[0008] The drawings referred to below are all schematic drawings, and the dimensional ratios of the components in the drawings do not necessarily reflect the actual dimensional ratios.

[0009] 1. Overview The method for manufacturing a transfer foil 4 according to the embodiment is a method for manufacturing a transfer foil 4 for transferring a decorative layer 7 including a decorative layer 70 to an object 5. In this method, first, a hot stamp foil 2 and an intermediate member (first intermediate member 1) are prepared (see FIGS. 1 and 2). The hot stamp foil 2 includes a substrate 50 and a metal foil 40 disposed on one surface of the substrate 50. The first intermediate member 1 includes a resin layer 20 and a colored layer 10 containing a coloring material that is partially disposed on one surface of the resin layer 20. In this method, the metal foil 40 of the hot stamp foil 2 is thermally transferred only to the entire surface of the colored layer 10 of the first intermediate member 1 opposite the resin layer 20 side, thereby producing a metal layer 41 disposed on the surface of the colored layer 10 opposite the resin layer 20 side (see FIGS. 2 and 3). This produces a decorative layer 70 including the colored layer 10 and the metal layer 41.

[0010] When the transfer foil 4 is manufactured in this manner, the outer periphery of the colored layer 10 and the outer periphery of the metal layer 41 are easily aligned in the decorative layer 70 of the transfer foil 4. In other words, misalignment between the colored layer 10 and the metal layer 41, such as the metal layer 41 protruding outward from the outer periphery of the colored layer 10 or the colored layer 10 protruding outward from the outer periphery of the metal layer 41, is unlikely to occur.

[0011] Therefore, when the transfer foil 4 is used to transfer the decorative layer 70 onto the surface of an appropriate object 5 (see FIGS. 5 and 6), the decorative layer 70 imparts a colored metallic pattern or the like to the object 5. Furthermore, this pattern is less likely to suffer from poor appearance due to the colored layer 10 or metal layer 41 protruding.

[0012] Furthermore, in the embodiment, the manufacturing process of the transfer foil 4 can be simplified while suppressing misalignment between the colored layer 10 and the metal layer 41 as described above. In addition to the manufacturing method disclosed herein, other methods for suppressing misalignment between the colored layer 10 and the metal layer 41 in the transfer foil 4 can be considered, such as the following: First, an aqueous primer for resist is applied to a suitable substrate in a negative pattern. A layer containing a colorant is applied on top of this aqueous primer. Next, a metal layer is formed on top of this layer containing the colorant by a vapor deposition method or the like. Next, the aqueous primer is washed with water to remove the aqueous primer together with unnecessary portions of the layer containing the colorant and the metal layer. In this way, the remaining portions of the layer containing the colorant and the remaining portions of the metal layer can form a decorative layer as in the embodiment.

[0013] However, the above method requires the formation of a patterned metal layer, which requires complicated processes such as the formation of an aqueous primer, vapor deposition, and cleaning. Furthermore, it is difficult to completely remove the unnecessary portions of the colorant-containing layer and the metal layer by cleaning. This makes it easy for defects to occur in the shape of the decorative layer. In particular, when a pigment is used as the colorant, it is difficult to completely separate the colorant-containing layer into the necessary and unnecessary portions, which makes defects particularly likely to occur.

[0014] In contrast, according to the embodiment, there is no need to vapor-deposit metal in a pattern to produce the metal layer 41, which simplifies the manufacturing process of the transfer foil 4. Furthermore, regardless of whether a pigment is used or not, defects in the shape of the decorative layer 70 are less likely to occur when aligning the outer periphery of the colored layer 10 in the decorative layer 70 with the outer periphery of the metal layer 41.

[0015] 2.Details The configuration of the embodiment will be described in detail below.

[0016] The transfer foil 4 manufactured in this embodiment comprises a support sheet 30, a resin layer 20, a decorative layer 70, and an adhesive layer 60 (see FIG. 4). The resin layer 20 is disposed on one side of the support sheet 30. The decorative layer 70 is partially disposed on the surface of the resin layer 20 opposite the support sheet 30. The adhesive layer 60 is disposed on the surface of the resin layer 20 opposite the support sheet 30 so as to cover the decorative layer 70. The decorative layer 70 comprises a colored layer 10 containing a colorant disposed on the surface of the resin layer 20 opposite the support sheet 30, and a metal layer 41 disposed on the surface of the colored layer 10 opposite the resin layer 20. The periphery of the colored layer 10 is aligned with the periphery of the metal layer 41.

[0017] In this embodiment, when producing the transfer foil 4, first, a first intermediate member 1 and a hot stamp foil 2 are prepared (see FIGS. 1 and 2).

[0018] The hot stamp foil 2 has a substrate 50 and a metal foil 40 disposed on one surface of the substrate 50 .

[0019] The substrate 50 is, for example, a resin film. The substrate 50 preferably has heat resistance sufficient to withstand thermal transfer. More specifically, the substrate 50 is, for example, a polyester film such as a polyethylene terephthalate film, a polyamide film, or a polyimide film, but is not limited to these. The thickness of the substrate 50 is, for example, 12 μm or more and 25 μm or less.

[0020] The metal foil 40 is a layer made of metal. The metal foil 40 contains at least one selected from the group consisting of, for example, aluminum, alumina, tin, indium, nickel, silicon dioxide, titanium, zinc sulfide, copper, silver, gold, cobalt, chromium, etc. The metal foil 40 is formed on one surface of the substrate 50 by, for example, a vapor deposition method. The thickness of the metal foil 40 is, for example, 100 Å (10 nm) or more and 700 Å (70 nm) or less.

[0021] A hot melt adhesive is preferably applied to the surface of the metal foil 40 opposite to the substrate 50. The hot melt adhesive contains at least one selected from the group consisting of, for example, vinyl chloride-vinyl acetate resin, ethylene vinyl acetate resin, urethane resin, acrylic resin, and polyester resin.

[0022] The hot stamp foil 2 may further include layers other than those described above. For example, one or more layers for adjusting the adhesion or peelability between the substrate 50 and the metal foil 40 may be interposed between the substrate 50 and the metal foil 40. The layer interposed between the substrate 50 and the metal foil 40 includes, for example, at least one layer selected from the group consisting of a release layer, a release layer, and an anchor layer.

[0023] A commercially available product may be used as the hot stamp foil 2. Commercially available hot stamp foils 2 having various thicknesses and colors for various applications are sold by, for example, KURZ Group, Katani Sangyo Co., Ltd., Murata Gold Leaf Group, and Tanaka Takashi Shoten Co., Ltd. An appropriate hot stamp foil 2 can be selected and used from these.

[0024] The first intermediate member 1 includes a support sheet 30, a resin layer 20, and a colored layer .

[0025] The support sheet 30 is, for example, a resin film, more specifically, a polyester film such as a polyethylene terephthalate film, a polyamide film, or a polyimide film. A release layer for improving releasability may be formed on the surface of the support sheet 30 on which the resin layer 20 is disposed. The release layer contains at least one material selected from the group consisting of, for example, a silicone resin, carnauba wax, and a paraffin resin.

[0026] In the embodiment, the resin layer 20 is disposed over the entire surface of one surface of the support sheet 30, and is supported by the support sheet 30. That is, the support sheet 30 and the resin layer 20 are laminated such that the resin layer 20 overlaps one surface of the support sheet 30. The resin layer 20 is transparent.

[0027] The thickness of the support sheet 30 is, for example, 16 μm or more and 50 μm or less, but is not limited to this.

[0028] The resin layer 20 is made of, for example, a transparent resin composition containing an appropriate resin material. There is no limitation on the type of resin material. The resin material may be a thermosetting resin or a thermoplastic resin. The resin material may include at least one selected from the group consisting of, for example, butyral resin, polyamide resin, polyethyleneimine resin, sulfonamide resin, polyester polyol resin, petroleum-based resin, epoxy resin, styrene resin, acrylic resin, modified acrylic resin, vinyl resin, polyester resin, and vinyl chloride resin. It is desirable that the resin material include a modified acrylic resin.

[0029] The resin composition may further contain, as needed, an appropriate additive selected from the group consisting of a mold release agent, a softener, a coating reinforcing agent, a slip agent, a surfactant, etc. Furthermore, the resin composition may also contain, as needed, an appropriate solvent.

[0030] For example, the resin layer 20 is produced by applying the resin composition onto the surface of the support sheet 30 by an appropriate method such as a gravure coater, and then drying and curing it as necessary.

[0031] The thickness of the resin layer 20 is, for example, not less than 0.2 μm and not more than 2.5 μm, but is not limited to this.

[0032] The colored layer 10 is partially disposed on the surface of the resin layer 20 opposite to the support sheet 30. For example, a plurality of colored layers 10 are disposed at a plurality of locations spaced apart from one another on the surface of the resin layer 20. The plurality of colored layers 10 may include a plurality of types of colored layers 10 having different colors from one another.

[0033] The colored layer 10 is made of, for example, an ink composition containing a resin material (resin binder) and a colorant.

[0034] There are no limitations on the type of colorant in the ink composition. The colorant may contain, for example, at least one of a pigment and a dye. The pigment may contain at least one selected from the group consisting of inorganic pigments such as carbon black (ink), iron black, titanium white, antimony white, yellow lead, titanium yellow, red iron oxide, cadmium red, ultramarine blue, and cobalt blue; organic pigments such as azo, phthalocyanine, quinacridone, thioindigo, anthraquinone, and isoindolinone; metal pigments consisting of scaly flakes such as aluminum and brass; and scaly flakes such as titanium dioxide-coated mica and basic lead carbonate. The dye may contain at least one selected from the group consisting of organic dyes such as azo, phthalocyanine, quinacridone, thioindigo, anthraquinone, and isoindolinone.

[0035] When the coloring material contains a pigment in particular, the light resistance of the colored layer 10 is increased, and deterioration such as fading of the colored layer 10 can be suppressed.

[0036] The type of resin material in the ink composition is not particularly limited. The resin material includes at least one selected from the group consisting of, for example, butyral resin, polyamide resin, polyethyleneimine resin, sulfonamide resin, polyester polyol resin, petroleum-based resin, epoxy resin, styrene resin, acrylic resin, vinyl resin, polyester resin, and vinyl chloride resin. More specifically, it is desirable that the resin material contains at least one selected from the group consisting of vinyl chloride-vinyl acetate resin, acrylic resin, urethane resin, and polyester resin.

[0037] The ink composition may further contain appropriate additives such as a release agent, a softener, a surfactant, etc. The ink composition may also contain appropriate solvents as needed.

[0038] For example, the ink composition is applied onto the surface of the resin layer 20 by an appropriate method such as screen printing or inkjet printing, and then cured as necessary, to form the colored layer 10.

[0039] When the colored layer 10 consists of only one layer, the thickness of the colored layer 10 is, for example, 1.5 μm or more and 3.0 μm or less, but is not limited thereto. The colored layer 10 may be configured by laminating multiple layers having different colors. In this case, the thickness of each layer included in the colored layer 10 is, for example, 1.5 μm or more and 3.0 μm or less, but is not limited thereto.

[0040] It is preferable that there is a difference in affinity between the colored layer 10 and the resin layer 20 for the metal foil 40 in the hot stamp foil 2 (or for the hot melt adhesive if a hot melt adhesive is applied to the metal foil 40). That is, it is preferable that the colored layer 10 has a higher affinity for the metal foil 40 or the hot melt adhesive than the resin layer 20. In this case, the metal layer 41 is easily transferred selectively onto the surface of the colored layer 10 using the hot stamp foil 2. The affinity for the hot melt adhesive can be adjusted by an appropriate method. For example, the affinity can be adjusted by including a component that has a high affinity for the metal or the hot melt adhesive in the colored layer 10 or on the surface of the colored layer 10, by including a component that has a low affinity for the metal or the hot melt adhesive in the resin layer 20 or on the surface of the resin layer 20, or by adjusting the content of such a component. More specifically, for example, to increase the affinity between the hot melt adhesive and the colored layer 10, it is desirable to include at least one resin selected from the group consisting of vinyl chloride-vinyl acetate resins and urethane resins in the colored layer 10 or on the surface of the colored layer 10, although this depends on the components contained in the hot melt adhesive. Specific acrylic resins and polyester resins can also improve affinity. To decrease the affinity between the hot melt adhesive and the resin layer 20, it is desirable to include at least one resin selected from the group consisting of acrylic resins and thermosetting resins in the resin layer 20 or on the surface of the resin layer 20, although this depends on the components contained in the hot melt adhesive.

[0041] The first intermediate member 1 and the hot stamp foil 2 are stacked together so that the colored layer 10 of the first intermediate member 1 faces the metal foil 40 of the hot stamp foil 2. In this state, pressure is applied to the hot stamp foil 2 toward the first intermediate member 1, and the hot stamp foil 2 is heated. For example, a heated roll 81 is pressed against the base material 50 of the hot stamp foil 2 while the roll 81 is rotated and moved, thereby applying pressure and heating the entire hot stamp foil 2 (see FIG. 2). In this way, the hot melt adhesive applied to the metal foil 40 melts and then solidifies, thereby bonding the metal foil 40 to the colored layer 10. The pressure applied to the hot stamp foil 2 is, for example, 5 kgf / cm.2 (0.49MPa) or more 30kgf / cm 2 The heating temperature of the hot stamp foil 2 is, for example, 110°C or higher and 160°C or lower.

[0042] Next, the base material 50 of the hot stamp foil 2 is peeled off from the first intermediate member 1 (see FIG. 3). At this time, the portion of the metal foil 40 that is adhered to the colored layer 10 remains on the side of the colored layer 10 opposite the resin layer 20. The portion 42 of the metal foil 40 that is not adhered to the colored layer 10 remains on the side of the base material 50. In this way, by using the hot stamp foil 2, the metal layer 41 is selectively transferred onto the side of the colored layer 10 opposite the resin layer 20. This produces a decorative layer 70 having the colored layer 10 and the metal layer 41, and a second intermediate member 3 that includes the support sheet 30, the resin layer 20, and the decorative layer 70.

[0043] Next, an adhesive layer 60 is formed on the surface of the resin layer 20 of the second intermediate member 3 on the side where the decorative layer 70 is disposed, so as to cover the decorative layer 70 (see FIG. 4).

[0044] The adhesive layer 60 is made, for example, from an adhesive composition.

[0045] The adhesive composition contains, for example, at least one of a thermoplastic adhesive and a hot melt adhesive. The adhesive contained in the adhesive composition is appropriately selected depending on the material of the object.

[0046] The thermoplastic adhesive contains at least one selected from the group consisting of, for example, two-component curing urethane adhesives, polyester urethane adhesives, polyether urethane adhesives, acrylic adhesives, polyester adhesives, polyamide adhesives, polyvinyl acetate adhesives, epoxy adhesives, and rubber adhesives.

[0047] The hot melt adhesive contains at least one selected from the group consisting of, for example, ethylene-vinyl acetate resin, vinyl chloride-vinyl acetate resin, polyolefin resin, polyamide resin, nylon resin, polyester resin, rubber resin, acrylic resin, urethane resin, cellulose resin, and reactive hot melt resin.

[0048] The adhesive composition may contain at least one additive selected from the group consisting of pigments, dyes, antioxidants, curing agents, catalysts, leveling agents, antifoaming agents, thixotropic agents, extender pigments, and ultraviolet absorbers.

[0049] More specifically, when the material of the object is ABS resin, for example, the adhesive composition preferably contains a vinyl chloride-vinyl acetate resin.

[0050] For example, the adhesive layer 60 is produced by applying the adhesive composition to the surface of the resin layer 20 on which the decorative layer 70 is disposed, using a screen printing method or the like.

[0051] The thickness of the adhesive layer 60 is, for example, not less than 1.0 μm and not more than 10.0 μm, but is not limited to this.

[0052] In this way, the transfer foil 4 shown in FIG. 4 is manufactured.

[0053] The transfer foil 4 is used to transfer a decorative layer 7 including a decorative layer 70 onto an appropriate object 5.

[0054] The material of the target object 5 may be, for example, organic materials such as plastics and natural materials, or inorganic materials such as glass, metal, and ceramics, but is not limited to these.

[0055] When using the transfer foil 4, first, the transfer foil 4 is placed on one side of the object 5 so that the object 5 and the adhesive layer 60 face each other. In this state, pressure is applied to the transfer foil 4 toward the object 5, and the transfer foil 4 is heated. For example, a heated roll 82 is pressed against the support sheet 30 of the transfer foil 4, and the roll 82 is rotated and moved, thereby heating the entire transfer foil 4 while applying pressure (see FIG. 5). This causes the adhesive layer 60 to adhere to the substrate 50. The pressure applied to the transfer foil 4 is, for example, 5 kgf / cm 2 (0.49MPa) or more 30kgf / cm 2 The heating temperature of the transfer foil 4 is, for example, 170°C or higher and 270°C or lower.

[0056] Next, the support sheet 30 is peeled off from the resin layer 20 (see FIG. 6). At this time, the unnecessary portion 22 of the resin layer 20 that protrudes from the adhesive layer 60 is separated together with the support sheet 30 from the portion of the resin layer 20 other than the unnecessary portion 22.

[0057] As a result, a decorative layer 7 is provided on the surface of the object 5, the decorative layer 7 including the adhesive layer 60, the decorative layer 70, and the surface layer 21 derived from the resin layer 20. The surface layer 21 is the portion of the resin layer 20 where the unnecessary portion 22 has been removed. In the decorative layer 7, the adhesive layer 60 and the surface layer 21 are laminated together, with the decorative layer 70 partially interposed between the adhesive layer 60 and the surface layer 21, and the decorative layer 70 being adhered to the object 5 by the adhesive layer 60. As a result, a product 6 is obtained that includes the object 5 and the decorative layer 7 that covers the surface of the object 5.

[0058] When the decorative layer 7 is observed from the outside, a pattern with a metallic and colored appearance can be seen due to the decorative layer 70. Furthermore, in the decorative layer 7, the outer periphery of the colored layer 10 and the outer periphery of the metal layer 41 are aligned, so the metal layer 41 does not appear to protrude from the colored layer 10, and the colored layer 10 does not appear to protrude from the metal layer 41. This improves the appearance of the pattern presented by the decorative layer 70.

[0059] 3. Variations In the embodiment, the resin layer 20 and the surface layer 21 are each a single layer, but the resin layer 20 and the surface layer 21 may each comprise multiple layers, and these layers may be laminated. Furthermore, another layer may be interposed between the resin layer 20 and the surface layer 21. For example, an anchor layer may be interposed between the resin layer 20 and the surface layer 21 to improve adhesion between the decorative layer 70 and the adhesive layer 60.

[0060] Additionally, another layer may be interposed between the resin layer 20 and the adhesive layer 60, and between the surface layer 21 and the adhesive layer 60 and the decorative layer 70. For example, an anchor layer may be formed on the adhesive layer 60 surface on which the decorative layer 70 is formed, covering the decorative layer 70, thereby interposing an anchor layer between the decorative layer 70 and the adhesive layer 60. The anchor layer is a layer for improving the adhesion of the adhesive layer 60 to the decorative layer 70 and is designed according to the composition of the adhesive layer 60, which is designed with the adhesiveness to the target object in mind. Furthermore, a colored layer (additional colored layer) different from the colored layer 10 may be formed before the adhesive layer 60 is formed (after the anchor layer is formed, if an anchor layer is formed, but before the adhesive layer 60 is formed). The additional colored layer may be formed on the surface of the resin layer 20 on which the decorative layer 70 is formed, in a portion where the decorative layer 70 is not formed, or may be formed so as to overlap the decorative layer 70. [Example]

[0061] More specific examples of the present embodiment will be described below, although the present disclosure is not limited to the following examples.

[0062] As the hot stamp foil 2, a hot stamp foil was prepared which had a polyester film, a release layer, an acrylic resin peel layer, an anchor layer, an aluminum foil (thickness in the range of 20 to 70 nm), and a hot melt adhesive containing a vinyl chloride-vinyl acetate resin (thickness in the range of 0.2 to 1.2 μm) laminated in this order.

[0063] As the support sheet 30, a polyester film (having a thickness in the range of 16 μm to 50 μm) was prepared.

[0064] The following raw materials were mixed to prepare a resin composition. Modified acrylic resin: 94 parts by mass Polyethylene wax: 6 parts by mass

[0065] An ink composition was prepared by mixing the following raw materials. Vinyl chloride resin: 70 parts by weight Urethane resin: 30 parts by weight

[0066] An adhesive composition was prepared from the following ingredients: Olefin resin: 100 parts by mass

[0067] As the object 5, a plate-shaped injection-molded product (3 mm thick) made of ABS resin was prepared.

[0068] The resin composition was applied onto one surface of the support sheet 30 by gravure coating, and then dried with hot air at 70° C. for 3 minutes to form a resin layer 20 having a thickness in the range of 0.5 to 1.5 μm.

[0069] An ink composition was partially applied by silk screen printing to the surface of the resin layer 20 opposite the support sheet 30, and then hot air dried at 80°C for 1 minute to produce a colored layer 10 with a thickness in the range of 0.8 to 1.8 μm. In this way, a first intermediate member 1 was produced.

[0070] The hot stamp foil 2 was placed on the first intermediate member 1 so that the surface of the first intermediate member 1 on the colored layer 10 side and the surface of the hot stamp foil 2 on the metal foil 40 side faced each other. In this state, a heated roll 81 was used to apply a pressure of 5 kgf / cm 2 to the hot stamp foil 2 toward the first intermediate member 1. 2 (0.49MPa)~30kgf / cm 2 The hot stamp foil 2 was heated at a temperature ranging from 125 to 155°C while applying a pressure ranging from 2.94 MPa to 1.55 MPa. Next, the base material 50 of the hot stamp foil 2 and unnecessary portions of the metal foil 40 were removed, thereby transferring the metal layer 41 onto the surface of the colored layer 10. In this way, the second intermediate member 3 was produced.

[0071] Next, the adhesive composition was applied by silkscreen printing to one surface of the resin layer 20 of the second intermediate member 3 so as to cover the decorative layer 70, and then hot air dried at 80°C for 1 minute to produce an adhesive layer 60 with a thickness in the range of 0.8 to 1.8 μm. In this way, the transfer foil 4 was produced.

[0072] The transfer foil 4 was placed on one surface of the object 5 so that the object 5 and the adhesive layer 60 faced each other. In this state, a heated roller was used to apply a pressure of 5 kgf / cm2 to the transfer foil 4 and the object 5. 2 (0.49MPa)~30kgf / cm 2 The transfer foil 4 was heated at a temperature ranging from 170 to 270° C. while applying a pressure ranging from 2.94 MPa to 1.25 MPa. Next, the support sheet 30 of the transfer foil 4 and unnecessary portions of the resin layer 20 were removed, thereby transferring the decorative layer 7 onto the surface of the object 5.

[0073] When the decorative layer 7 was observed, the metal layer 41 did not appear to protrude from the colored layer 10 in the decorative layer 70, and the colored layer 10 did not appear to protrude from the metal layer 41 either.

[0074] [Aspect] A method for manufacturing a transfer foil (4) according to a first aspect of the present disclosure is a method for manufacturing a transfer foil (4) for transferring a decorative layer (7) including a decorative layer (70) to an object (5). In this method, a hot stamp foil (2) is prepared, which includes a substrate (50) and a metal foil (40) disposed on one side of the substrate (50). An intermediate member (first intermediate member (1)) is prepared, which includes a resin layer (20) and a colored layer (10) containing a coloring material partially disposed on one side of the resin layer (20). The metal foil (40) of the hot stamp foil (2) is thermally transferred only to the entire surface of the colored layer (10) of the first intermediate member (1) opposite the resin layer (20) side, thereby producing a metal layer (41) disposed on the surface of the colored layer (10) opposite the resin layer (20) side. This produces a decorative layer (70) including the colored layer (10) and the metal layer (41).

[0075] According to this embodiment, the decorative layer (70) of the transfer foil (4) can be efficiently produced, and when the decorative layer (70) is transferred onto the surface of the object (5) using the transfer foil (4), a colored metallic pattern or the like is imparted to the object (5). Furthermore, this pattern is less likely to suffer from poor appearance due to the colored layer (10) or metal layer (41) protruding.

[0076] In the second aspect, the first intermediate member (1) in the first aspect further includes a support sheet (30). A resin layer (20) is disposed on one surface of the support sheet (30), and a colored layer (10) is partially disposed on the surface of the resin layer (20) opposite the support sheet (30).

[0077] According to this embodiment, the support sheet (30) improves the handling properties of the transfer foil (4).

[0078] In the third embodiment, an adhesive layer (60) is formed on the surface of the resin layer (20) opposite to the support sheet (30) in the first or second embodiment so as to cover the decorative layer (70).

[0079] According to this embodiment, the decorative layer (7) including the decorative layer (70) can be adhered to the object (5) using the adhesive layer (60).

[0080] In a fourth aspect, in any one of the first to third aspects, the colorant contains a pigment.

[0081] According to this embodiment, the colored layer (10) can have good weather resistance while suppressing defects in the shape of the colored layer (10) when it is produced. [Explanation of symbols]

[0082] 1 First intermediate member (intermediate member) 2. Hot stamping foil 4 Transfer foil 5. Object 7 Decorative layer 10 Colored layer 20 Resin layer 30 Support Sheet 40 Metal foil 41 Metal layer 50 Base material 60 Adhesive layer 70 decorative layer

Claims

1. A method for producing a transfer foil for transferring a decorative layer including a decorative layer to an object, the method comprising: A hot stamping foil is provided, the hot stamping foil having a substrate and a metal foil disposed on one surface of the substrate; An intermediate member is provided, the intermediate member including a resin layer and a colored layer partially disposed on one surface of the resin layer and containing a coloring material; The method includes thermally transferring the metal foil of the hot stamp foil only onto the entire surface of the colored layer of the intermediate member opposite to the resin layer side, thereby producing a metal layer disposed on the surface of the colored layer opposite to the resin layer side, thereby producing the decorative layer having the colored layer and the metal layer. Method for manufacturing transfer foil.

2. the intermediate member further includes a support sheet, the resin layer is disposed on one surface of the support sheet, and the colored layer is partially disposed on a surface of the resin layer opposite to the support sheet. The method for producing the transfer foil according to claim 1 .

3. Further comprising forming an adhesive layer on the surface of the resin layer opposite to the support sheet so as to cover the decorative layer. The method for producing the transfer foil according to claim 2 .

4. The colorant contains a pigment. The method for producing the transfer foil according to claim 1 .

Images