JP7804973B2 - Heat transfer material manufacturing method and heat transfer material manufacturing device - Google Patents

Description

The present invention relates to a method and apparatus for manufacturing heat transfer materials for thermally transferring designs onto target articles such as clothing and other textile products.

Conventionally, when producing transfer paper for transferring designs onto textile products such as clothing, the desired design layer and adhesive layer were formed by screen printing on a substrate such as release-treated paper or synthetic resin film.

To form the design layer, it was necessary to create a screen plate corresponding to each color that made up the design, and then print using a screen printing machine using a separate screen plate for each color of ink.

In addition, to prevent the transferred design from being affected by the background color of the object being transferred, it was necessary to perform screen printing using a separately prepared screen to form a concealing white ink layer over the design layer.

Furthermore, to form an adhesive layer for adhering to the transfer target, it was necessary to screen print hot-melt resin ink using a separately prepared screen, or to spray hot-melt resin powder and perform heat treatment.

However, producing transfer paper using this conventional method requires time and money to create each screen, making it extremely inefficient, costly, and low-productivity, especially when producing a wide variety of small lots.

JP 2010-64354 A discloses a method for producing transfer paper using inkjet printing without plate making, in which a pattern or the like is transferred to polyester fiber fabric or the like by sublimation using transfer paper with a paper base printed with sublimation dyes.

However, this method is limited to transfer onto polyester fiber substrates, and it is not possible to apply a concealing white ink layer that would prevent transfer by sublimation. Therefore, it is difficult to use this method for anything other than transferring designs onto white (or light-colored) polyester fiber substrates that are hardly affected by the background color.

Meanwhile, WO 2019/142657 discloses a method for producing transfer paper without plate-making, in which a peelable adhesive layer is formed on one or more predetermined post-printing areas on a predetermined surface of a substrate, and a design layer is printed on the adhesive layer using a plate-less inkjet printing method to obtain transfer paper.

However, this method requires the creation of a screen plate and screen printing to form the adhesive layer, so it cannot be said to be producing transfer paper without a plate.

In addition, Japanese Patent Application Laid-Open No. 2019-39082 discloses a method for producing a transfer printing ink containing a pigment and a fixing resin,
an image forming step of forming an image by ejecting the transfer printing ink onto a transfer paper using an inkjet recording device;
a drying step of drying the transfer paper on which the image has been formed in the image forming step at a temperature lower than the crosslinking temperature of the fixing resin;
a transfer step in which the transfer paper dried in the drying step is superimposed on a fabric, and the image formed on the transfer paper is transferred to the fabric by applying pressure while heating at a temperature higher than the crosslinking temperature of the fixing resin;
a peeling step of peeling the transfer paper from the fabric after the image has been transferred in the transfer step;
A transfer printing method comprising:
the transfer paper has a hydrophilic ink-receiving layer and a surface layer formed of a release layer-forming agent comprising an emulsion of hydrophobic particles whose surface is coated with a hydrophilic emulsifier;
There is disclosed a transfer printing method in which the release layer forming agent is heated in the drying step or the transfer step to form a hydrophobic release layer in the vicinity of the ink receiving layer.

However, with this method, the image is formed on the transfer paper substrate, and adhesion to the target fabric is achieved solely by the fixing resin contained in the transfer printing ink. Therefore, for textile products and other products that require durability, the robustness required of the transferred image is thought to be insufficient.

Furthermore, since this transfer paper does not have a concealing layer that can adequately prevent the background color of the textile product to be transferred from being affected, it is difficult to use it on anything other than white (or light-colored) textile products.

Furthermore, transfer paper is obtained by drying at a temperature lower than the crosslinking temperature of the fixing resin, and when the image is transferred to the target fabric using this transfer paper, it is heated and pressurized at a temperature higher than the crosslinking temperature of the fixing resin. Therefore, it is expected that inconveniences will arise due to the gradual crosslinking of the fixing resin in the transfer paper before use.

In addition, Japanese Patent Application Laid-Open No. 2020-1233 discloses a decoration method for decorating at least one of a fabric and a textile product as a decoration target,
a preparation step of preparing a thermal transfer sheet including a release sheet and a transfer layer formed on the release sheet and containing thermoplastic resin particles and decorative particles for decorating the object to be decorated;
a transfer step in which the surface of the thermal transfer sheet on the side of the transfer layer is brought into contact with the object to be decorated and heated, and then the release sheet is peeled off to fix the transfer layer to the surface of the object to be decorated;
an image forming step of forming an image by penetrating ink into at least the transfer layer;
and a decorating method using an inkjet printer in the image forming step.

This method uses opacifying pigments, such as a white pigment ink layer, in the transfer layer, preventing the background color of the textile product being transferred from affecting the transferred image.

However, this decoration method involves transferring a transfer layer formed on a release sheet onto fabric, textile products, etc., and then forming an image on the transfer layer transferred to the target using a method such as inkjet printing, making it an extremely inefficient and complicated manufacturing process.

Furthermore, because the transfer sheet layer is formed over the entire surface of the fabric or fiber, issues with texture and breathability also become a concern. To improve breathability and texture, the pattern must be cut into individual pieces, and the unnecessary parts must be removed before the transfer sheet is thermally transferred to form the image.

JP 2010-64354 A International Publication No. 2019/142657 Japanese Patent Application Laid-Open No. 2019-39082 Japanese Patent Application Laid-Open No. 2020-1233

The present invention aims to provide a method and apparatus for manufacturing heat transfer materials for thermally transferring designs onto target articles such as textile products, which can efficiently form the designs to be thermally transferred and the hot-melt adhesive joints on the target articles without plate-making.

The present invention can be expressed, for example, as follows:

(1) Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
at a retention layer forming position which is located ahead of the ink image layer forming position in the path or which is the same position as the ink image layer forming position, a retention layer is formed on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder;
forming a hot-melt resin powder layer from hot-melt resin powder on one or both of the retention layer and the ink image layer on which no retention layer is present at a powder layer formation position which is a position ahead of the retention layer formation position in the path;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or that is the same position as the powder layer formation position, before the heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer.

(2) The method described in (1) above, in which the hot melt resin powder layer is formed in a state in which the hot melt resin powder can adhere to both the retention layer-forming ink that forms the retention layer on which the hot melt resin powder layer is formed and the ink image-forming ink that forms the ink image layer without the retention layer.

(3) The ink image layer is formed by inkjet printing at the ink image layer forming position after detecting that the thermal transfer position on the substrate is located at the ink image layer forming position,
the formation of the retention layer by inkjet printing at the retention layer formation position is performed after detecting that the thermal transfer location is located at the retention layer formation position,
the formation of the hot-melt resin powder layer at the powder layer formation position is carried out after detecting that the thermal transfer location is located at the powder layer formation position;
The removal of unnecessary hot melt resin powder at the resin powder removal position is performed after detecting that the thermal transfer location is located at the resin powder removal position,
The method described in (1) or (2) above, wherein the formation of the hot melt resin layer by heat treatment of the hot melt resin powder at the resin layer formation position is carried out after detecting that the thermal transfer location is located at the resin layer formation position.

(4) The method according to any one of (1) to (3) above, wherein the substrate is made of a polyester resin film.

(5) The method according to any one of (1) to (4), wherein at least the portion of the ink-receiving layer on which ink-jet printing with ink for forming an ink image is performed contains a porous substance having a pore volume of 0.3 cm ³ /g or more.

(6) A method according to any one of (1) to (5) above, wherein the surface free energy of at least the portion of the ink receiving layer on which inkjet printing with ink for forming an ink image is performed is 25 (mJ/ ^m2 ) to 35 (mJ/ ^m2 ).

(7) The method according to any one of (1) to (6) above, wherein the ink-receiving layer contains a cationic compound monomer, a cationic compound polymer, or a basic inorganic metal salt as an ionic gelling agent.

(8) The method according to any one of (1) to (7) above, wherein the ink for forming an ink image is a water-based ink and has a surface tension of 23 to 35 (mN/m).

(9) The method according to any one of (1) to (8) above, wherein the ink for forming the retention layer is a water-based ink and has a surface tension of 23 to 35 (mN/m).

(10) The method according to any one of (1) to (9) above, wherein all or a portion of the hot melt resin powder used to form the hot melt resin powder layer that was not retained on the substrate is reused to form a new hot melt resin powder layer.

(11) Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
forming a hot-melt resin powder layer on the ink image layer at a powder layer forming position which is a position ahead of the ink image layer forming position in the path;
after forming a hot-melt resin powder layer on the ink image layer, unnecessary hot-melt resin powder that may be present in portions other than the ink image layer on the substrate is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, before the heat treatment of the hot-melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer.

(12) A drive or conveying system for driving or conveying a thin substrate along a predetermined path;
an ink image layer forming section for forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
a retention layer forming section for forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer, at a retention layer forming position which is located ahead of the ink image layer forming position in the path or at the same position as the ink image layer forming position;
a hot-melt resin powder layer forming section for forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, at a powder layer forming position which is a position ahead of the retention layer forming position on the path;
a resin powder removal section for removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on portions other than the ink image layer on which no retention layer is present, at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, from the substrate before heat treatment of the hot melt resin powder, after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present;
The thermal transfer material manufacturing device includes a hot melt resin layer forming section for melting and solidifying the hot melt resin powder that constitutes the hot melt resin powder layer by heat treatment at a resin layer forming position that is either forward of the resin powder removal position on the path or at the same position as the resin powder removal position, and the ink receiving layer is provided directly on one side of the substrate, or if the ink receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer.

(13) The apparatus described in (12) above, in which the hot melt resin layer forming unit forms a hot melt resin powder layer in a state in which the hot melt resin powder can adhere to both the retention layer forming ink that forms the retention layer on which the hot melt resin powder layer is to be formed and the ink image forming ink that forms the ink image layer without the retention layer.

(14) A detecting means is provided for detecting that the thermal transfer position on the substrate is located at the ink image layer forming position, and the ink image layer is formed by the ink jet printing after the detecting means detects that the thermal transfer position is located at the ink image layer forming position,
a detection means for detecting that the thermal transfer location is located at the retention layer formation position, and after the detection means detects that the thermal transfer location is located at the retention layer formation position, the retention layer is formed by the inkjet printing;
a detection means for detecting that the thermal transfer portion is located at the powder layer formation position, and after the detection means detects that the thermal transfer portion is located at the powder layer formation position, a hot melt resin powder layer is formed using the hot melt resin powder;
a detection means for detecting that the thermal transfer location is located at the resin powder removal position, and after the detection means detects that the thermal transfer location is located at the resin powder removal position, the unnecessary hot melt resin powder is removed;
The apparatus described in (12) or (13) above has a detection means for detecting that the thermal transfer location is located at the resin layer formation position, and after detecting that the thermal transfer location is located at the resin layer formation position using the detection means, forms a hot melt resin layer by heat treating the hot melt resin powder.

The thermal transfer material manufacturing method and thermal transfer material manufacturing apparatus of the present invention enable efficient production of thermal transfer materials that can thermally transfer ink images, etc., to an object by forming ink image layers and hot melt resin layers, etc., without plate-making.

FIG. 1 is an explanatory diagram of a heat transfer material manufacturing device that uses a belt-shaped substrate. 1A and 1B are schematic plan and cross-sectional views of a process for manufacturing a heat transfer material using a belt-shaped substrate. 1A to 1C are schematic plan views, side views, and cross-sectional views of a process for manufacturing a heat transfer material using a belt-shaped substrate. FIG. 1 is a schematic plan view of a T-shirt onto which an ink image has been transferred using a thermal transfer material. FIG. 5 is a schematic cross-sectional view of a main part taken along line VV in FIG. 4. FIG. 1 is an explanatory diagram of a heat transfer material manufacturing device that uses a sheet-shaped substrate. 1A and 1B are schematic plan and cross-sectional views of a process for manufacturing a heat transfer material using a sheet-like substrate. 1A and 1B are schematic plan and cross-sectional views of a process for manufacturing a heat transfer material using a sheet-like substrate.

[1] An embodiment of the present invention will be described.

The method for producing a thermal transfer material of the present invention comprises the steps of:
Driving or conveying the substrate along a predetermined path;
At each predetermined position on the route,
forming an ink image layer by inkjet printing on an ink-receiving layer provided on one surface of the substrate;
forming a retention layer by inkjet printing using a retention layer-forming ink for retaining hot melt resin powder on one or both of the entire ink image layer or a required portion thereof and the portion of the ink receiving layer other than the ink image layer;
forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer where no retention layer is present;
removing unwanted hot melt resin powder from the substrate; and
This method involves melting and solidifying hot-melt resin powder through heat treatment to form a hot-melt resin layer.

Another method for producing a heat transfer material of the present invention comprises the steps of:
Driving or conveying the substrate along a predetermined path;
At each predetermined position on the route,
forming an ink image layer by inkjet printing on an ink-receiving layer provided on one surface of the substrate;
forming a hot melt resin powder layer on the ink image layer;
removing unwanted hot melt resin powder from the substrate; and
This method involves melting and solidifying hot-melt resin powder through heat treatment to form a hot-melt resin layer.

The thermal transfer material manufacturing apparatus of the present invention further comprises:
a drive or transport system that drives or transports the substrate along a predetermined path;
At each predetermined position on the route,
an ink image layer forming unit for forming an ink image layer by inkjet printing on an ink receiving layer provided on one surface of the substrate;
a retention layer forming section for forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on one or both of the entirety or a required portion of the ink image layer and the portion of the ink receiving layer other than the ink image layer;
a hot-melt resin powder layer forming section for forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which the retention layer is not present;
a resin powder removal unit for removing unwanted hot melt resin powder from the substrate;
and,
The apparatus has a hot melt resin layer forming section for forming a hot melt resin layer by melting and solidifying hot melt resin powder through heat treatment.

(1) Base material

The substrate is thin (e.g., strip-shaped or sheet-shaped).

(1-1) The material of the substrate is not particularly limited, but can be one that has heat resistance and strength (pressure resistance, etc.) that can withstand the conditions of heat and pressure transfer (e.g., transfer temperature of 100 to 200°C, transfer time of 2 to 30 seconds, transfer pressure of 10 to 200 kPa).

Specific examples of substrate materials include, but are not limited to, synthetic resin films (e.g., 20 to 400 μm thick) such as polyester resin and polyimide resin, and paper. Examples of polyester resins include polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polybutylene naphthalate (PBN).

Synthetic resin films such as PET and other polyester resin films are preferred because they are less susceptible to changes in humidity due to seasons and regions than paper.

(1-2) An ink-receiving layer is provided on one side of the strip-shaped substrate, either directly or via another layer. An ink image layer or a retention layer is formed on the ink-receiving layer, for example, at intervals of a predetermined length or at intervals defined by other divisions, and a hot-melt resin layer is then formed. For example, the strip-shaped substrate can be used for thermal transfer of ink image layers, etc., at each divided section, or it can be cut into each divided section or each ink image layer and used for thermal transfer.

If necessary, the other surface of the strip-shaped substrate may be treated to prevent blocking (for example, provided with a release layer to prevent blocking).

Furthermore, the strip-shaped substrate may be continuous over a length at least as long as necessary for use in the method and apparatus of the present invention, and may be, for example, continuous over a length that is 5 to 1000 times the length of the specified path along which the strip-shaped substrate is driven, but is not limited to this.

A strip-shaped substrate generally has a constant width at any position in the continuous direction, but it can also have a width (dimension perpendicular to the continuous direction) that varies depending on the position in the continuous direction.

The strip-shaped substrate is preferably a continuous strip-shaped substrate that is already in the form of a roll (for example, wound around a reel or core), but this is not limited to this. It is also possible to use a continuous strip-shaped substrate in the form of a roll, which is made by cutting a sheet into strips, joining them lengthwise with adhesive tape (for example, water-soluble adhesive tape in the case of paper, or thermal adhesive tape in the case of polyester film) or adhesive, and then winding it up.

(1-3) An ink-receiving layer is provided on one side of the sheet-like substrate, either directly or via another layer; an ink image layer and a retention layer are formed on the ink-receiving layer; and a hot-melt resin layer is then formed. For example, the substrate can be used for thermal transfer as is; or two or more ink image layers can be provided on a single sheet-like substrate, and thermal transfer can be performed separately for each ink image layer, or the substrate can be cut into individual ink image layers for use.

If necessary, the other side of the sheet substrate may be treated to prevent blocking (for example, provided with a release layer to prevent blocking).

The shape of the sheet-like substrate can be rectangular, as well as various polygonal, circular, elliptical, and other shapes surrounded by closed curves.

(2) Drive or transport system

(2-1) The drive system can, for example, be capable of advancing or stopping the strip-shaped substrate in the continuous direction of the strip-shaped substrate along a predetermined path (for example, it can also be capable of advancing the strip-shaped substrate at intervals of the predetermined length or at intervals separated by other intervals, and can also be capable of reversing the strip-shaped substrate if necessary).

This allows each thermal transfer location, which can be set sequentially in the direction of the strip of substrate (e.g., at predetermined intervals or at other intervals), to advance sequentially to an ink image layer formation position, a retention layer formation position (including when there is no retention layer formation position or when it is the same position as the ink image layer formation position), a powder layer formation position, a resin powder removal position (including when it is the same position as the powder layer formation position), and a resin layer formation position (including when it is the same position as the resin powder removal position), and the ink image layer formation, retention layer formation, hot melt resin powder layer formation, unwanted hot melt resin powder removal, and hot melt resin layer formation processes can be performed at each position. Note that if there are multiple positions where a process can be performed on a thermal transfer location while the strip of substrate is stationary, it is desirable to set the location of each thermal transfer location, the position where each process is performed, and the path for driving the substrate so that different thermal transfer locations are simultaneously located at two or more of these multiple positions and each process can be performed while the strip of substrate is stationary.

(a) The drive system can be, for example, a system in which the strip-shaped substrate is set in a winding section, and stretches the strip-shaped substrate between the winding section and the unwinding section, and, if necessary, can be provided with a guide section, tension maintaining section, intermediate drive section, etc. in between to maintain the path or change the direction of the strip-shaped substrate.

The guide section can be, for example, a guide roller.

The intermediate drive unit can be, for example, a drive roller and pinch roller, or a pair of drive rollers, that clamp the strip-shaped substrate, and whose rotation and stopping are controlled by an electric motor controlled by the control unit.

The tension of the strip-shaped substrate between the unwinding section and the take-up section (or tension at required locations such as other tension maintaining units, intermediate drive units, ink image layer formation positions, retention layer formation positions, powder layer formation positions, resin powder removal positions, and resin layer formation positions) can be controlled, for example, by controlling the rotation of the unwinding section or other driven rollers or drive rollers such as guide rollers using a brake unit or electric motor controlled by the control unit, or by controlling the rotation axis position of the driven rollers or drive rollers such as guide rollers using various actuators controlled by the control unit.

(b) The strip-shaped substrate may be provided with a detectable portion, printed, perforated, or otherwise provided with a photocell mark, punched hole, or other detection (e.g., optical or electromagnetic detection), which allows alignment by driving and stopping (or, if necessary, driving backward) the required length in the direction of the strip-shaped substrate so that the thermal transfer locations located at intervals in the direction of the strip-shaped substrate are aligned with the respective positions, such as the ink image layer formation positions.

In addition, detection means for detecting the position of the thermal transfer point on the strip-shaped substrate can be provided at necessary locations along a specified path, or the driving distance of a winding section, drive roller, driven roller, etc. can be measured.

Alignment by detecting detectable portions on the strip-shaped substrate can be performed, for example, by providing each thermal transfer location at a predetermined continuous length on the strip-shaped substrate and maintaining the required tension on the strip-shaped substrate, thereby allowing the drive system to align only the ink image layer formation position, thereby simultaneously aligning the retention layer formation position (including when there is no retention layer formation position or when it is the same position as the ink image layer formation position), powder layer formation position, resin powder removal position (including when it is the same position as the powder layer formation position), and resin layer formation position (including when it is the same position as the resin powder removal position). Furthermore, fine-tuning devices that can individually align each position (for example, align with the required tension applied) can be provided at locations corresponding to each position on the drive system.

(2-2) The conveying system can be capable of advancing or stopping the sheet-like substrate along a predetermined path (for example, by a fixed length [for example, a length corresponding to the length of the sheet-like substrate in the conveying direction]) (it can also be capable of moving backward if necessary).

This allows the thermal transfer locations that can be set on the sheet-like substrate (multiple locations can be set on a single sheet-like substrate, if necessary) to be sequentially advanced to the ink image layer formation position, retention layer formation position (including when there is no retention layer formation position or when it is the same location as the ink image layer formation position), powder layer formation position, resin powder removal position (including when it is the same location as the powder layer formation position), and resin layer formation position (including when it is the same location as the resin powder removal position), and the processing steps of ink image layer formation, retention layer formation, hot melt resin powder layer formation, unnecessary hot melt resin powder removal, and hot melt resin layer formation can be performed at each position. Furthermore, if there are multiple positions where any of the processing steps can be performed on the thermal transfer locations while the sheet-like substrate is stationary, it is desirable to set the processing step execution positions and the path for driving the sheet-like substrate so that the thermal transfer locations of different sheet-like substrates are simultaneously located at two or more of these multiple positions and the respective processing steps can be performed while the multiple positions are stationary.

The conveying system may, for example, have a drive roller and pinch roller or a pair of drive rollers that clamp the sheet-like substrate to move it forward or stop (or move it backward if necessary) along a predetermined path at required locations on the path, as well as a guide unit (such as a guide roller) or conveyor belt for maintaining the path or changing direction.

In addition, detection means for detecting the position and orientation of the sheet-like substrate can be provided at necessary locations along a specified path, or the conveying distance can be measured using a drive roller, driven roller, conveyor belt, etc.

The sheet-like substrate may have edges such as a leading edge, trailing edge, and side edges that can be detected to advance or stop (or retreat if necessary) the sheet-like substrate along a predetermined path and align the thermal transfer point on the sheet-like substrate with each of the above-mentioned positions, such as the ink image layer formation position (or to correct its posture).In addition, the sheet-like substrate may also have detectable portions printed, perforated, or provided by other means, such as photoelectric marks, punched holes, or other detection (e.g., optical or electromagnetic detection) that enable alignment.

The conveyor belt is intended for transporting a sheet-like substrate placed or held on its upper surface (for example, by holding it using negative pressure such as air suction through suction holes in the conveyor belt, or by holding it using a pressure body that moves together with the conveyor belt and sandwiches the sheet-like substrate between the conveyor belt and the belt).

The orientation of the sheet-like substrate is, for example, the inclination of the long or short side of a rectangular sheet-like substrate being transported along a predetermined transport surface relative to the transport direction.

The above-mentioned sensors may, for example, detect one or more locations on the leading edge, trailing edge, or side edge of a sheet-like substrate, or may detect photocell marks, punched holes, or other detection marks (e.g., optical or electromagnetic detection) on the sheet-like substrate.

Furthermore, the conveying system may, for example, detect or measure the attitude, such as the tilt, of the sheet-like substrate relative to the conveying direction as needed, and have the drive roller perform an operation to correct the tilt, or may be provided with a correction means such as a separate correction roller, or may be provided with a means such as a guide member to detect lateral deviation of the sheet-like substrate relative to the specified path and correct the lateral deviation.

(2-3) Such control of the drive or conveyance system can be performed, for example, by a control unit (e.g., a computer such as a personal computer, or other digital control device) controlling electric motors and other actuators based on detection information from each sensor.

(3) Release properties to aid in the removal of the substrate during thermal transfer.

The ink-receiving layer is provided on one side of the substrate either directly or via another layer. When the ink-receiving layer is provided directly on one side of the substrate or via another layer, the other layer is provided to have releasability to facilitate peeling of the substrate during thermal transfer.

Removal of the substrate during thermal transfer refers to the removal of the substrate after the hot melt resin layer is brought into contact with the transfer target and the thermal transfer material is heated and pressurized between the back surface of the substrate of the thermal transfer material and the transfer target when thermally transferring an ink image or the like to a transfer target such as a fabric product using the thermal transfer material obtained by the method or apparatus of the present invention. Releasability that aids in the removal of the substrate refers, for example, to releasability that makes the substrate removal smooth or easy, or that prevents damage to the transferred ink image or the like due to the removal of the substrate.

Examples of the ink receiving layer provided directly on one surface of the substrate or the ink receiving layer provided via the other layer, in which the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer, include:
When an ink receiving layer or another layer is provided on one surface of the substrate via a release layer,
When an ink receiving layer having releasability or the other layer having releasability is provided on one surface of the substrate,
The substrate itself or at least one surface of the substrate itself may have releasability.

An example of such another layer is a colorless and transparent protective layer, and the other layer may also have releasability.

(4) Ink-receiving layer

At least that portion of the ink-receiving layer where inkjet printing with ink for forming an ink image is performed (preferably the entire ink-receiving layer) can contain a porous substance having a pore volume of, for example, 0.3 ^cm3 /g or more, preferably 0.5 ^cm3 /g or more (for example, a porous substance containing a sufficient or uniform amount to exhibit the aforementioned clarity, sharpness, anti-bleeding, and anti-color mixing properties) so that the ink for forming an ink image by inkjet printing can exhibit good clarity, sharpness, anti-bleeding, and anti-color mixing properties. The same applies to that portion of the ink-receiving layer where no ink image layer is formed and ink for forming a retention layer is to be inkjet printed.

Examples of the porous material include crystalline silica, amorphous silica, and aluminum silicate. Combinations of two or more of these materials can also be used, but the material is not necessarily limited to these.

Furthermore, the surface free energy of the surface (e.g., the coated surface) of at least the portion of the ink-receiving layer where inkjet printing with ink for forming an ink image is performed is preferably 25 (mJ/ ^m2 ) to 35 (mJ/ ^m2 ).The same applies to the portion of the ink-receiving layer where inkjet printing with ink for forming a retention layer is performed without forming an ink image layer.

The surface free energy is measured using a contact angle measuring device (CAX-150, manufactured by Kyowa Interface Science Co., Ltd.).

The contact angle of each liquid on the film was measured using three liquids: water, diiodomethane, and n-hexadecane, and calculated using the Kitazaki-Hata formula.

Surface free energy can be adjusted using surface tension modifiers.

The surface tension adjuster is preferably one that does not impair the physical properties required of the ink-receiving layer (for example, properties that enable the ink image-forming ink to exhibit clarity, sharpness, anti-bleeding, and anti-color mixing), and examples thereof include various oils, surfactants, and silicone-grafted surfactants.

The ink-receiving layer can be formed (fixed) by coating or other means on the entire surface or desired areas of one side of the substrate, either directly or via another layer, with an ink-receiving layer-forming treatment agent, which is made by converting the porous material, surface tension adjuster, and other components into ink together with a fixing resin. Fixing resins that can be used include, for example, acrylic resins, polyester resins, polyurethane resins, ethylene vinyl acetate resins, polyamide resins, and rosinate ester resins, which can be used in the form of emulsions, dispersions, or organic solvent solutions.

An ink-receiving layer with releasability can be formed using an ink-receiving layer-forming treatment agent in which a releasable component selected from, for example, various waxes, paraffin, silicone resin, silicone oil, or fluororesin is blended with the components that form the ink-receiving layer.

When an ink-receiving layer or other layer is provided on one side of a substrate via a release layer, the release layer can be formed by coating one side of the substrate with a release treatment agent containing a release component selected from, for example, various waxes, paraffin, silicone resin, silicone oil, fluororesin, etc.

In addition, to improve the clarity, sharpness, anti-bleeding properties, and anti-color mixing properties of the ink for forming an ink image (or ink for forming a retention layer) by inkjet printing, the components forming the ink-receiving layer can be blended with one or, if appropriate, two or more of the following ionic gelling agents: cationic compound monomers, cationic compound polymers, basic inorganic metal salts, etc.

Examples of the cationic compound monomer include dodecyltrimethylammonium chloride, dodecylbenzyldimethylammonium chloride, and cetylpyridinium chloride. Examples of the cationic polymer include polyallylamine hydrochloride, diallylamine hydrochloride polymer, methyldiallylamine hydrochloride polymer, diallyldimethylammonium chloride polymer, 2-(acryloyloxy)ethyltrimethylammonium chloride polymer, dimethylamine-epichlorohydrin condensate, cationized starch, and cationized cellulose. Examples of the basic inorganic metal salt include, but are not limited to, calcium nitrate, calcium chloride, magnesium nitrate, and magnesium chloride. Furthermore, two or more of each can be used in combination.

(5) Ink image layer formation section

(5-1) The ink image layer forming unit, at the ink image layer forming position on the specified path (not necessarily when the substrate is stationary), detects, as necessary, using a detection means that the thermal transfer location on the substrate is located at the ink image layer forming position, and then forms an ink image layer on the ink receiving layer by inkjet printing using ink for forming an ink image to represent the required image, in accordance with input printing data (for example, printing data input via the control unit of a computer such as a personal computer or other digital control device). The printing data usually assumes that the ink image formed on the ink receiving layer will be reverse-transferred to a transfer target such as a fabric-like product.

(5-2) Inkjet printing can be performed, for example, using an inkjet printing device equipped with a multi-color printing inkjet head, but is not limited to this. When performing multi-color printing, inks for forming ink images can be, for example, four colors of ink: the three basic primary colors (cyan, magenta, yellow) and black, but are not limited to these. For example, the color gamut can be expanded by adding special color inks such as green, orange, purple, and white to these four colors.

(5-3) The inkjet method used in inkjet printing is not particularly limited, and examples include a charge control method that uses electrostatic attraction to eject ink, a drop-on-demand method (pressure pulse method) that uses the vibration pressure of a piezoelectric element, an acoustic inkjet method that uses radiation pressure to convert an electric signal into an acoustic beam and irradiate the ink, and a thermal inkjet method that heats the ink to form bubbles and uses the resulting pressure, but the piezoelectric method is preferred.

(5-4) The print head of an inkjet printer can be, for example, a serial head that prints by moving the head in the width direction of the substrate (a direction perpendicular to the direction of the specified path), or a line head that does not require widthwise head movement because the head covers the required range in the width direction of the substrate.

Regarding the path direction of the substrate, the head can be positioned at a fixed position in the path direction and print while moving the substrate in that direction, or the head can be moved in the path direction of the substrate while the substrate is stationary and print (for example, in the case of a serial head, the head can be moved in the width direction of the substrate at a fixed position in the path direction and print, then the serial head can be moved a required distance in the path direction of the substrate and the head can be moved in the width direction of the substrate at that position and print, repeating this process as many times as necessary to perform the required printing; in the case of a line head, the head can be printed at a fixed position in the path direction of the substrate and then the line head can be moved a required distance in the path direction of the substrate and print at that position, repeating this process as many times as necessary to perform the required printing). Furthermore, for example, the head can cover the required range in both the width direction and path direction of the substrate, allowing the required printing to be performed while both the substrate and head are stationary.

(5-5) In order to print accurately, it is preferable to perform the inkjet printing described above while the substrate is stationary.

When inkjet printing is performed while the substrate is stationary, printing accuracy can be maximized by temporarily positioning and supporting the substrate at a specified printing position on a specified path.

An example of such temporary positioning support for a strip-shaped substrate is a predetermined path near the printing position.
(a) One side edge and the other side edge of the strip-shaped substrate are guided in a state where they pass through the grooves of a pair of groove-shaped guide parts that face each other inward, thereby preventing the substrate from meandering in the width direction;
(b) Providing holding sections that press and hold the belt-shaped substrate in the thickness direction (for example, by air pressure, hydraulic pressure, electromagnetic force, etc.) at multiple locations across the ink image layer forming section, and pressing and holding the substrate by these holding sections during printing (the pressing and holding is released after printing);
(c) Applying negative pressure by air suction or the like to the back side of the strip-shaped substrate to hold it in place during printing (the holding by negative pressure is released after printing), or a combination of two or more of these.

An example of such temporary positioning support for a sheet-like substrate is stopping it with the required tension applied between one end and the other end in the path direction. Stopping it in this state can be achieved by pinching one end of the substrate in a stationary state between a drive roller and a pinch roller, and pinching the other end in a stationary state between a drive roller or a driven roller whose rotation is controlled to stop and a pinch roller.

(6) Ink for forming ink images

Water-based inks are preferred as inks for forming ink images, as they have a low environmental impact and are less stressful for workers. Pigments are preferably used as colorants for water-based inks to achieve good durability.

Aqueous inks for forming ink images that use pigments as colorants can be made by dispersing the pigment in water and then using a fixing resin to form an ink. By fixing such ink image forming inks on a substrate by inkjet printing, an ink image layer with good durability, such as wash resistance after thermal transfer, can be obtained.

Examples of preferred pigments for aqueous inks include azo-, indanthrene-, or imidazolone-based yellow pigments; azo-, quinacridone-, cromophthalic-, or diketopyrrolopyrrole-based red pigments; phthalocyanine-based blue pigments; carbon black; phthalocyanine-based green pigments; indanthrene-based orange pigments; oxazoline-based purple pigments; and white pigments such as titanium oxide, aluminum silicate, and zinc oxide.

The fixing resin in the aqueous ink is not particularly limited, but preferred examples of fixing resins that can achieve robustness as a thermal transfer material include acrylic resin, polyester resin, polyurethane resin, and ethylene vinyl acetate resin. Of these, polyurethane resin is more preferred in terms of good adhesion of the hot melt resin powder and robustness after thermal transfer.

Furthermore, the surface tension of the aqueous ink for forming an ink image can be, for example, in the range of 23 to 35 (mN/m). To achieve clarity, sharpness, prevention of bleeding, and prevention of color mixing (prevention of ink mixing of multicolor inks) for the ink image layer formed on the ink-receiving layer on the substrate (particularly a synthetic resin film substrate such as a polyester resin film including PET), the surface tension is preferably 24 to 30 (mN/m), and more preferably 24 to 27 (mN/m). These surface tensions are determined by the Wilhelmy method using a surface tension measuring device (DY-300: Kyowa Interface Science Co., Ltd.).

The surface tension of aqueous ink for forming ink images can be adjusted, for example, using a surface tension modifier. There are no particular limitations on the surface tension modifier, as long as it does not impair the physical properties of the ink for forming ink images, which is an inkjet ink. For example, silicone-based surface modifiers, acrylic-based surface modifiers, vinyl-based surface modifiers, fluorine-based surface modifiers, or acetylene glycol-based surface modifiers can be used.

(7) Retention layer forming part

(7-1) The retention layer forming unit, at a retention layer forming position (not necessarily when the substrate is stationary) located between the ink image layer forming position and the powder layer forming position on the specified path or at the same position as the ink image layer forming position, uses a detection means to detect, as necessary, that the thermal transfer location on the substrate is located at the retention layer forming position, and then (similar to the ink image layer forming unit), forms a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on all or required portions of the ink image layer (for example, to cover the ink image layer) and/or on portions of the ink receiving layer other than the ink image layer, in accordance with the input printing data.

It is preferable that the retention layer be formed over the entire ink image layer. In this case, it is possible to leave the retention layer unformed in areas other than the ink image layer, but it is also possible to form a retention layer made from a retention layer-forming ink in areas of the ink-receiving layer other than the ink image layer.

The retention layer can also be formed in a required area on the ink image layer. In this case, the retention layer may not be formed in areas other than the ink image layer, but a retention layer made from a retention layer-forming ink can also be formed in areas of the ink-receiving layer other than the ink image layer.

It is also possible to manufacture heat transfer materials without forming a retaining layer in the retaining layer forming section, or to use a heat transfer material manufacturing device that does not have a retaining layer forming section.

(7-2) Inkjet printing using the retention layer-forming ink to form the retention layer can be carried out while the inkjet-printed ink image-forming ink is still wet (for example, within 60 seconds, preferably within 30 seconds, and more preferably within 10 seconds after printing the ink image-forming ink). However, this is not a limitation, and printing with the retention layer-forming ink can also be carried out when the ink image-forming ink is dry.

(7-3) As with the ink image forming ink, the ink for forming the retention layer is preferably an aqueous ink, as this ink has a low environmental impact and a low burden on workers. When a colorant is used in an aqueous retention layer forming ink, it is preferable to use a pigment in order to achieve good fastness.

The ink for forming the retention layer can be, for example, a white opacifying ink containing a white pigment such as titanium oxide, or it can be a colored ink using pigments of the various colors exemplified as inks that can be used for ink image formation, or it can be one that does not contain a colorant such as a pigment (for example, an uncolored ink or a colorless, transparent ink).

By covering the ink image layer with a white opaque ink as the ink for forming the retention layer, the portion of the ink image transferred to the transfer target object where the white opaque retention layer is present on the back side (for example, the entire ink image) is prevented from being affected by the background color of the transfer target object, allowing the ink image itself to appear clearly.

When a retention layer is formed using a white-opacifying retention layer-forming ink in the ink-receiving layer other than the ink image layer, it is possible to prevent the influence of the background color of the transfer target from appearing clearly when the retention layer is transferred to the transfer target.

Aqueous inks for forming a retention layer that use a pigment as a colorant can be made by dispersing the pigment in water and using a fixing resin to form an ink. Alternatively, inks made by using a fixing resin without using a pigment can be used as retention layer inks. Fixing such ink image-forming inks on a substrate by inkjet printing can produce retention layers with good durability, including resistance to washing after thermal transfer.

As with ink image-forming inks, there are no particular limitations on the fixing resins that can be blended into the aqueous ink. However, preferred examples of fixing resins that can achieve robustness as a thermal transfer material include acrylic resins, polyester resins, polyurethane resins, and ethylene vinyl acetate resins. Of these, polyurethane resins are more preferred in terms of good adhesion of the hot-melt resin powder and robustness after thermal transfer.

The surface tension of the aqueous retention layer-forming ink, like the ink image-forming ink, can be in the range of, for example, 23 to 35 (mN/m). The surface tension of the aqueous retention layer-forming ink is preferably 24 to 30 (mN/m), more preferably 24 to 27 (mN/m), in order to achieve clarity, sharpness, prevention of bleeding, and prevention of color mixing (prevention of mixing of inks to be layered, such as multicolor inks) for the retention layer formed with the retention layer-forming ink on the ink image layer formed on the ink-receiving layer (or retention layer-forming ink printed on an ink-receiving layer on which no ink image layer is formed). Like the ink image-forming ink, the surface tension of the aqueous retention layer-forming ink can be adjusted using a surface tension adjuster.

(8) Hot melt resin powder layer forming section

(8-1) At the powder layer formation position (not necessarily when the substrate is stationary), which is a position on the predetermined path ahead of the ink image layer formation position and the retention layer formation position, the hot melt resin powder layer forming unit detects, as necessary, using a detection means that the thermal transfer location on the substrate is located at the powder layer formation position, and then forms a hot melt resin powder layer from hot melt resin powder on either or both of the retention layer and the ink image layer where no retention layer is present (preferably on the retention layer) (if necessary, in accordance with data input in the same way as the ink image layer forming unit).

If there is no retention layer formation position, the hot melt resin powder layer forming unit forms a hot melt resin powder layer on the ink image layer at a powder layer formation position that is ahead of the ink image layer formation position on the specified path.

(8-2) The formation of a hot-melt resin powder layer using hot-melt resin powder is carried out by adhering the hot-melt resin powder onto the retention layer while the inkjet-printed retention layer-forming ink is still wet. The hot-melt resin powder can be adhered, for example, within 90 seconds after the inkjet printing of the retention layer-forming ink. Preferably, it is adhered within 60 seconds, and more preferably within 30 seconds.

In cases where an ink image layer exists on which no retention layer has been formed (is not coated), hot-melt resin powder is applied to the ink image layer and retention layer while the ink image forming ink in the ink image layer and the retention layer forming ink in the retention layer are still wet. The application of the hot-melt resin powder can be carried out, for example, within 90 seconds after inkjet printing of the ink image forming ink. Preferably, this is done within 60 seconds, and more preferably within 30 seconds.

(8-3) Examples of means for supplying and adhering hot melt resin powder onto the retention layer (or ink image layer) while the retention layer-forming ink (or ink image-forming ink) is in a wet state include, but are not limited to, means for sprinkling hot melt resin powder onto the retention layer (or ink image layer) to adhere to the retention layer (or ink image layer), means for causing the hot melt resin powder to reach the retention layer (or ink image layer) and adhere thereto by an air current, means for causing the hot melt resin powder to reach the retention layer (or ink image layer) and adhere thereto by electrostatic force, and means for causing the hot melt resin powder to pass through a pool of hot melt resin powder to adhere to the retention layer (or ink image layer).

It is preferable to apply the hot melt resin powder uniformly to the retention layer (or ink image layer) to form a hot melt resin powder layer of as uniform a thickness as possible. Examples of equipment for this purpose include a container containing hot melt resin powder or a pipe through which hot melt resin powder is fed, which can feed hot melt resin powder through a slit-shaped hole (for example, a slit-shaped hole of a constant narrow width along a straight line that crosses the entire retention layer (or ink image layer)) at a substantially constant feed rate (amount of resin powder fed per unit time) over the entire length of the hole.

It is also possible to use a container or pipeline equipped with a mesh-like supply section that can identify the area where the hot melt resin powder is sprayed, or to move a mesh- or slit-like head that can supply the hot melt resin powder from a container or pipeline in accordance with input data from the control unit (or move it and open and close the head opening to supply and stop the hot melt resin powder), thereby controlling the area where the hot melt resin powder is sprayed and supplying the hot melt resin powder to the retention layer (or ink image layer).

(8-4) If necessary, a resin powder leakage prevention unit may be provided to prevent hot melt resin powder from leaking from the powder layer formation position to the retention layer formation position or the ink image layer formation position, such as a curtain-shaped unit or air curtain unit that can be opened or closed to prevent leakage in response to instructions from the control unit [for example, in the case of a strip-shaped substrate, this can prevent resin powder leakage in the portion between the subsequent retention layer (or ink image layer) in the path, or in the case of a sheet-shaped substrate, this can prevent resin powder leakage in the portion between the subsequent sheet-shaped substrate in the path].

(8-5) The hot-melt resin powder is not particularly limited, but is preferably one that exhibits sufficient robustness when transferred and adhered to the thermal transfer target (e.g., various textile products). Considering the heat resistance during thermal transfer of the thermal transfer target (e.g., fibers constituting various textile products), it is preferable to use powders such as polyurethane resin, polyester resin, polyamide resin, and ethylene vinyl acetate resin, which have a melting point of 100 to 140°C and a particle size of approximately 30 to 300 μm. In particular, considering stretchability and washability, polyurethane resin powder, for example, polyurethane resin powder with a melting point of 100 to 140°C, is preferred. The hot-melt resin can be, for example, one that becomes colorless and transparent after heating, pressurizing, and cooling, but is not necessarily limited to this.

(9) Unwanted hot melt resin powder removal section

After a hot melt resin powder layer is formed on either or both of the retention layer and the ink image layer on which no retention layer is present, any unwanted hot melt resin powder that may be present on the retention layer on the substrate or in areas other than the ink image layer on which no retention layer is present (i.e., not covered by a retention layer) (or, if any other unwanted hot melt resin powder is present, this hot melt resin powder) can be removed from the substrate at a position ahead of the powder layer formation position on the specified path or at a resin powder removal position which is the powder layer formation position (not limited to a state where the substrate is stopped), after a detection means detects, as necessary, that the thermal transfer location on the substrate is located at the resin powder removal position, and before the hot melt resin powder is heat-treated.

The unwanted hot melt resin powder removal unit that removes the unwanted hot melt resin powder from the substrate is required to be able to remove the unwanted hot melt resin powder without damaging the ink image layer or the retention layer.

Devices used to remove unwanted hot melt resin powder include, for example, devices that apply vibrations to the substrate (preferably from the backside of the substrate) by striking it, rotating contact with a rotating brush, or other means to cause the hot melt resin powder to fall off the substrate; suction devices that act on the front (and back) sides of the substrate to suck and remove the hot melt resin powder; and airbrush devices that use a gas flow to remove the hot melt resin powder from the substrate. Combinations of two or more of these devices are also possible, but the present invention is not limited to these.

As an airbrush device, for example, one can be used in which multiple airflow nozzles are arranged in a matrix to spray a vertical or oblique airflow onto one surface of the substrate, and the airflow is sprayed from a nozzle selected based on data on the peripheral position of the retention layer (or ink image layer).

In addition, of the hot melt resin powder used to form the hot melt resin powder layer, all or part of the hot melt resin powder that was not retained on the substrate, such as hot melt resin powder that was removed from the substrate (for example, dropped to a designated location below), hot melt resin powder that did not adhere to or rest on the substrate (for example, dropped to a designated location below), and hot melt resin powder that was suctioned and removed from the substrate, can be returned to the hot melt resin powder supply location by a recovery and circulation device or the like and reused (for example, automatically) for forming the hot melt resin powder layer.

(10) Hot melt resin layer forming section

At the resin layer formation position, which is a position on the predetermined path ahead of the resin powder removal position or the same position as the resin powder removal position (preferably a position ahead of the resin powder removal position) (not necessarily when the substrate is stationary), the hot melt resin layer formation unit uses a detection means to detect, as necessary, that the thermal transfer location on the substrate is located at the resin layer formation position, and then melts and solidifies the hot melt resin powder that makes up the hot melt resin powder layer through heat treatment (after melting, the molten resin is solidified by cooling, such as by natural cooling or cooling with a forced cooling device), to form the hot melt resin layer.

By performing heat treatment on the ink image layer on the substrate, or the ink image layer and retention layer, along with the hot melt resin powder that makes up the hot melt resin powder layer, the drying of the ink image layer or the ink image layer and retention layer can be accelerated or made more complete, improving the unity with the hot melt resin layer and improving the physical properties of the transferred image after thermal transfer to the transfer target (textile product, etc.).

The heat treatment can be carried out, for example, at 100 to 160°C for approximately 1 to 5 minutes.

The heat treatment device used to form the hot melt resin layer can be, for example, a box-type or tunnel-type heat treatment device. Tunnel-type heat treatment devices are preferred for strip-shaped substrates (e.g., roll-shaped or other continuous substrates), while box-type heat treatment devices are preferred for sheet-shaped substrates.

When a roll or other continuous strip-shaped substrate is used, the resulting heat transfer material can be perforated (using a perforation device) or slit (using a slitter) before the hot melt resin layer formation section, and then wound up or cut into multiple sheets.

The perforation process involves processing the strip-shaped heat transfer material in a direction perpendicular to its continuous direction (or in another intersecting direction), for example, at predetermined intervals in the continuous direction, so that it can be later separated. The cutting process involves immediately cutting in the same direction.

On the other hand, the slitting process involves dividing the strip-shaped thermal transfer material into two or more sections of a specified width (e.g., half the width) along the entire length in the continuous direction.

(11) Heat and pressure transfer

Thermal transfer of ink images, etc., using a thermal transfer material obtained by the method or apparatus of the present invention can be carried out by contacting the hot melt resin layer with a transfer target such as a fabric product, applying heat and pressure to the thermal transfer material between the backside of the substrate of the thermal transfer material and the transfer target (for example, heat pressing at 100 to 200°C using a heat press or hot iron), and then peeling off the substrate while hot or after cooling (depending on the physical properties of the substance that causes releasability between the substrate and the ink-receiving layer).

Examples of transfer targets include, but are not limited to, various colored fabrics, white fabrics, clothing (e.g., sportswear, T-shirts, underwear, sweatshirts, socks), and other textile products made from various fibers.

(12) Control Unit

The control unit can be, for example, a computer such as a personal computer or other digital control device.

The control unit detects, for example, the detection of detectable portions or edge portions, etc., provided at required locations on the strip-shaped or sheet-shaped substrate using a detection device (e.g., an optical detection device or an electromagnetic detection device, etc.) provided at required positions along a predetermined path, or measures the driving distance of the strip-shaped substrate using a winding unit, drive roller, driven roller, etc., or measures the conveying distance of the sheet-shaped substrate using a drive roller, driven roller, conveyor belt, etc., and detects each thermal transfer location on the strip-shaped substrate, for example, at each section separated by a predetermined length or other divisions. This allows the position of the substrate, the position (or posture) of the sheet-like substrate and the position of the thermal transfer location, and the positions on the strip-like or sheet-like substrate where ink image layer formation, retention layer formation, and hot melt resin powder layer formation should be performed, and the positions where unnecessary hot melt resin powder removal and hot melt resin layer formation should be performed to be identified. Therefore, the control unit can issue instructions to the drive or conveyance system, while also issuing instructions to the ink image layer formation unit, retention layer formation unit, hot melt resin powder layer formation unit, unnecessary hot melt resin powder removal unit, and hot melt resin layer formation unit, allowing for efficient production of thermal transfer materials.

(13) As described above, the thermal transfer material manufacturing method and thermal transfer material manufacturing apparatus of the present invention enable efficient production of thermal transfer materials capable of thermally transferring ink images, etc., to an object by forming ink image layers and hot melt resin layers, etc., without plate-making, and also enables automatic production of thermal transfer materials.

[2] An example of an embodiment of the present invention will be described with reference to the drawings.

All of the drawings relate to a method and apparatus for manufacturing heat transfer materials as examples of embodiments of the present invention.

(1) Heat transfer material manufacturing equipment for strip-shaped substrates

The thermal transfer material manufacturing device A includes a drive system D that can advance or stop (and, if necessary, move backward) the strip-shaped substrate R along a predetermined path, which is unwound from an unwinding unit D1 where a wound strip-shaped substrate R is set and stretched between the unwinding unit D1 and the take-up unit D2; an ink image layer forming unit E that forms an ink image layer m at an ink image layer forming position 10 on the path; a retention layer forming unit F that forms a retention layer n at a retention layer forming position 20 adjacent to and forward of the ink image layer forming position 10 on the path; a hot melt resin powder layer forming unit G that forms a hot melt resin powder layer p at a powder layer forming position 30 at the lowest position, which is lowered forward of the retention layer forming position 20 on the path; and an unwanted hot melt resin powder removal unit 40 that rises steeply forward of the powder layer forming position 30 on the path, which removes unwanted hot melt resin powder. the hot melt resin powder removal unit H; the unwanted hot melt resin powder receiving unit I for receiving unwanted hot melt resin powder; the unwanted hot melt resin powder circulating unit C for circulating the hot melt resin powder received in the unwanted hot melt resin powder receiving unit I for reuse; the hot melt resin layer forming unit J for forming a hot melt resin layer q at a resin layer forming position 50, which is a horizontal position after rising forward from the resin powder removal position 40 on the path; and a programmed control unit and required detection means (not shown) that instructs the drive system based on position information detected at key points about the strip-shaped substrate R driven along a predetermined path, and instructs the ink image layer forming unit, retention layer forming unit, hot melt resin powder layer forming unit, unwanted hot melt resin powder removal unit, and hot melt resin layer forming unit to carry out the thermal transfer material manufacturing process.

The path can also be horizontal, with no descent or ascent, or the descent and ascent can be small or gradual.

(2) Heat transfer material manufacturing equipment for sheet-type substrates

The thermal transfer material manufacturing apparatus B includes a conveying system T that can advance or stop (and, if necessary, move backward) the sheet-like substrate S along a predetermined path. Similar to the thermal transfer material manufacturing apparatus A, the thermal transfer material manufacturing apparatus B also includes an ink image layer forming unit E, a retention layer forming unit F, a hot melt resin powder layer forming unit G, an unwanted hot melt resin powder removing unit H, an unwanted hot melt resin powder receiving unit I, an unwanted hot melt resin powder circulating unit C, a hot melt resin layer forming unit J, as well as a control unit and detection means (not shown). The path can be horizontal, as shown in Figure 6, without descending or ascending, or the descending and ascending can be small or gradual.

1. Creating a substrate with an ink-receiving layer

(1) Base material R(1)

An ink-receiving layer-forming treatment agent containing silica, silicone oil, polyurethane resin, and silicone wax was applied to the entire surface of one side of a strip-shaped substrate made of a polyester resin film (thickness 100 μm), thereby forming an ink-receiving layer with a surface free energy of 26 mJ/ ^m2 and possessing releasability, to obtain substrate R(1).

(2) Base material R (2)

A release treatment agent containing silicone wax and an ink-receiving layer-forming treatment agent containing silica, silicone oil, and polyurethane resin were applied in that order to the entire surface of one side of a strip-shaped substrate made of polyester resin film (thickness 100 μm), thereby forming an ink-receiving layer with a surface free energy of 28 mJ/ ^m² via the release layer, thereby obtaining substrate R(2).

(3) Base material S(3)

Substrate R(1) was cut into a rectangular sheet measuring 500 mm x 400 mm to obtain substrate S(3).

(4) Comparison base material R (4)

A release treatment agent containing silicone wax was applied to the entire surface of one side of a belt-shaped substrate made of a polyester resin film (thickness 100 μm), thereby forming a release layer with a surface free energy of 19 mJ/ ^m² , to obtain a comparative substrate R(4).

(5) Comparison base material R (5)

A strip-shaped substrate made of a polyester resin film (thickness: 100 μm) having a surface free energy of 70 mJ/ ^m² and not coated with a release treatment agent or an ink-receiving layer-forming treatment agent was used as comparative substrate R(5).

2. Preparation of ink for ink image formation

(1) Ink for forming ink images

An aqueous blue ink containing a phthalocyanine blue pigment, polyurethane resin, and silicone surface conditioner and having a surface tension of 26.7 mN/m; an aqueous red ink containing a quinacridone red pigment, polyurethane resin, and silicone surface conditioner and having a surface tension of 26.2 mN/m; an aqueous yellow ink containing an azo yellow pigment, polyurethane resin, and silicone surface conditioner and having a surface tension of 28.2 mN/m; and an aqueous black ink containing carbon black, polyurethane resin, and silicone surface conditioner and having a surface tension of 25.6 mN/m were prepared, and named ink image forming inks J-1C, J-1M, J-1Y, and J-1K, respectively.

(2) Comparative ink image forming ink

A water-based blue ink containing a phthalocyanine blue pigment and polyurethane resin with a surface tension of 37.8 mN/m, a water-based red ink containing a quinacridone red pigment and polyurethane resin with a surface tension of 38.3 mN/m, a water-based yellow ink containing an azo yellow pigment and polyurethane resin with a surface tension of 37.5 mN/m, and a water-based black ink containing carbon black and polyurethane resin with a surface tension of 38.1 mN/m were prepared and named comparative ink image forming inks H-1C, H-1M, H-1Y, and H-1K, respectively.

3. Preparation of ink for forming the retention layer

(1) Retention layer forming ink 1

An opacifying water-based white ink with a surface tension of 24.9 mN/m was created containing titanium oxide white pigment, polyurethane resin, and a silicone-based surface conditioner, and designated as ink J-1W for forming an opacifying retention layer.

(2) Retention layer forming ink 2

An aqueous clear ink containing polyurethane resin and a silicone-based surface conditioner with a surface tension of 25.3 mN/m was created and designated ink J-2CL for forming the retention layer.

(3) Comparative retention layer forming ink 1

A water-based white opacifying ink with a surface tension of 38.4 mN/m was prepared containing titanium oxide white pigment and polyurethane resin, and designated comparative retention layer ink H-1W.

4. Examples 1 to 6 and Comparative Examples 1 to 3

(1) Example 1

Using the thermal transfer material manufacturing device A, the substrate R(1) was driven along a predetermined path by the drive system D under the direction of the control unit based on positional information detected at key points, while the following process was carried out to manufacture the thermal transfer material.

When the detection means detected that one of the thermal transfer locations Ra set sequentially in the continuous direction of the strip-shaped substrate R(1) was located at the ink image layer formation position 10, the substrate R(1) was stopped, and an ink image layer m (a reversed image of the letter M) was formed on the ink receiving layer by inkjet printing using ink image forming inks (J-1C, J-1M, J-1Y, J-1K) using the ink image layer forming unit E (inkjet printing device).

Next, while maintaining the substrate R(1) in a stationary state, at the retention layer formation position 20, which is the same position as the ink image layer formation position 10, a concealing retention layer n was formed by inkjet printing using retention layer formation ink J-1W in the retention layer formation unit F (inkjet printing device) on the wet ink image forming ink that forms the ink image layer m and on the ink receiving layer in the area that protrudes 1 mm wide from the periphery of the ink image layer m (the protruding area is omitted in the drawings).

Next, the substrate R(1) was driven forward, and the detection means detected that the thermal transfer location Ra was located at powder layer formation position 30, which was ahead of retention layer formation position 20 on the predetermined path. While the ink for forming the retention layer was still wet, the hot melt resin powder layer forming unit G sprayed hot melt resin powder p1 onto the retention layer n, thereby forming a hot melt resin powder layer p.

Next, the substrate R(1) was driven forward, and with the thermal transfer location Ra positioned at the resin powder removal position 40, which was ahead of the powder layer formation position 30 on the specified path, the unwanted hot melt resin powder removal unit H applied vibrations to the backside of the substrate R(1), thereby removing any hot melt resin powder p1 that may have been present in areas of the substrate R(1) other than the retention layer n.

The substrate R(1) is then driven forward, and at the resin layer formation position 50, located forward of the resin powder removal position 40 on the specified path, the hot melt resin layer formation unit J heat-treats the thermal transfer area Ra at 150°C for 3 minutes, thoroughly drying the ink image layer m and retention layer n and melting the hot melt resin powder p1 that makes up the hot melt resin powder layer p. The molten resin is then allowed to solidify by natural cooling, forming a hot melt resin layer q. This results in a thermal transfer area Ra in which the ink image layer m (an image of the inverted letter M) formed on the releasable ink-receiving layer of the substrate R(1) is covered with the hot melt resin layer q.

The above process was performed for each thermal transfer location while the substrate R(1) was driven along a predetermined path by the drive system D, and then wound up by the winding device. Each thermal transfer location Ra set sequentially in the continuous direction of the substrate R(1) was similarly processed, and a strip-shaped thermal transfer material bearing the image of the letter M was obtained.

(2) Example 2

A strip-shaped thermal transfer material with an image of the letter M was obtained by the same process as in Example 1, except that substrate R(1) was replaced with substrate R(2).

(3) Comparative Example 1

A band-shaped thermal transfer material with an image of the letter M was obtained by processing in the same manner as in Example 1, except that substrate R(1) was replaced with comparative substrate R(4).

(4) Comparative Example 2

A band-shaped thermal transfer material with an image of the letter M was obtained by processing in the same manner as in Example 1, except that substrate R(1) was replaced with comparative substrate R(5).

(5) Example 3

A band-shaped thermal transfer material with an M letter image was obtained by the same process as in Example 1, except that the opacifying retaining layer forming ink J-1W was replaced with retaining layer forming ink J-2CL.

(6) Comparative Example 3

A band-shaped thermal transfer material with an M letter image was obtained by processing in the same manner as in Example 1, except that the ink image-forming inks (J-1C, J-1M, J-1Y, J-1K) and the opaque retaining layer-forming ink J-1W were replaced with comparative ink image-forming inks (H-1C, H-1M, H-1Y, H-1K) and comparative retaining layer-forming ink H-1W, respectively.

(7) Example 4

Using the thermal transfer material manufacturing device B, the substrate S(3) was held on the conveyor belt of the transport system T and transported along a predetermined route under the direction of the control unit based on positional information detected at key points, while the following process was carried out to manufacture the thermal transfer material.

When the detection means detected that the thermal transfer point on the sheet-like substrate S(3) was located at the ink image layer formation position 10, the substrate S(3) was stopped, and an ink image layer m (a reversed image of the letter M) was formed on the ink receiving layer by inkjet printing using ink image forming inks (J-1C, J-1M, J-1Y, J-1K) in the ink image layer forming unit E (inkjet printing device).

Next, while maintaining the substrate S(3) in a stationary state, at the retention layer formation position 20, which is the same position as the ink image layer formation position 10, a concealing retention layer n was formed by inkjet printing using retention layer formation ink J-1W in the retention layer formation unit F (inkjet printing device) on the wet ink image forming ink that forms the ink image layer m and on the ink receiving layer in the area that protrudes 1 mm wide from the periphery of the ink image layer m.

Next, the substrate S (3) was conveyed forward, and the detection means detected that the thermal transfer location was located at powder layer formation position 30, which was ahead of retention layer formation position 20 on the specified path. While the retention layer forming ink was still wet, the hot melt resin powder layer forming unit G sprayed hot melt resin powder p1 onto the retention layer n, thereby forming a hot melt resin powder layer p.

Next, the substrate S(3) was conveyed forward, and with the thermal transfer location positioned at the resin powder removal position 40, which is ahead of the powder layer formation position 30 on the specified path, the unwanted hot melt resin powder removal unit H, which blows air from above, removed any hot melt resin powder p1 that may have been present in areas other than the retention layer n on the substrate S(3).

The substrate S(3) is then conveyed forward, and at the resin layer formation position 50, located forward of the resin powder removal position 40 on the specified path, the hot melt resin layer formation unit J applies heat treatment to the thermal transfer area at 150°C for 3 minutes, thoroughly drying the ink image layer m and retention layer n and melting the hot melt resin powder p1 that makes up the hot melt resin powder layer p. The molten resin is then allowed to solidify by natural cooling, forming a hot melt resin layer q, resulting in a sheet-like thermal transfer material in which the ink image layer m (an image of the inverted letter M) formed on the releasable ink receiving layer of the substrate S(3) is covered with the hot melt resin layer q.

(8) Example 5

A band-shaped thermal transfer material with a white image of the letter M was obtained by processing in the same manner as in Example 1, except that no ink image layer m was formed by inkjet printing using an ink image forming ink. Instead, an inverted M letter image was formed using a concealing retention layer n by inkjet printing using retention layer forming unit F (inkjet printing device) at retention layer forming position 20 on the ink receiving layer in the area corresponding to ink image layer m in Example 1 and in the area extending 1 mm outside the ink image layer m.

(9) Example 6

A band-shaped thermal transfer material with an image of the letter M was obtained by processing in the same manner as in Example 1, except that the retention layer n was not formed by inkjet printing using retention layer forming ink J-1W.

(10) Thermal transfer

Each of the heat transfer materials obtained in Examples 1 to 6 and Comparative Examples 1 to 3 was applied to a white or black cotton knit fabric T-shirt X, with the hot melt resin layer q in contact with the T-shirt, and heat pressed for 10 seconds at 160°C and 300 g/ ^cm2 using a heat press machine. Thereafter, each substrate was peeled off, thereby forming an image of the letter M on each of the cotton knit fabric T-shirts X.
5. Evaluation of physical properties and performance in each example and comparative example

(1) The surface free energy of the ink-receiving layer or release layer formed on the substrate or the substrate itself, as well as the surface tension of the ink for forming the ink image and the ink for forming the retention layer, are shown in Table 1.

The surface free energy was measured using a contact angle measuring device (CAX-150, manufactured by Kyowa Interface Science Co., Ltd.).

The contact angles of three liquids, water, diiodomethane, and n-hexadecane, on the film were measured and calculated using the Kitazaki-Hata formula.

Surface tension was measured using the Wilhelmy method with a surface tension measuring device (DY-300: Kyowa Interface Science Co., Ltd.).

(2) Table 2 shows the evaluation of the printed and transferred images for the thermal transfer materials in each Example and Comparative Example, as well as the evaluation of the releasability during transfer, and the hiding power and selectivity fastness after transfer.

Note that the post-transfer hiding power was evaluated for an image heat-transferred onto a black cotton knit T-shirt X.

The symbols in Table 2 have the following meanings:
○・・・Excellent △・・・Inferior ×・・・Poor

10 Ink image layer forming position 20 Retention layer forming position 30 Powder layer forming position 40 Resin powder removal position 50 Resin layer forming position A Thermal transfer material manufacturing apparatus for belt-shaped substrate B Thermal transfer material manufacturing apparatus for sheet-shaped substrate C Unwanted hot melt resin powder circulation section D Drive system D1 Unwinding section D2 Winding section E Ink image layer forming section F Retention layer forming section G Hot melt resin powder layer forming section H Unwanted hot melt resin powder removal section I Unwanted hot melt resin powder receiving section J Hot melt resin layer forming section R Belt-shaped substrate Ra Thermal transfer position S Sheet-shaped substrate T Transport system X T-shirt m Ink image layer n Retention layer p Hot melt resin powder layer p1 Hot melt resin powder q Hot melt resin layer

Claims (19)

Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on at least the entirety or a required portion of the ink image layer at a position ahead of the ink image layer forming position in the path or at the retention layer forming position which is the same position as the ink image layer forming position;
forming a hot-melt resin powder layer from hot-melt resin powder on one or both of the retention layer and the ink image layer on which no retention layer is present at a powder layer formation position which is a position ahead of the retention layer formation position in the path;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or that is the same position as the powder layer formation position, before the heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
Inkjet printing using a retention layer-forming ink to form the retention layer can be performed while the inkjet-printed ink image-forming ink is in a wet state,
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. 2. The method according to claim 1, wherein a releasing component selected from the group consisting of waxes, paraffin, silicone resins, silicone oils and fluororesins is used to provide said releasing properties. Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
at a retention layer forming position which is located ahead of the ink image layer forming position in the path or which is the same position as the ink image layer forming position, a retention layer is formed on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder;
forming a hot-melt resin powder layer from hot-melt resin powder on one or both of the retention layer and the ink image layer on which no retention layer is present at a powder layer formation position which is a position ahead of the retention layer formation position in the path;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or that is the same position as the powder layer formation position, before the heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
The ink-receiving layer corresponds to one or both of the following i) and ii):
i ) The surface free energy of at least the portion of the surface on which inkjet printing with ink for forming an ink image is performed is 25 (mJ/m ² ) to 35 (mJ/m ² ).
ii ) A method for producing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or in the case where an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer, and the ionic gelling agent is a cationic compound monomer, a cationic compound polymer, or a basic inorganic metal salt. Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
at a retention layer forming position which is located ahead of the ink image layer forming position in the path or which is the same position as the ink image layer forming position, a retention layer is formed on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder;
forming a hot-melt resin powder layer from hot-melt resin powder on one or both of the retention layer and the ink image layer on which no retention layer is present at a powder layer formation position which is a position ahead of the retention layer formation position in the path;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or that is the same position as the powder layer formation position, before the heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
the ink for forming the retention layer is a water-based ink having a surface tension of 23 to 35 (mN/m),
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. The method according to any one of claims 1 to 4, wherein the hot melt resin powder layer is formed in a state in which the hot melt resin powder can adhere to both the retention layer-forming ink that forms the retention layer on which the hot melt resin powder layer is formed and the ink image-forming ink that forms the ink image layer without the retention layer. forming an ink image layer by inkjet printing at the ink image layer forming position after detecting that a thermal transfer location on the substrate is located at the ink image layer forming position,
the formation of the retention layer by inkjet printing at the retention layer formation position is performed after detecting that the thermal transfer location is located at the retention layer formation position,
the formation of the hot-melt resin powder layer at the powder layer formation position is carried out after detecting that the thermal transfer location is located at the powder layer formation position;
The removal of unnecessary hot melt resin powder at the resin powder removal position is performed after detecting that the thermal transfer location is located at the resin powder removal position,
A method according to any one of claims 1 to 5, wherein the formation of the hot melt resin layer by heat treatment of the hot melt resin powder at the resin layer formation position is carried out after detecting that the thermal transfer location is located at the resin layer formation position. The method according to any one of claims 1 to 6, wherein the ink for forming the ink image is an aqueous ink and the surface tension of the ink is 23 to 35 (mN/m). The method according to any one of claims 1 to 7, wherein all or a portion of the hot melt resin powder used to form the hot melt resin powder layer that was not retained on the substrate is reused for forming a new hot melt resin powder layer. Driving or conveying a thin substrate along a predetermined path;
forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
forming a hot-melt resin powder layer on the ink image layer at a powder layer forming position which is a position on the path forward of the ink image layer forming position;
after forming a hot-melt resin powder layer on the ink image layer, unnecessary hot-melt resin powder that may be present in portions other than the ink image layer on the substrate is removed from the substrate at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, before the heat treatment of the hot-melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position on the path or the same position as the resin powder removal position,
The ink-receiving layer corresponds to one or both of the following i) and ii):
i ) The surface free energy of at least the portion of the surface on which inkjet printing with ink for forming an ink image is performed is 25 (mJ/m ² ) to 35 (mJ/m ² ).
ii ) A method for producing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or in the case where an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer, and the ionic gelling agent is a cationic compound monomer, a cationic compound polymer, or a basic inorganic metal salt. An ink image layer is formed by ink-jet printing using an ink image-forming ink for representing a desired image on an ink-receiving layer provided on one side of a thin substrate directly or via another layer;
forming a retention layer on at least the entire surface of the ink image layer or on a required portion thereof by inkjet printing using a retention layer forming ink for retaining the hot melt resin powder;
forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which the retention layer is not present;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present from the substrate before heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment,
Inkjet printing using a retention layer-forming ink to form the retention layer can be performed while the inkjet-printed ink image-forming ink is in a wet state,
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. 11. The method according to claim 10, wherein a releasing component selected from the group consisting of waxes, paraffin, silicone resin, silicone oil and fluororesin is used to provide the releasing property. An ink image layer is formed by ink jet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one side of a thin substrate directly or via another layer;
forming a retention layer by inkjet printing using a retention layer-forming ink for retaining hot melt resin powder on one or both of the entirety or a required portion of the ink image layer and the portion of the ink receiving layer other than the ink image layer;
forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which the retention layer is not present;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present from the substrate before heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment,
The ink-receiving layer corresponds to one or both of the following i) and ii):
i ) The surface free energy of at least the portion of the surface on which inkjet printing with ink for forming an ink image is performed is 25 (mJ/m ² ) to 35 (mJ/m ² ).
ii ) A method for producing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or in the case where an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer, and the ionic gelling agent is a cationic compound monomer, a cationic compound polymer, or a basic inorganic metal salt. An ink image layer is formed by ink-jet printing using an ink image-forming ink for representing a desired image on an ink-receiving layer provided on one side of a thin substrate directly or via another layer;
forming a retention layer by inkjet printing using a retention layer-forming ink for retaining hot melt resin powder on one or both of the entirety or a required portion of the ink image layer and the portion of the ink receiving layer other than the ink image layer;
forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which the retention layer is not present;
after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on a portion other than the ink image layer on which no retention layer is present from the substrate before heat treatment of the hot melt resin powder;
and,
and forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through a heat treatment,
the ink for forming the retention layer is a water-based ink having a surface tension of 23 to 35 (mN/m),
A method for manufacturing a thermal transfer material, in which an ink-receiving layer is provided directly on one side of the substrate, or if an ink-receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. a drive or conveying system for driving or conveying the thin substrate along a predetermined path;
an ink image layer forming section for forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
a retention layer forming section for forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on at least the entirety or a required portion of the ink image layer at a position ahead of the ink image layer forming position in the path or at the retention layer forming position which is the same position as the ink image layer forming position;
a hot-melt resin powder layer forming section for forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, at a powder layer forming position which is a position ahead of the retention layer forming position on the path;
a resin powder removal section for removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on portions other than the ink image layer on which no retention layer is present, at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, from the substrate before heat treatment of the hot melt resin powder, after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present;
a hot melt resin layer forming section for forming a hot melt resin layer by melting and solidifying the hot melt resin powder constituting the hot melt resin powder layer through heat treatment at a resin layer forming position which is a position ahead of the resin powder removal position in the route or the same position as the resin powder removal position;
Inkjet printing using a retention layer-forming ink to form the retention layer can be performed while the inkjet-printed ink image-forming ink is in a wet state,
A thermal transfer material manufacturing apparatus in which an ink receiving layer is provided directly on one side of the substrate, or if an ink receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. 15. The device according to claim 14, wherein a releasing component selected from the group consisting of waxes, paraffin, silicone resin, silicone oil and fluororesin is used to provide the device with the releasing properties. a drive or conveying system for driving or conveying the thin substrate along a predetermined path;
an ink image layer forming section for forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
a retention layer forming section for forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer, at a retention layer forming position which is located ahead of the ink image layer forming position in the path or at the same position as the ink image layer forming position;
a hot-melt resin powder layer forming section for forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, at a powder layer forming position which is a position ahead of the retention layer forming position on the path;
a resin powder removal section for removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on portions other than the ink image layer on which no retention layer is present, at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, from the substrate before heat treatment of the hot melt resin powder, after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present;
a hot melt resin layer forming section for forming a hot melt resin layer by melting and solidifying hot melt resin powder constituting the hot melt resin powder layer through heat treatment at a resin layer forming position that is ahead of the resin powder removal position on the path or at the same position as the resin powder removal position, and the ink receiving layer corresponds to one or both of the following i) and ii):
i ) The surface free energy of at least the portion of the surface on which inkjet printing with ink for forming an ink image is performed is 25 (mJ/m ² ) to 35 (mJ/m ² ).
ii ) A thermal transfer material manufacturing apparatus containing a cationic compound monomer, a cationic compound polymer, or a basic inorganic metal salt as an ionic gelling agent, wherein an ink receiving layer is provided directly on one side of the substrate, or when an ink receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. a drive or conveying system for driving or conveying the thin substrate along a predetermined path;
an ink image layer forming section for forming an ink image layer by inkjet printing using an ink image forming ink to represent a desired image on an ink receiving layer provided on one surface of the substrate directly or via another layer, at an ink image layer forming position in the path;
a retention layer forming section for forming a retention layer by inkjet printing using a retention layer forming ink for retaining hot melt resin powder on all or a required portion of the ink image layer and/or a portion of the ink receiving layer other than the ink image layer, at a retention layer forming position which is located ahead of the ink image layer forming position in the path or at the same position as the ink image layer forming position;
a hot-melt resin powder layer forming section for forming a hot-melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present, at a powder layer forming position which is a position ahead of the retention layer forming position on the path;
a resin powder removal section for removing unnecessary hot melt resin powder that may be present on the retention layer on the substrate or on portions other than the ink image layer on which no retention layer is present, at a resin powder removal position that is a position ahead of the powder layer formation position on the path or the same position as the powder layer formation position, from the substrate before heat treatment of the hot melt resin powder, after forming a hot melt resin powder layer on one or both of the retention layer and the ink image layer on which no retention layer is present;
a hot melt resin layer forming section for melting and solidifying hot melt resin powder constituting the hot melt resin powder layer by heat treatment at a resin layer forming position that is ahead of the resin powder removal position in the path or at the same position as the resin powder removal position, and the retention layer forming ink is an aqueous ink having a surface tension of 23 to 35 (mN/m);
A thermal transfer material manufacturing apparatus in which an ink receiving layer is provided directly on one side of the substrate, or if an ink receiving layer is provided via another layer, the other layer is provided so as to have releasability to assist in peeling off the substrate during thermal transfer. An apparatus described in any one of claims 14 to 17, wherein the formation of the hot melt resin powder layer by the hot melt resin layer forming section is carried out in a state in which the hot melt resin powder can be adhered to both the ink for forming a retention layer that forms the retention layer on which the hot melt resin powder layer is formed and the ink for forming an ink image that forms an ink image layer that does not have a retention layer. a detection means for detecting that a thermal transfer position on the substrate is located at the ink image layer forming position, and after the detection means detects that the thermal transfer position is located at the ink image layer forming position, the ink image layer is formed by the inkjet printing,
a detection means for detecting that the thermal transfer location is located at the retention layer formation position, and after the detection means detects that the thermal transfer location is located at the retention layer formation position, the retention layer is formed by the inkjet printing;
a detection means for detecting that the thermal transfer portion is located at the powder layer formation position, and after the detection means detects that the thermal transfer portion is located at the powder layer formation position, a hot melt resin powder layer is formed using the hot melt resin powder;
a detection means for detecting that the thermal transfer location is located at the resin powder removal position, and after the detection means detects that the thermal transfer location is located at the resin powder removal position, the unnecessary hot melt resin powder is removed;
An apparatus as described in any one of claims 14 to 18, which has a detection means for detecting that the thermal transfer location is located at the resin layer formation position, and after detecting that the thermal transfer location is located at the resin layer formation position using the detection means , forms a hot melt resin layer by heat treating the hot melt resin powder.