Transferring Apparatus and Transferring Method

The present invention relates to a transferring apparatus and a transferring method for performing a transfer of a transferring member to a three-dimensional molded article.

Transfer methods are widely utilized to form patterns or characters on the surface of an article such as a household electric appliance, a cosmetic container, ornaments or the like. Fundamentally, a transferring member to be used in transferring method has a construction comprising a in transferring layer such as a pattern layer and an adhesive layer formed on a release sheet. The transferring member may include a surface protecting layer as necessary or may not include the adhesive layer when the pattern layer has an adhesive property. As transfer methods, a roll transfer method and an up-down transfer method are well known and utilized for many articles such as household electric appliances, cosmetic containers, sundry goods or the like. According to these transfer methods, a pressurizing member such as a roller or a member moving vertically presses a heated silicon rubber provided on the transferring member against a material (or article) so that the pattern of the transferring member is transferred to the material. In the roll transfer method, the thickness of the silicon rubber is in the range from 10 mm to 50 mm and the hardness thereof is in the range from 60.degree. to 90.degree.. In the up-down transfer method, the thickness of the silicon rubber is in the range from 2 to 5 mm and the hardness thereof is in the range from 60.degree. to 90.degree..

However, in these transfer methods, since the contact surface of the silicon rubber serving as a heat source is linear or flat, the configuration of the material (or article) to which the pattern of the transferring member is to be transferred is limited to a two-dimensional curved surface or a flat surface. Thus, it is difficult to transfer the pattern of the transferring member to a three-dimensional material.

Accordingly, an object of the present invention is to solve the above-described problem and provide a transferring apparatus and a transferring method for easily and reliably transferring the pattern of a transferring member to a material (or article) in a three-dimensional configuration.

In order to achieve the above-described object, the present invention is so constructed that a flexible sheet is pressed against a material (or article) through a transferring member by applying fluid pressure to the flexible sheet and the transferring member conforms to the surface of the material even though the material has a three-dimensional configuration.

That is, a transferring apparatus of the present invention comprises:

a placing base for placing a material (or article) thereon;

a flexible sheet opposed to a transfer region of the material placed on the base;

in a transferring member mounted between the flexible sheet and the base;

a sheet supporting frame for supporting the sheet on a surface opposed to the material, having a sheet pressurizing chamber on the side of the sheet opposite to the side of the sheet opposed to the material, and a means for heating the sheet;

a fluid supply member for supplying fluid to the pressurizing chamber of the supporting member; and

a driving member for moving one of the sheet and the material placed on the base with respect to the other.

In the above-described construction, after the sheet is pressed against the material through the transferring member, the fluid supply member may supply the fluid to the pressurizing chamber to apply pressure to the sheet.

In the above-described construction, the fluid supply member may supply the fluid to the pressurizing chamber so as to pressurize the sheet before the sheet contacts the transferring member.

In the above-described construction, the driving member may move the supporting member relative to the material placed on the base.

In the above-described construction, the driving member may move the base relative to the supporting member.

In the above-described construction, the base may have a plurality of suction holes and a suction member for sucking gas through the sucking holes when a transfer is carried out with the transferring member contacting the material.

A transferring method according to the present invention comprises the steps of:

placing a material on a base;

placing on a transfer region of the material the transferring member having a pattern layer formed on a release sheet so that a pattern of the pattern layer is positioned on the material;

pressing a heated flexible sheet against the material through the transferring member;

transferring the pattern of the pattern layer of the transferring member to the material by further pressing the sheet against the material through the transferring member by applying fluid pressure to the sheet; and

removing the sheet and the release sheet of the transferring member from the material after the transferring step is completed.

A transferring method according to the present invention comprises the steps of:

placing a material on a base;

placing on a transfer region of the material a transferring member having a pattern layer formed on a release sheet so that a pattern of the pattern layer is positioned on the side of the material;

pressing a heated flexible sheet to which fluid pressure is being applied against the material through the transferring member so as to transfer the pattern of the pattern layer of the transferring member to the material; and

removing the sheet and the release sheet of the transferring member from the material after the transferring step is completed.

In the above-described method, fluid existing between the material and the transferring member may be discharged in carrying out the transferring operation.

In the above-described method, an adhesive layer may be formed on one of the pattern layer and the material before the sheet is pressed against the material through the transferring member.

The "pattern layer" includes a colorless, transparent surface protecting layer for protecting the surface of a material to which a pattern is transferred and a ground adjusting layer serving as a ground when a pattern is formed with a painting brush neither by means of a transfer.

According to the construction of the above-described present invention, even though the material has a three-dimensional configuration on its surface, when the sheet is pressed against the material through the transferring member, fluid is supplied to the pressurizing chamber of the supporting member so that the sheet and the transferring member conform to the surface of the material in a three-dimensional configuration by the fluid pressure, and the pattern of the pattern layer of the transferring member can be easily and reliably transferred to the material surface in the three-dimensional configuration. In addition, during the transfer, since the suction member evacuates gas existing between the material and the transferring member, the unnecessary gas does not penetrate into the space between the material and the transferring member. Consequently, the transferring member is capable of closely contacting the surface of the material and the pattern of the transferring member can be finely transferred to the surface of the material. Therefore, even if a concave is formed on the material to which the pattern of a transferring member is to be transferred, the transferring member can be brought into close contact with the surface of the concave by means of the suction device which evacuates gas existing in the concave. Thus, the pattern of the transferring member is finely transferred to the concave surface of the material. An in-mold transferring apparatus is used to transfer the pattern of the transferring member to the material in a three-dimensional configuration. In an in-mold transferring method, since the transferring member is inserted into a molding die before a transfer is carried out, disadvantageously, the space for placing the transferring member is limited and the configuration of the molding die is complicated, whereas the transferring apparatus of the above-described present invention does not have such a disadvantage.

According to the above-described embodiment, even though the material has a three-dimensional configuration on its surface, when the sheet is pressed against the material through the transferring member, the sheet and the transferring member are capable of conforming to the surface of the material in a three-dimensional configuration by the fluid pressure. Thus, the pattern of the pattern layer of the transferring member can be reliably and easily transferred to the surface of the material in the three-dimensional configuration. In addition, during the transfer, unnecessary gas does not penetrate into the space between the material and the transferring member because fluid existing between the material and the transferring member is discharged. Consequently, the transferring member is capable of closely contacting the surface of the material and the pattern of the transferring member can be finely transferred to the surface of the material. Therefore, even if a concave is formed on a material to which the pattern of a transferring member is to be transferred, the transferring member can be brought into close contact with the surface of the concave by discharging fluid in the concave. Thus, the pattern of the transferring member is finely transferred to the concave surface of the material. Further, in-mold transferring method is used to transfer the pattern of the transferring member to the material in a three-dimensional configuration. In the in-mold transferring method, since the transferring member is inserted into a molding die before a transfer is carried out, disadvantageously, the space for placing the transferring member is limited and the configuration of the molding die is complicated, whereas the transferring apparatus of the above-described present invention does not have such a disadvantage.

These and other objects and features of the present invention will become clear from the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings, in which:

FIG. 1 is a sectional view showing a transferring apparatus in use in a transferring process according to an embodiment of the present invention;

FIG. 2 is a sectional view showing the use in the transferring apparatus in transferring process;

FIG. 3 is a sectional view showing the transferring apparatus in use in the transferring process;

FIG. 4 is a sectional view showing the transferring apparatus in use in the transferring process; and

FIG. 5 is a sectional view showing the transferring apparatus in use in the transferring process.

Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings.

The embodiments of the present invention are described in detail below based on FIGS. 1 through 5.

In order to perform a transfer, in a transferring apparatus according to the invention, a material 1 to which the pattern of a transferring member 3 is to be transferred is placed on a base 2. A heated flexible sheet 4 supported by a supporting member 5 is on a side of the material 1 opposite the transferring member 3. A driving member (not shown) is provided to drive the supporting member 5 downward toward the base 2 to press the sheet 4 against the material 1 through the transferring member 3 as shown in FIG. 2.

The upper surface of the base 2 is flat and has many suction holes 2a formed therein and these suction holes 2a are connected with a suction member 12 so that gas existing between the material 1 and the transferring member 3 is evacuated.

The transferring member 3 is roll-shaped and comprises a release sheet 3b, a release layer formed on the release sheet 3b a pattern layer 3a formed on the release layer, and an adhesive layer formed on the pattern layer 3a. The release sheet 3b consists of a base film having a releasing property, and the release layer is left on the pattern layer 3a when the release sheet 3b is separated from the pattern layer 3a to function as a protecting layer to protect the pattern layer 3a. The pattern layer 3a has patterns such as pictures thereon. The pattern layer 3a may be formed of multiple layers or include a metal evaporating layer. The pattern layer 3a may include a surface protecting layer as necessary. That is, the above-described "pattern layer" includes a colorless, transparent surface protecting layer for protecting the surface of a material 1 to which the pattern of the transferring member is transferred and a ground adjusting layer serving as a ground when a design is formed with a painting brush rather than by means of a transfer.

A feed-out roller 8 and a winding roller 9 are provided, respectively on both sides of a region in which the base 2 and the supporting member 5 are provided in opposition to each other. The roll-shaped transferring member 3 is sequentially fed out from the feed-out roller 8 toward the winding roller 9. When a predetermined pattern of the pattern layer 3a is transferred to the material 1, a subsequent pattern of the pattern layer 3a formed on the release sheet 3b is fed out from the feed-out roller 8 by a predetermined pitch while the release sheet 3b removed as a result of the transfer of the pattern layer 3a to the material 1 is rolled round the winding roller 9. The transferring member 3 is not limited to a roll configuration, but may be composed of strips of paper so that the transferring member 3 is replaced each time a transfer is performed.

The sheet 4 may consist of, for example, a silicon rubber elastically deformable along a three-dimensional configuration of the material 1 which is approximately 2 mm to 3 mm thick.

The supporting member 5 supports the sheet 4 on the side of the transferring member 3 opposite the material 1 (i.e. above the transferring member 3 as shown in the drawings) by bringing the sheet 4 into close contact with a container 5a thereof. A sheet pressurizing chamber 11 which can be enclosed by the container 5a is formed on the side of the sheet 4 opposite the material 1 (i.e. above the sheet 4 as shown in the drawings). The sheet 4 is heated by heaters 6 provided on a bottom surface of the container 5a. Reference numeral 10 in the drawings denotes a discharge pipe for discharging fluid supplied into the pressurizing chamber 11.

Liquid such as water or oil or gas such as vapor or compressed air is supplied from a fluid supply member 7 into the pressurizing chamber 11 of the supporting member 5, thus supporting the sheet 4 in a pressurized state against the transferring member 3.

The supporting member 5 can be moved toward the material 1 placed on the base 2 or moved away therefrom by a driving member (not shown).

According to the above-described construction, as shown in FIG. 1, the material 1 is placed on the upper surface of the base 2 and the pattern layer 3a of the transferring member 3 which is to be transferred is opposed to the material 1 via the adhesive layer. At this time, the sheet 4 is heated by the heaters 6. Then, as shown in FIG. 2, the supporting member 5 is moved downward so that the sheet 4 causes the transferring member 3 to contact the material 1, and so that the lower end surface of the container 5a of the supporting member 5 is pressed against the upper surface of the base 2 through the sheet 4. Thereafter, as shown in FIG. 3, fluid is supplied from the fluid supply member 7 into the pressurizing chamber 11 of the supporting member 5 so that pressure is applied to the sheet 4 and the sheet 4 presses the transferring member 3 against the upper surface of the material 1. Thus, the sheet 4 and the transferring member 3 conform to the three-dimensional configuration of the upper surface of the material 1 and the pattern of the pattern layer 3a of the transferring member 3 is transferred to the surface of the material 1 in the three-dimensional configuration by the fluid pressure and heat transmitted from the sheet 4. In this transfer, the suction member 12 sucks fluid such as gas existing between the material 1 and the transferring member 3 through the suction holes 2a of the base 2 so that the pattern layer 3a of the transferring member 3 closely contacts the surface of the material 1 via the adhesive layer. Then, the supporting member 5 is moved upward as shown in FIG. 4 after the fluid in the pressurizing chamber 11 is released from the discharge pipe 10. Thereafter, as shown in FIG. 5, the feed-out roller 8 and the winding roller 9 are driven so that the release sheet 3b from which the pattern of the pattern layer 3a has been transferred to the material 1 is moved away from the surface of the material 1 by rolling the release sheet 3b around the winding roller 9, and the subsequent pattern layer 3a is positioned above the base 2. In this state, the release layer separated from the release sheet 3b and a pattern 13 of the pattern layer 3a have been transferred and adhered to the surface of the material 1 through the adhesive layer. The release layer functions as the protecting layer of the pattern layer 3a.

According to the above-described embodiment, even though the material has a three-dimensional configuration on its surface, when the sheet 4 is pressed against the material 1 via the transferring member 3, fluid is supplied to the pressurizing chamber 11 of the supporting member 4 so that the sheet 4 and the transferring member 3 conform to the surface of the material 1 in the three-dimensional configuration by the fluid pressure and the pattern of the pattern layer 3a of the transferring member 3 can be easily and reliably transferred to the surface of the material 1 in the three-dimensional configuration. Accordingly, if a material has a rounded corner, the sheet and the transferring member contact each other along the rounded corner to which a pattern is to be transferred. Therefore, the pattern of the transferring member can be finely and reliably transferred to the material at the rounded corner. In addition, during the transfer, since the suction member 12 evacuates gas existing between the material 1 and the transferring member 3, the unnecessary gas does not penetrate into the space between the material 1 and the transferring member 3. Consequently, the transferring member 3 is capable of closely contacting the surface of the material 1 and the pattern of the transferring member 3 can be finely transferred to the surface of the material 1. Therefore, even if a concave is formed on the material to which the pattern of the transferring member 3 is to be transferred, the transferring member can be brought into close contact with the surface of the concave by the suction device which evacuates gas existing in the concave. Thus, the pattern of the transferring member 3 is finely transferred to the concave surface of the material 1. An in-mold transferring method has been used to transfer patterns of the from transferring members to the surfaces of material in a three-dimensional configuration. In the in-mold transferring method, since the transferring member is inserted into a molding die before a transfer is carried out, disadvantageously, the space for placing the transferring member is limited and the configuration of the molding die is complicated; whereas the transferring apparatus of the above-described embodiment does not have such a disadvantage.

The present invention is not limited to the above-described embodiment, but various modifications may be made.

For example, a similar operation and effect can be brought about by moving the base 2 toward the supporting member 5 or moving it away therefrom.

It is possible to bring the pressurized sheet 4 into contact with the transferring member 3 by supplying fluid to the pressurizing chamber 11 of the supporting member 5 before the sheet 4 contacts the transferring member 3 and press the sheet 4 against the material 1 through the transferring member 3.

Fluid may be discharged from the pressurizing chamber 11 after the sheet 4 separates from the transferring member 3.

The sheet 4 may be pressed against the material 1 through the transferring member 3 only in the region in which the pattern of the transferring member 3 is transferred to the material 1.

The construction of the transferring member 3 is not limited to the above-described one, but may be varied.

For example, in the above embodiment, when the release sheet 3b is separated from the material 1, the release layer of the release sheet 3b is left on the pattern layer 3a, thus functioning as the protecting layer of the pattern layer 3a. However, the release sheet 3b may consist of a base film and a release layer so that the release layer is separated from the pattern layer 3a by separating the release sheet 3b from the pattern layer 3a. Preferably, the release layer may consist of the base film and coated resin on the base film or films laminated one on the other.

The transferring member 3 may be composed without forming the adhesive layer on the pattern layer. That is, the transferring member 3 may consist of the release sheet made of a base film; the release layer which is left on the pattern layer when the release sheet is separated from the material; and the pattern layer having adhesive property and patterns. In this case, the pattern layer functions as the adhesive layer. Thus, the construction of the transferring member can be simplified by not providing the adhesive layer.

Further, the transferring member 3 may consist of the release sheet made of the base film; the release layer which is left on the pattern layer when the release sheet is separated from the material; and the pattern layer having patterns but no adhesive property. In this construction, an adhesive agent is applied to the pattern layer of the transferring member before a transfer is carried out, or the pattern of the pattern layer may be transferred to the material after an adhesive tape is adhered to the pattern layer. In this case, an adhesive agent having a great adhesive property or a water adhesive agent may be used so that a transfer can be carried out at a low temperature and a thermal deformation of the material can be prevented. When the above adhesive tape is used, a heating operation can be advantageously eliminated in a transfer process.

In addition, the transferring member 3 may consist of the release sheet made of the base film; the release layer which is left on the pattern layer when the release sheet is separated from the material; and the pattern layer having patterns but no adhesive property. In this construction, the pattern of the pattern layer of the transferring member is transferred to the material having an adhesive agent applied thereto or the material having an adhesive tape stuck thereto. In this case, an adhesive agent having a great adhesive property or a water adhesive agent may be used so that a transfer can be carried out at a low temperature and a thermal deformation of the material can be prevented. When the above adhesive tape is used, a heating operation can be eliminated in a transfer process.

Although the present invention has been fully described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications are apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom.