Thermal transfer apparatus and transfer method

A thermal transfer apparatus includes a controller to control a transfer tool and a pressing body conveyor. The controller controls the pressing body conveyor to press a predetermined region of a transfer object, and controls the transfer tool and the pressing body conveyor to press at least a portion of thermal transfer foil placed on the predetermined region pressed by the transfer tool and a light absorption film having a light absorption property and placed on the thermal transfer foil and to apply light to the light absorption film.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to Japanese Patent Application No. 2018-191728 filed on Oct. 10, 2018. The entire contents of this application are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a thermal transfer apparatus and a transfer method. In particular, the present invention relates to a thermal transfer apparatus and a transfer method for transferring foil onto a transfer object using thermal transfer foil.

2. Description of the Related Art

A decorative process by a heat transfer technique using thermal transfer foil (also called a heat transfer sheet) has been performed to date for purposes such as enhancement of aesthetic design. The thermal transfer foil is generally constituted by stacking a base material, a decorative layer, and an adhesive layer in this order. In transfer (i.e., transfer of thermal transfer foil to a transfer object), thermal transfer foil is overlaid on the transfer object such that an adhesive layer of the foil contacts the transfer object, and the thermal transfer foil is heated by applying light to the thermal transfer foil while the thermal transfer foil from above is pressed with a transfer tool (e.g., a laser pen) including a light source for applying light (e.g., laser light). Accordingly, the adhesive layer in a pressed portion of the thermal transfer foil is melted and attached to the surface of the transfer object, and then is cured by heat dissipation. Consequently, the base material of the thermal transfer foil is separated from the transfer object so that a decorative layer having a shape corresponding to the portion stamped with foil can be attached to the transfer object together with the adhesive layer. In this manner, the surface of the transfer object is provided with a decoration of foil having an intended shape (e.g., a figure or a character).

Japanese Patent Application Publication No. 2018-69501, for example, discloses a technique for transferring foil onto a transfer object with a transfer tool that applies laser light.

Examples of some transfer objects onto which thermal transfer foil is to be transferred include a member whose surface onto which thermal transfer foil is to be transferred has a small amount of surface unevenness and is relatively smooth and a member whose surface onto which thermal transfer foil is to be transferred has a large amount of surface unevenness and is relatively coarse. In either case, although thermal transfer foil can be transferred onto the transfer object, transfer of the thermal transfer foil is less appropriately performed on a member having a large amount of surface unevenness than a member having a small amount of surface unevenness in some cases.

SUMMARY OF THE INVENTION

Preferred embodiments of the present invention provide thermal transfer apparatuses each capable of transferring thermal transfer foil onto a transfer object more appropriately.

A thermal transfer apparatus according to a preferred embodiment of the present includes a stand that holds a transfer object, a transfer tool to press the transfer object and to apply light to the transfer object, a conveyor that moves one of the stand and the transfer tool relative to the other, and a controller that controls the transfer tool and the conveyor, wherein the controller controls at least the conveyor such that a predetermined region of the transfer object is pressed by the transfer tool, and controls the transfer tool and the conveyor such that at least a portion of thermal transfer foil placed on the predetermined region pressed by the transfer tool and a light absorption film having a light absorption property and placed on the thermal transfer foil is pressed, and light is applied to the light absorption film.

A thermal transfer apparatus according to a preferred embodiment of the present invention includes a controller to control a transfer tool and a conveyor. The controller controls at least the conveyor to press a predetermined region of a transfer object. In this manner, since the predetermined region of the transfer object is pressed by the transfer tool before thermal transfer foil is transferred to the predetermined region, the predetermined region of the transfer object is smoother than that before pressing. The controller controls the transfer tool and the conveyor to press at least a portion of thermal transfer foil and the light absorption film disposed on the smooth predetermined region, while (at the same time) applying light to the light absorption film. Accordingly, the thermal transfer foil is able to be more appropriately transferred onto the predetermined region of the transfer object.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention will be described hereinafter with reference to the drawings as necessary. The preferred embodiments described here are, of course, not intended to particularly limit the present invention. Elements and features having the same functions are denoted by the same reference numerals, and description for the same elements, features, and portions will not be repeated or will be simplified as appropriate.

First, a configuration of a thermal transfer apparatus10will be described.FIG. 1is a perspective view schematically illustrating the thermal transfer apparatus10.FIG. 2is a partially broken perspective view schematically illustrating an aspect of the thermal transfer apparatus10.FIG. 3is a left side view schematically illustrating a pressing body conveyor22during transfer. In the following description, left, right, up, and down refer to left, right, up, and down, respectively, when an operator (user) in front of the thermal transfer apparatus10sees a power supply switch14a. When seen from the operator, a direction toward the thermal transfer apparatus10will be referred to as rearward, and a direction away from the thermal transfer apparatus10will be referred to as forward. Characters F, Rr, L, R, U, and D in the drawings represent front, rear, left, right, up, and down, respectively. Suppose axes orthogonal to one another are an X axis, a Y axis, and a Z axis, the thermal transfer apparatus10according to this preferred embodiment is placed on a plane constituted by the X axis and the Y axis. Here, the X axis extends leftward and rightward. The Y axis extends forward and rearward. The Z axis extends upward and downward. It should be noted that these directions are defined simply for convenience of description, and do not limit the state of installation of the thermal transfer apparatus10.

As illustrated inFIG. 3, the thermal transfer apparatus10is an apparatus that applies (also referred to as transfers) a decorative layer in a sheet-shaped thermal transfer foil82to a surface of a transfer object80by pressing and heating the thermal transfer foil82and a light absorption film84by using a transfer tool60described later with the thermal transfer foil82and the light absorption film84overlaid on the transfer object80. The thermal transfer foil82is indirectly pressed against the transfer tool60with the light absorption film84interposed therebetween. With some materials, shapes, and configurations, for example, of the transfer object80and the thermal transfer foil82, the light absorption film84may be omitted.

The transfer object80is not limited to a specific material and a specific shape. Examples of materials for the transfer object80include metals such as gold, silver, copper, platinum, brass, aluminum, iron, titanium, and stainless, resin materials such as acrylic, polyvinyl chloride (PVC), polyethylene terephthalate (PET), and polycarbonate (PC), papers such as plain paper, drawing paper, and Japanese paper, and rubbers. The transfer object80may also be a human-made leather (e.g., an artificial leather or a synthetic leather) at least partially including the resin materials.

The thermal transfer foil82may be, but is not limited to, transfer foil commercially available for heat transfer, for example. The thermal transfer foil82is typically a stack of a base material, a decorative layer, and an adhesive layer in this order. The thermal transfer foil82includes, for example, metallic foil such as gold foil and sliver foil, half metallic foil, pigment foil, multi-color printing foil, hologram foil, and electrostatic destruction measures foil. The thermal transfer foil82has a band shape or a sheet shape. The thermal transfer foil82is placed on the transfer object80. The thermal transfer foil82is placed on the transfer object80such that the adhesive layer of the thermal transfer foil82contacts the transfer object80. The thermal transfer foil82may further include a light absorption layer between the base material and the decorative layer. In a case where the thermal transfer foil82includes a light absorption layer, the base material is made of a transparent material. The light absorption layer has a configuration similar to that of the light absorption film84described later. In the case where the thermal transfer foil82includes the light absorption layer, the thermal transfer apparatus10does not need to include the light absorption film84in some cases. Even in the case where the thermal transfer foil82includes the light absorption layer, the thermal transfer apparatus10preferably includes the light absorption film84.

Some configurations of the thermal transfer foil82to be used may have no or poor light absorption property to light applied from a light source62(seeFIG. 2) of the transfer tool60described later. In such cases, the light absorption film84is placed on top of the thermal transfer foil82. The light absorption film84refers to a sheet configured to efficiently absorb light in a predetermined wavelength range (e.g., laser light) applied from the light source62of the transfer tool60and capable of converting optical energy to thermal energy. The light absorption film84has a heat resistance at about 100° C. to about 200° C., for example. The light absorption film84is made of a resin such as polyimide. The light absorption film84is monochrome. From the viewpoint of efficiently converting optical energy to thermal energy, the hue of the light absorption film84is preferably complementary to the color of light (e.g., laser light) applied from the light source62. For example, in a case where light (e.g., laser light) from the light source62is blue, the light absorption film84is preferably yellow. The light absorption film84may be provided with a support film to increase strength as necessary. The support film has a light absorption property significantly lower than that of the light absorption film84. The support film is made of a material transparent to laser light emitted from the light source62. The support film is, for example, transparent. The support film is a plastic film such as polyester.

As illustrated inFIG. 1, the thermal transfer apparatus10has a box shape. The thermal transfer apparatus10includes a housing12that is open at the front, a pressing body conveyor22disposed in the housing12, a carriage21, and the transfer tool60. The housing12includes a bottom wall14, a left side wall15, a right side wall16, an upper wall17, and a rear wall18(seeFIG. 2). The housing12is made of a steel plate, for example.

As illustrated inFIG. 2, a fixture20such as a vice is detachably attached to the bottom wall14. The fixture20is an example of a stand to hold the transfer object80. A front region of the bottom wall14is a fixture placing region14bto place the fixture20. A center portion of the fixture placing region14bincludes four attachment holes14cto attach the fixture20, for example. A front surface of the bottom wall14is provided with the power supply switch14a.

As illustrated inFIG. 2, the left side wall15extends upward at the left end of the bottom wall14. The left side wall15is perpendicular or substantially perpendicular to the bottom wall14. The right side wall16extends upward at the right end of the bottom wall14. The right side wall16is perpendicular or substantially perpendicular to the bottom wall14. The rear wall18extends upward at the rear end of the bottom wall14. The rear wall18is connected to the rear end of the left side wall15and the rear end of the right side wall16. The rear wall18is provided with a box-shaped case18a. The case18ahouses a controller90described later. The upper wall17is connected to the upper end of the left side wall15, the upper end of the right side wall16, and the upper end of the rear wall18. A portion of a first conveyor30described later of the pressing body conveyor22is disposed on the upper wall17. A region surrounded by the bottom wall14, the left side wall15, the right side wall16, the upper wall17, and the rear wall18is an internal space of the housing12.

The internal space of the housing12is a space where the thermal transfer foil82is transferred onto the transfer object80. The pressing body conveyor22is provided in the internal space. That is, the pressing body conveyor22is housed in the housing12. The pressing body conveyor22is an example of the conveyor. The pressing body conveyor22includes a carriage21, the first conveyor30that moves the carriage21along the Z axis, a second conveyor40that moves the carriage21along the Y axis, and a third conveyor50that moves the carriage21along the X axis. The carriage21is disposed below an elevation base33described later. The pressing body conveyor22moves the carriage21in three dimensions. The carriage21is movable relative to the fixture20(i.e., the transfer object80) by the first conveyor30, the second conveyor40, and the third conveyor50. That is, the pressing body conveyor22moves a pressing body66mounted on the carriage21relative to the fixture20. The first conveyor30, the second conveyor40, and the third conveyor50are disposed above the bottom wall14.

As illustrated inFIG. 1, the first conveyor30moves the carriage21along the Z axis (upward and downward). That is, the first conveyor30moves the pressing body66of the transfer tool60disposed on the carriage21along the Z axis. The first conveyor30preferably is a feed screw mechanism including a Z-axis feed screw rod31, a Z-axis moving motor32, and a feed nut33a. The Z-axis feed screw rod31extends along the Z axis. The Z-axis feed screw rod31includes a helical screw groove. An upper portion of the Z-axis feed screw rod31is fixed to the upper wall17. An upper end portion of the Z-axis feed screw rod31penetrates the lower surface of the upper wall17along the Z axis, and is partially disposed inside the upper wall17. A lower end portion of the Z-axis feed screw rod31is rotatably supported on a frame14d(see alsoFIG. 3). The frame14dis fixed onto the bottom wall14. The Z-axis moving motor32is an electric motor. The Z-axis moving motor32is connected to the controller90(seeFIG. 2). The Z-axis moving motor32is fixed to the upper wall17. A driving shaft of the Z-axis moving motor32penetrates the lower surface of the upper wall17along the Z axis and is partially disposed inside the upper wall17. In the upper wall17, the Z-axis feed screw rod31is coupled to the Z-axis moving motor32. The Z-axis moving motor32causes the Z-axis feed screw rod31to rotate.

As illustrated inFIG. 2, the feed nut33ahaving a screw thread is engaged with the Z-axis feed screw rod31. The feed nut33ais coupled to an elevation base33. The feed nut33apenetrates the upper surface of the elevation base33along the Z axis. The elevation base33is supported on the Z-axis feed screw rod31with the feed nut33ainterposed therebetween. The elevation base33is parallel or substantially parallel to the bottom wall14. The lengths of the elevation base33along the X axis and the Y axis are larger than the lengths of the fixture placing region14balong the X axis and the Y axis. As illustrated inFIG. 2, slide shafts33band33ceach extending along the Z axis are provided at the inner sides of the left side wall15and the right side wall16. The slide shafts33band33care parallel or substantially parallel to the Z-axis feed screw rod31. The slide shafts33band33care disposed to enable the elevation base33to slide along the Z axis. When the Z-axis moving motor32is driven, rotation of the Z-axis feed screw rod31causes the elevation base33to move up and down along the slide shafts33band33c. The second conveyor40and the third conveyor50are coupled to the elevation base33. Thus, the second conveyor40and the third conveyor50integrally move up and down with upward and downward movement of the elevation base33. The carriage21moves up and down with upward and downward movement of the elevation base33.

As illustrated inFIG. 2, the second conveyor40moves the carriage21along the Y axis (forward and rearward). That is, the second conveyor40moves the pressing body66of the transfer tool60disposed on the carriage21along the Y axis. The second conveyor40is a feed screw mechanism including a Y-axis feed screw rod41, a Y-axis moving motor42, and a feed nut43. The Y-axis feed screw rod41extends along the Y axis. The Y-axis feed screw rod41is disposed on the elevation base33. The Y-axis feed screw rod41includes a helical screw groove. A rear end portion of the Y-axis feed screw rod41is coupled to the Y-axis moving motor42. The Y-axis moving motor42is an electric motor. The Y-axis moving motor42is connected to the controller90. The Y-axis feed moving42is fixed to the rear of the elevation base33. The Y-axis moving motor42causes the Y-axis feed screw rod41to rotate. A feed nut43including a screw thread is engaged with a screw groove of the Y-axis feed screw rod41. A pair of slide shafts43band43cextending along the Y axis is disposed on the elevation base33. The two slide shafts43band43care parallel or substantially parallel to the Y-axis feed screw rod41. A slide base44is provided on the slide shafts43band43cto be slidable along the Y axis. When the Y-axis moving motor42is driven, rotation of the Y-axis feed screw rod41causes the slide base44to move forward and rearward along the slide shafts43band43c.

As illustrated inFIG. 1, the third conveyor50moves the carriage21along the X axis (leftward and rightward). That is, the third conveyor50moves the pressing body66of the transfer tool60disposed on the carriage21along the X axis. The third conveyor50is a feed screw mechanism including an X-axis feed screw rod51, an X-axis moving motor52, and an unillustrated feed nut. The X-axis feed screw rod51extends along the X axis. The X-axis feed screw rod51is disposed ahead of the slide base44. The X-axis feed screw rod51includes a helical screw groove. An end of the X-axis feed screw rod51is coupled to the X-axis moving motor52. The X-axis moving motor52is an electric motor. The X-axis moving motor52is connected to the controller90(seeFIG. 2). The X-axis moving motor52is disposed ahead of the slide base44and is fixed to a plate44aextending forward. The X-axis moving motor52causes the X-axis feed screw rod51to rotate. A feed nut including a screw thread is engaged with a screw groove of the X-axis feed screw rod51. A pair of slide shafts54band54cextending along the X axis is disposed ahead of the slide base44. The two slide shafts54band54care parallel or substantially parallel to the X-axis feed screw rod51. The carriage21is disposed on the slide shafts54band54cto be slidable along the X axis. When the X-axis moving motor52is driven, rotation of the X-axis feed screw rod51causes the carriage21to move leftward and rightward along the slide shafts54band54c.

FIG. 4is a cross-sectional view schematically illustrating the thermal transfer tool60according to a preferred embodiment of the present invention. The transfer tool60presses the thermal transfer foil82placed on the transfer object80, while applying light (e.g., laser light) to the transfer object80. The transfer tool60applies light to the thermal transfer foil82and the light absorption film84placed on the transfer object80to supply heat to the thermal transfer foil82. In this preferred embodiment, the transfer tool60presses a protective film86described later and the transfer object80, while applying laser light to the protective film86to supply heat to the transfer object80. The transfer tool60presses the thermal transfer foil82and the light absorption film84, while applying laser light to the light absorption film84to supply heat to the thermal transfer foil82. The transfer tool60transfers the thermal transfer foil82onto the transfer object80. The transfer tool60is disposed above the fixture20. The transfer tool60includes the light source62, a pen body61, and the pressing body66fixed to the lower end of the pen body61. The expression “pressing the transfer object80” includes a case where the pressing body66of the transfer tool60contacts the transfer object80to press the transfer object80directly and a case where the pressing body66presses the transfer object80indirectly with the protective film86interposed between the pressing body66and the transfer object80.

The light source62supplies heat to the thermal transfer foil82. The light source62applies light serving as a heat source to the light absorption layer of the thermal transfer foil82and the light absorption film84. Light supplied from the light source62to the light absorption layer of the thermal transfer foil82and the light absorption film84is converted to thermal energy in the light absorption layer and the light absorption film84and heats the thermal transfer foil82. The light source62is communicably connected to the controller90. The light source62is controlled by the controller90. As illustrated inFIG. 2, the light source62is disposed on an upper surface33X of the elevation base33. The light source62is housed in a metal case55. The case55is not limited to a specific material, and is made of, for example, aluminum having high thermal conductivity. The case55is fixed to the upper surface33X of the elevation base33. The light source62in the present preferred embodiment preferably is a laser diode (semiconductor laser) that applies laser light and an optical system, for example. Since laser light shows a high response speed, a change in, for example, energy of the laser light as well as switching between application and non-application of the light is able to be performed quickly. Accordingly, laser light having desired properties can be applied to the light absorption layer of the thermal transfer foil82and the light absorption film84.

As illustrated inFIG. 1, the pen body61is held by the carriage21. As illustrated inFIG. 4, the pen body61has an elongated cylindrical shape. The pen body61is oriented to have its longitudinal direction coincide with the upward and downward directions (i.e., the Z axis). The axis of the pen body61extends upward and downward. The pen body61incorporates optical fibers64and a ferrule65. The pen body61includes a holder68described later. The holder68is attached to the lower end of the pen body61.

The optical fibers64are an optical transfer medium to transfer light applied from the light source62. The optical fibers64include a core portion (not shown) through which light passes and a cladding portion (not shown) that surrounds the core portion and reflects light. The optical fibers64are connected to the light source62. The optical fibers64include an upper end e1extending to the outside of the pen body61. The end e1of the optical fibers64is inserted in a connector62aincluded in the light source62. With this configuration, the optical fibers64are connected to the light source62with a reduced optical loss. The optical fibers64have a lower end e2equipped with the ferrule65. The ferrule65is a cylindrical optical photojunction. The ferrule65has a through hole65hpenetrating the ferrule65along the axis of the ferrule65. The end e2of the optical fibers64is inserted in the through hole65hof the ferrule65.

As illustrated inFIG. 4, the pen body61is provided with the holder68. The holder68is disposed at the lower end of the pen body61and used to hold the ferrule65at a predetermined position. The holder68has a cap shape. An upper portion of the holder68has a cylindrical shape whose outer diameter corresponds to the pen body61. A lower portion of the holder68includes a cylindrical projection68gwhose outer diameter is smaller than that of the pen body61. The projection68gincludes a ferrule holding portion68fthat is a cylindrical recess. The ferrule holding portion68fhas an inner diameter corresponding to the outer diameter of the ferrule65. The ferrule holding portion68fhouses the lower end of the ferrule65.

The holder68has an aperture P penetrating the holder68upward and downward. The core portion of the end e2of the optical fibers64is exposed to the outside through the aperture P. That is, in bottom view, the core portion of the end e2of the optical fibers64overlaps the aperture P. Accordingly, the holder68does not interfere with an optical path L of laser light. Consequently, laser light applied from the light source62is able to be emitted to the outside from the lower end of the pan body61.

The holder68also holds the pressing body66at a predetermined position on the lower end of the pen body61. The pressing body66presses the transfer object80and the thermal transfer foil82placed on the transfer object80. The pressing body66is configured to press the transfer object80and the thermal transfer foil82with downward movement of the elevation base33. In this preferred embodiment, the pressing body66further presses the light absorption film84and the transfer object80. The pressing body66is detachably provided in the holder68. In this preferred embodiment, the pressing body66is spherical. The pressing body66is made of a hard material. The pressing body66is not strictly limited to a specific hardness, and is made of, for example, a material having a Vickers hardness of about 100 HV0.2 or more (e.g., about 500 HV0.2 or more). The holder68holds the pressing body66on the optical path L of laser light. The pressing body66is made of a material through which laser light emitted from the light source62passes. Accordingly, even in a case where the pressing body66is disposed on the optical path L, laser light passes through the pressing body66. The pressing body66may be made of, for example, glass. The pressing body66according to the present preferred embodiment is made of synthetic quartz glass.

The expression “transparent to laser light” refers to having a predetermined transmittance of laser light. Specifically, “transparent to laser light to the pressing body66” refers to having a predetermined laser light transmittance to the pressing body66. For example, the predetermined laser light transmittance is about 50% or more. The predetermined laser light transmittance is preferably about 70% or more. The predetermined laser light transmittance is more preferably about 80% or more. The predetermined laser light transmittance is especially preferably about 85% or more. The predetermined laser light transmittance is most preferably about 90% or more. The transmittance refers to a transmittance including a surface reflection loss of a sample having a predetermined thickness (e.g., about 10 mm) measured in accordance with JIS R3106:1998, for example.

An overall operation of the thermal transfer apparatus10is controlled by the controller90. As illustrated inFIG. 5, the controller90is communicably connected to the pressing body conveyor22, the light source62of the transfer tool60, and is configured or programmed to enable control of the pressing body conveyor22and the light source62. The controller90is communicably connected to the Z-axis moving motor32, the Y-axis moving motor42, and the X-axis moving motor52and is configured or programmed to enable control of these motors. The controller90is typically a computer. The controller90includes, for example, an interface (I/F) that receives foil transfer data and other data from external equipment such as a host computer, a central processing unit (CPU) that executes instructions of a control program, a ROM that stores programs to be executed by the CPU, a RAM to be used as a working area where a program is developed, and a memory device such as a memory to store the programs and various types of data.

As illustrated inFIG. 5, a controller90includes a memory95, a first controller91, and a second controller92. The functions of these elements of the controller90may be implemented by a program. This program may be read from a recording medium such as a CD or a DVD. This program may be downloaded through the Internet. The functions of the elements of the controller90may be implemented by, for example, processor(s) and/or circuit(s). Specific function or functions of each portions or elements of the controller90described above will be described later.

The memory95stores first image data representing a shape (e.g., a figure or a character) of a predetermined region80T (seeFIG. 7) of the transfer object80pressed by the transfer tool60. The memory95stores second image data representing a shape (e.g., a figure or a character) of the thermal transfer foil82in transferring the thermal transfer foil82onto the transfer object80. The first image data and the second image data may be the same or different from each other. In the case where the first image data and the second image data are different, the shape of the thermal transfer foil80in transferring the thermal transfer foil82onto the transfer object80is included in the predetermined region80T of the transfer object80. That is, the shape of the thermal transfer foil82in transferring the thermal transfer foil82onto the transfer object80overlaps with a predetermined region80T of the transfer object80.

FIG. 6is a flowchart depicting a flow of transferring the thermal transfer foil82onto the transfer object80In this example, the transfer object80is pressed with interposition of the protective film86, and then the thermal transfer foil82is transferred onto the transfer object80by using the light absorption film84.

In step S10, the fixture20holding the transfer object80is attached to the bottom wall14of the thermal transfer apparatus10. Then, the protective film86(seeFIG. 7) is placed on the transfer object80. The protective film86is placed on at least the predetermined region80T (seeFIG. 7) of the transfer object80. The predetermined region80T may be the entire upper surface of the transfer object80while the transfer object80is held by the fixture20or may be a portion of the upper surface of the transfer object80, for example. The protective film86is larger than the predetermined region80T. The protective film86of this preferred embodiment has a light absorption property. The protective film86is, for example, a sheet configured to efficiently absorb light in a predetermined wavelength range applied from the light source62of the transfer tool60and capable of converting optical energy to thermal energy. The protective film86has a configuration similar to that of the light absorption film84, for example.

In step S20, as illustrated inFIG. 7, the predetermined region80T of the transfer object80is pressed by the transfer tool60. The first controller91controls the pressing body conveyor22to press the predetermined region80T of the transfer object80. Here, the predetermined region80T of the transfer object80is pressed by the pressing body66of the transfer tool60with the protective film86interposed therebetween. The first controller91controls the transfer tool60to apply light to the protective film86. The first controller91generally causes the pressing body66of the transfer tool60to press the predetermined region80T of the transfer object80while (at the same time as) causing the light source62of the transfer tool60to apply light to the protective film86. More specifically, light from the light source62is applied to a portion of the protective film86pressed by the pressing body66. At this time, in a portion of the protective film86irradiated with laser light of the light source62, the protective film86absorbs laser light and converts optical energy to thermal energy. Accordingly, the protective film86generates heat, and the heat is transferred to the predetermined region80T of the transfer object80. In this manner, the surface of the predetermined region80T of the transfer object80is softened (e.g., melted if the predetermined region80T is made of a resin material), and becomes smooth by a pressing force of the transfer tool60.

Based on the first image data stored in the memory95, the first controller91controls the transfer tool60and the pressing body conveyor22. The first controller91moves the carriage21along the X axis, the Y axis, and the Z axis to move the transfer tool60. The first controller91controls application and stop of laser light from the light source62. Through the process in the step S20, the predetermined region80T of the transfer object80becomes smooth. After the process in step S20has been completed, the protective film86placed on the transfer object80is removed.

In step S30, the thermal transfer foil82is placed on the pressed predetermined region80T. The thermal transfer foil82placed here may be larger than the predetermined region80T or may be disposed only in a portion of the predetermined region80T.

In step S40, the light absorption film84is placed on the thermal transfer foil82. A support film may be further placed on the light absorption film84. The light absorption film84is, for example, larger than the predetermined region80T.

In step S50, as illustrated inFIG. 8, the transfer tool60presses at least a portion of the thermal transfer foil82and the light absorption film84. The second controller92controls the pressing body conveyor22to press at least a portion of the thermal transfer foil82and the light absorption film84. The second controller92controls the transfer tool60to apply light to the light absorption film84. The second controller92generally presses the thermal transfer foil82and the light absorption film84with the pressing body66of the transfer tool60, while (at the same time) applying light from the light source62of the transfer tool60to the light absorption film84. More specifically, light from the light source62is applied to a portion of the light absorption film84pressed by the pressing body66.

At this time, in a portion of the light absorption film84irradiated with laser light of the light source62, the light absorption film84absorbs laser light and converts optical energy to thermal energy. Accordingly, the light absorption film84generates heat, and the heat is transferred to the adhesive layer of the thermal transfer foil82. In this manner, the adhesive layer is softened, and adhesion is able to be obtained. The adhesive layer is attached to the surface of the transfer object80, and brings the decorative layer of the thermal transfer foil82and the transfer object80into close contact with each other. Thereafter, the transfer tool60is moved or application of laser light from the light source62is stopped, thus finishing supply of optical energy to this irradiated portion. Then, the adhesive layer is cooled by heat dissipation and is hardened. Consequently, the decorative layer and the surface of the transfer object80are fixed to each other.

Based on the second image data stored in the memory95, the second controller92controls the transfer tool60and the pressing body conveyor22. In controlling movement of the transfer tool60by the second controller92, the transfer tool60may move the entire predetermined region80T or may move only a portion of the predetermined region80T. The second controller92moves the carriage21along the X axis, the Y axis, and the Z axis to move the transfer tool60. The second controller91controls application and stop of laser light from the light source62. After the process in step S50, the light absorption film84and the base material of the thermal transfer foil82placed on the transfer object80are removed. Consequently, a transfer object80in which a desired pattern or the like by the thermal transfer foil82is appropriately transferred onto the pressed surface of the predetermined region80T can be obtained.

As described above, the thermal transfer apparatus10according to this preferred embodiment includes the controller92including the first controller91and the second controller92. The first controller91controls the pressing body conveyor22to press the predetermined region80T of the transfer object80. As described above, since the predetermined region80T is pressed by the transfer tool60before the thermal transfer foil82is transferred onto the predetermined region80T of the transfer object80, the predetermined region80T of the transfer object80is smoother than that before being pressed. Then, the second controller92controls the transfer tool60such that the thermal transfer foil82and the light absorption film84disposed on the smooth predetermined region80T are pressed, and (at the same time) light is applied to the light absorption film84. Accordingly, the thermal transfer foil82is more appropriately transferred onto the predetermined region80T of the transfer object80.

In the thermal transfer apparatus10according to this preferred embodiment, the protective film86is placed on the transfer object80. The first controller91of the controller90controls the pressing body conveyor22to press the predetermined region80T of the transfer object80with the protective film86interposed therebetween. In this manner, since the transfer tool60presses the predetermined region80T indirectly with the protective film86interposed therebetween, abrasion of a pressed portion (pressing body66in this case) of the transfer tool60is able to be reduced, as compared to a case where the transfer tool60contacts the transfer object80to press the predetermined region80T directly.

In the thermal transfer apparatus10of this preferred embodiment, the protective film86has a light absorption property. The first controller91of the controller90controls the transfer tool60and the pressing body conveyor22such that the predetermined region80T of the transfer object80is pressed with the protective film86interposed therebetween and, at the same time, light is applied to the protective film86. While the transfer tool60presses the predetermined region80T indirectly, light is applied to the protective film86. Thus, heat generated in the protective film86is conducted to the predetermined region80T. In this manner, the predetermined region80T of the transfer object80is pressed with application of heat, and thus, the surface thereof becomes smoother.

In the thermal transfer apparatus10according to the present preferred embodiment, the predetermined region80T of the transfer object80includes a resin material. Since the resin material of the predetermined region80T is melted with heat, the surface of the predetermined region80T becomes smoother.

The foregoing description is directed to the preferred embodiments of the present invention. The preferred embodiments described above, however, are merely examples, and the present invention can be performed in various modes.

In the preferred embodiments described above, the protective film86is used in pressing the predetermined region80T of the transfer object80. However, the present invention is not limited to this. The protective film86may not be used, and the predetermined region80T of the transfer object80may be pressed directly with the transfer tool60. Tools other than the transfer tool60may be used so that an operator is able to manually press the predetermined region80T of the transfer object80.

In the preferred embodiments described above, the protective film86is used in pressing the predetermined region80T of the transfer object80, and the light absorption film84is used in transferring the thermal transfer foil82onto the transfer object80. However, the present invention is not limited to this. The light absorption film84may be used instead of the protective film86in pressing the predetermined region80T of the transfer object80with the previously used light absorption film84being used again in transferring the thermal transfer foil82onto the transfer object80. In this case, the first controller91is able to control the light source62of the transfer tool60such that a first quantity of light applied to the light absorption film84in pressing the predetermined region80T of the transfer object80(quantity of light in step S20of the flowchart) is smaller than a second quantity of light applied to the light absorption film84in transferring the thermal transfer foil82onto the transfer object80(quantity of light in step S50of the flowchart). For example, the first quantity of light is about 70% to about 95% (e.g., about 90%) of the second quantity of light. Accordingly, degradation of the light absorption film84is able to be reduced with appropriate heat being applied to the predetermined region80T of the transfer object80.

In the preferred embodiments described above, the protective film86has a light absorption property similarly to the light absorption film84. However, the present invention is not limited to this. The protective film86may have a significantly low light absorption property similarly to the support film. In a case where light is applied from the transfer tool60to the transfer object80in pressing the predetermined region80T of the transfer object80, the protective film86preferably has a light transmittance. The protective film86is preferably made of a material transparent to laser light emitted from the light source62. The protective film86is preferably a transparent member having a high light transmittance, for example. The transfer object80preferably has a light absorption property. In this case, the first controller91controls the transfer tool60and the pressing body conveyor22such that the predetermined region80T of the transfer object80is pressed with interposition of the protective film86and, at the same time, light is applied to the protective film86. In this manner, while the predetermined region80T is indirectly pressed by the transfer tool60, light that has passed through the protective film86is applied to the transfer object80, and thus, heat is generated in the predetermined region80T of the transfer object80. In this manner, the predetermined region80T of the transfer object80is pressed with generation of heat so that the surface thereof becomes smoother.

In the preferred embodiments, the pressing body66of the transfer tool60moves relative to the fixture20. However, the present invention is not limited to this example. In the thermal transfer apparatus10, the fixture20may move relative to the pressing body66or both the fixture20and the pressing body66may be movable. For example, the fixture20may be movable along the X axis with the pressing body66being movable along the Y axis and the Z axis.

In the preferred embodiments described above, the pressing body66is a sphere. The pressing body66, however, is not limited to this shape. For example, the pressing body66may be a hemisphere or a rectangular parallelepiped.

In the preferred embodiments described above, the controller90includes the first controller91to perform predetermined control and the second controller92to perform predetermined control. However, the present invention is not limited to this. The controller90may be configured or programmed such that control by the first controller91and control by the second controller92are performed by one controller.

The terms and expressions used herein are for description only and are not to be interpreted in a limited sense. These terms and expressions should be recognized as not excluding any equivalents to the elements shown and described herein and as allowing any modification encompassed in the scope of the claims. The present invention may be embodied in many various forms. This disclosure should be regarded as providing preferred embodiments of the principles of the present invention. These preferred embodiments are provided with the understanding that they are not intended to limit the present invention to the preferred embodiments described in the specification and/or shown in the drawings. The present invention encompasses any of preferred embodiments including equivalent elements, modifications, deletions, combinations, improvements and/or alterations which can be recognized by a person of ordinary skill in the art based on the disclosure. The elements of each claim should be interpreted broadly based on the terms used in the claim, and should not be limited to any of the preferred embodiments described in this specification or described during the prosecution of the present application.