JP2000238237A - Rotary recessed and projected pattern forming device for forming recessed and projected pattern on rigid plate surface, and recessed and projected pattern forming method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To deal with a required specification for an object product by clamping an ionizing radiation setting resin between an intaglio rotary roll and an ionizing radiation transmissible film and emitting an ionizing radiation. SOLUTION: A cured projected pattern of an ionizing radiation setting resin composition is formed on the surface of a rigid plate. An intaglio rotary roll having projected patterns as recessed patterns formed of a surface of release properties is provided, and an ionizing radiation setting resin composition is clamped continuously between ionizing radiation transmissible films of release properties. The ionizing radiation is emitted in the above claming state, and the ionizing radiation transmissible films are released from the surface of the intaglio rotary roll. A rigid plate is fed onto the intaglio rotary roll, and the rigid plate and a cured ionizing radiation setting resin composition are overlapped while keeping the given alignment accuracy and set them in the pressurized state. The rigid plate is released from the surface of the intaglio rotary roll. Projected patterns free from defects can be formed directly on the rigid plate by the rotary method by the arrangement.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for forming an uneven pattern on the surface of a flat rigid plate. The present invention relates to an apparatus and a method of a rotary printing method in which an ionizing radiation-curable resin composition is filled into a concave portion and cured using the same. Applications include the manufacture of various building materials and various electronic components. For example, decorative plywood, printed circuit boards,
There are color filters used for plasma display substrates, liquid crystal displays, and the like. Hereinafter, the expression of the intaglio plate will be complicated, and in the present invention, the intaglio plate can be regarded as a kind of intaglio, so it is expressed as an intaglio plate.

[0002]

2. Description of the Related Art When forming a convex pattern on a rigid plate using an intaglio plate, the first problem is that the intaglio plate is usually a rigid body, so that a portion where both are not sufficiently adhered to each other is generated. Insufficient transfer of ink from that part of the plate to the substrate,
That is, a transfer defect defect occurs. As a countermeasure, Japanese Patent Application Laid-Open No. 4-34551 is an example of a known technique. In this application, a pattern is formed on a glass substrate or the like, but an ink-repellent rubber elastic layer is formed on the plate surface other than the concave portions of the intaglio plate. At the time of printing, the rubber layer is deformed by printing pressure, and the ink is transferred from the plate to the substrate while being in close contact with a rigid plate having a thickness unevenness of the glass substrate or the like with some unevenness on the surface. Therefore, a pattern with few defects can be obtained. However, the ink at the time of transfer, depending on the viscosity of the ink, splits at a depth of less than half of the plate,
The thickness of the obtained convex pattern becomes thin. The shape of the obtained convex pattern is also affected by the ink splitting.

A method for preventing the ink from being split in the intaglio has been disclosed in Japanese Patent Application Laid-Open No. 57-87318.
The method is to cure the ink (paste) to be used with ultraviolet light,
An electron beam curing composition is used to cure and transfer the ink in the intaglio. It is also disclosed that silicone or the like is provided in (inside) the intaglio in order to enhance the releasability of the intaglio.

Next, Japanese Patent Application Laid-Open No. 4-35989 discloses a method which can be said to be an improved method of Japanese Patent Application Laid-Open No. 4-34551. That is, by making the inner surface of the concave portion a releasable material such as silicone rubber or Teflon, the transferability is improved, and if an adhesive layer is provided on the surface of a rigid printing material such as a glass substrate. The ink can be transferred after being cured, and the shape of the obtained convex pattern is excellent. However, since the inner surface of the concave portion is a surface that repels ink and has releasability, when the ink enters the concave portion and the inking roll separates from the plate, the ink adheres to the inking roll, and the concave portion is formed. There was a problem that it got out of the system.

Japanese Patent Application Laid-Open No. 4-35989 is an improvement of the printing plate and printing method disclosed in Japanese Patent Application Laid-Open No. 56-137989. In the latter, the plate had no ink repellent layer on the surface and was made of a hard material such as a chromium plating material or a stainless steel plate. In such a case, if the inking is performed using a doctor, even if the inner surface of the concave portion has a property that does not mix with the ink, the inner surface of the concave portion of the hard layer on the surface may be compatible with the ink. did it. Since the backing material has elasticity, it has the effect of pushing out the ink by pressurization, and there was no problem in transferring the ink to the rigid plate. In addition, it was possible to cure the ink inside the plate to improve the shape, and it was possible to extrude the cured ink toward the printing material as described above, but the adhesive was applied to the surface of the printing material. Could not be transcribed. This is because the plate surface and the printing material are stuck with the adhesive.

In order to avoid this, if the surface of the plate is made to be releasable from the ink or the adhesive material by using a silicone resin or a fluororesin, the resin is soft when the ink is scraped off by a doctor. There was a problem that the wound was painful and the tolerance was quite low.

[0007] An improvement of the inking method is a method described in JP-A-4-10936 and JP-A-5-241175. That is, this is a method in which the ink is pressed into the concave portion with a film having release properties. According to this method, the ink in the concave portions is not scraped off or hardened on the intaglio rotary rolls regardless of whether the ink in the concave portions is cured or not. However, only the method of inking and curing is shown, and the apparatus is not shown. Furthermore, there is another problem when inking into an intaglio. This is the entrapment of air bubbles, and it is more likely to occur as the depth of the intaglio becomes deeper, the pattern becomes finer, the viscosity of the ink becomes higher, and the filling speed becomes faster. Nothing is mentioned in the application indicated above for this problem.

The above description was mainly directed to the case where a pattern is formed on a glass substrate. The following is a description of a method of manufacturing a so-called decorative plywood having a concave and convex pattern used for building interior members such as doors. Explain the problem. Here, the decorative plywood is obtained by subjecting the surface of the plywood to various processings, mainly resin processing, to improve performance such as durability and water resistance and to improve appearance. As a simple matter,
In some cases, printed films are pasted on raw plywood. If you stick a printed beech tree texture, it looks like a beech board. In this case, in order to further improve the appearance, it is desirable to use a wood grain pattern having irregularities such as actual wood skin. It is very effective to form not only a grain pattern but also a pattern having irregularities in general, in order to enhance the real feeling.

The process for producing a plywood having a concavo-convex pattern is described in, for example, JP-A-56-017217 and JP-A-03-2076.
13, etc., a method for producing a decorative plywood with wood grain unevenness will be described with reference to FIGS.

FIG. 1 shows a method of manufacturing a matrix. a) First, a room-temperature-curable silicone rubber to which a predetermined amount of a curing agent has been added is placed on the selected natural wooden board. b) Separately, attach a plastic film to the frame, apply the above-mentioned primer for silicone rubber, and place the above-mentioned silicone rubber so as to spread it. It is also expanded by a roll or the like as an auxiliary. Leave in that state until the silicone rubber has hardened. c) The cured silicone rubber protruding from the periphery of the plate is cut, and the frame is lifted, whereby the integrated plastic film and silicone rubber are separated from the plate.
This is the matrix, and the grain of the wood (unevenness mainly of the conduit and sieve tube) is uneven.

FIG. 2 shows a method for manufacturing a wood-grain decorative plywood using this matrix. a) A film printed with a grain pattern is attached to unprocessed plywood. Fig. 1
It is the grain of the natural wooden board used in the above. An ultraviolet-curable polyester resin is placed thereon. b) Place the matrix so that the UV-curable polyester resin is spread. Pushing and spreading using a roll or the like is also performed. Thereafter, the polyester resin is cured by irradiation with ultraviolet rays.
c) When the frame is lifted upward, the interface between the silicone rubber and the polyester resin is peeled off, and the unevenness on the surface of the polyester resin on the natural wooden board is reproduced.

[0012] Similarly in the case other than wood grain, a decorative plywood having irregularities is formed. One of the problems of this method is that air bubbles easily enter between the resin and the matrix because of the superposition of planes. The `` bubble removal work '' to remove air bubbles once entered requires a considerable amount of time because the viscosity of the resin is high and the size is large, and the amount of paste must be reduced in order to avoid air bubbles. It needs to be set very high, and the extra amount is wasted. Still, the incorporation of air bubbles is inevitable, and a "bubble removal step" is required. Another problem with this method is that since it is a single-wafer type, a large space is required and the productivity is low.

Next, the manufacture of a printed circuit board will be described. There are two known methods of forming an etching resist pattern on a copper-clad laminate of a printed circuit board by rotary printing direct printing. One is a method called the EG plate method developed by Dainippon Screen, which uses a plate for waterless offset printing. The other is a method called DOP method developed by Toyo Ink Mfg. Co., Ltd., which uses a resin letterpress for letterpress printing as a plate.

Regarding the former, a method and problems will be described below. A TAP plate (registered trademark) manufactured by Toray used for offset printing without water is used as a plate, and exposure and development are performed according to a normal method to obtain a desired pattern. In the TAP plate, an ink-philic film and a silicone rubber layer are formed on an aluminum substrate, and when exposed and developed, the exposed portion of the silicone rubber film is removed.
The thickness of the silicone rubber is 10 μm, which can be considered as a shallow intaglio. The silicone rubber part is the ink-repellent surface. This plate is wound around a rotary roll to form a rotary intaglio. The resist ink is supplied to the plate using an inking roll. The ink is filled into the ink-philic part of the plate. The copper-clad laminate, which is the substrate, is set on a planar printing table, and as the printing table moves, the copper-clad laminate comes into contact with the intaglio, and the resist ink is transferred from the plate to the substrate. The main problem with this method was the incorporation of air bubbles. Even when printing twice, it was not possible to prevent the incorporation of air bubbles, the required etching resistance was not obtained, and the product was not put to practical use.

Next, a method of continuously forming partition walls of a flat plasma display panel (hereinafter referred to as PDP) by a rotary method will be described. Known ones are disclosed in Japanese Unexamined Patent Publication No.
321258 and JP-A-10-101373.

FIGS. 3A, 3B and 3C show the former method and the like.
According to the claim, the following two steps are required. PD
Using an intaglio having an intaglio recess formed of a shape for shaping the partition wall portion of P, filling at least the intaglio recess of the intaglio with an ionizing radiation-curable resin containing glass frit, and contacting the film substrate, Irradiating ionizing radiation while the film substrate is in contact with the intaglio plate, and curing the ionizing radiation-curable resin interposed between the film substrate and the film substrate and the ionizing radiation. Removing the radiation-curable resin layer from the concave portion; A step of adhering the surface of the cured ionizing radiation-curable resin layer having the shape of the barrier portion on the film substrate to the surface of the PDP substrate, followed by firing.

That is, in order to obtain a desired partition shape,
First, it is formed on a film substrate and then transferred onto a glass substrate.

The problems of the above manufacturing method are as follows: (1) First, it is formed on a film and then transferred, so that it is very difficult to secure positional accuracy (dimensional accuracy). This is because it is necessary to align the partition with the electrode interposed therebetween, and a positional accuracy of about ± 5 to 10 μm / m is required.

In FIG. 3A, the longitudinal direction of the partition wall is orthogonal to the longitudinal direction of the film. Therefore, if the partition wall is formed in the direction of FIG. 3A, the expansion and contraction of the film directly affects. For example, in the case of the polyester film used in Examples, precise tension control is performed in the longitudinal direction at the time of transfer. It is necessary to adjust the pitch of the partition walls by adjusting the elongation of the polyester film.

If the direction orthogonal to the direction of FIG.
That is, even if the partition wall is formed in a direction in which the longitudinal direction of the partition wall coincides with the longitudinal direction of the film, precise tension control in the width direction is required. In this case, the tension in the longitudinal direction of the film is also necessary to prevent the occurrence of defects such as disconnection of the partition walls. Rewinding is also quite difficult. As shown in FIG. 3a, it is most preferable to make the surface flat after the transfer onto the film.

(2) (Although the shape of the partition wall is desirably trapezoidal when viewed from the back substrate, it is described in FIGS. 2 and 4 of the application (shown here as FIGS. B and c, respectively). In this case, the shape of the intaglio becomes narrower near the surface, so that it is very difficult to separate the hardened partition wall material from the intaglio.

(3) Another problem with this method is the incorporation of air bubbles. However, nothing is described in this publication in this regard.

Next, JP-A-10-101373 is a very comprehensive and conceptual application, and the method of the apparatus of the present invention is also included in a part of the method of this application. FIG. 4 shows a diagram disclosed in JP-A-10-101373.

However, in the application of Japanese Patent Application Laid-Open No. 10-101373, equivalents and similar ones are found as follows in most of the claims.

Regarding the first aspect, Japanese Patent Application Laid-Open No. H8-2735
37, also described in JP-A-8-32258,
Furthermore, it is a very common method of forming a so-called ceramic fired product, and is described in a textbook in that direction.

Regarding claim 2, a similar method is described in Japanese Patent Publication No. 3-4398. In the method of this patent,
It is common knowledge for those skilled in the art that the example in which silver is removed from the composition of the silver paste is similar to a paste for a partition is described in Examples, but the pattern formation of a baked silver paste is described in the Examples. Is also clear.

[0027] Claim 3 is disclosed in Japanese Patent Application Laid-Open No. 8-2735.
37, JP-A-8-32258.

Regarding claim 4, Japanese Patent Application Laid-Open No. 8-3212
58. Other materials are different.
-13322 (Cannon).

Regarding claim 5, no prior application has been found for a firing paste.

Claim 6 has a thermal expansion coefficient suitable for so-called low expansion glass, for example, Corning # 7059. Since the composition is not described in the specification, the composition is not specified, but the one suitable for low expansion glass is simply specified.

The seventh aspect is a glass developed for a substrate of ordinary alkali glass or PDP, for example, having a thermal expansion coefficient suitable for PD-200 manufactured by Asahi Glass Company. Since the composition is not described in the specification, it does not specify the composition, but simply specifies what is suitable for those glasses.

Claims 8, 9 and 10 are within the range of ordinary paste for barrier ribs, and specify the range.

For the eleventh, twelfth, thirteenth and thirteenth aspects, see, for example, Japanese Patent Application Laid-Open Nos. 8-273737 and 8-321.
258.

Regarding claim 15, no prior application has been found.

Claim 16 is a general range in firing.

Claims 17, 18, and 19 are described in JP-A-8-32258. Further, except for the fact that the material is a frit-containing material, for example,
16.

As for the twentieth aspect, Japanese Patent Application Laid-Open No. 8-273 is disclosed.
537, and JP-A-8-32258.

Regarding claims 21, 22, and 23, except for the specification of materials, Japanese Patent Application Laid-Open Nos.
10936. In addition, a silicone resin mold having a desired concavo-convex pattern is superimposed on the curable resin composition applied on the substrate, cured in that state, and after curing, the silicone resin mold is peeled off. A method for forming a concavo-convex pattern of the curable resin composition is described in, for example, JP-A-58-84718.

Regarding claim 24, no prior application has been found.

Regarding Claims 25 and 26, there is an application of the above-mentioned Dai Nippon Printing Co., Ltd. for the radiation-curable component and the ultraviolet-curable resin for the ionizing radiation resin. No prior application has been found for thermoplastic organic materials.

In the present application, not only the rotary type but also a planar type is included, but an application relating to this is the above-mentioned application of Dai Nippon Printing Co., Ltd.

In conclusion, this Corning application is merely a compilation of the methods known in the prior application, except for the use of thermoplastic materials. Nor is it claimed that significant effects can be obtained in a particular combination.

However, there is no known device that actually implements the conventional method. The basic reason is that, although possible in terms of ideas, there are problems such as practical difficulty, lack of specific means to ensure accuracy, lack of durability, etc. is there. For example, Japanese Patent Application Laid-Open No. 10-101373 discloses a method of scraping off ink in an unnecessary portion with ink supplied to a roll.
As shown in the figure, it is scraped off with a member (such as a doctor). However, if this method is adopted, the hardness of the surface of the roll is considerably high, and if the slipperiness is not good, the surface of the intaglio is damaged due to wear over time. Therefore, in gravure printing, a metal roll having a chrome-plated surface is used. Plastic rolls have ideas and various advantages, but are not used because of insufficient hardness and wear. JP-A-10-10137
No. 3 describes nothing about the surface hardness and abrasion resistance of the roll. However, the silicone rubber mold is formed of a room-temperature-curable silicone material (RTV141) in the example, and is used in the example 1. Since the rubber hardness of the RTV is at most 100, it is considered that there is actually a problem in terms of durability. On the other hand, when the plate is hard, printing cannot be performed on a rigid body such as a glass substrate.

[0044]

An object of the present invention is to provide a method of directly forming a thick convex pattern having excellent shape reproducibility on a rigid plate by an intaglio printing method.
An object of the present invention is to provide a mass-produced apparatus and method. In response to the required specifications of the target product, it is possible to cope with the case where air bubbles must be avoided, and it can cope with the case where high-precision alignment is required. It is an object of the present invention to provide a method and an apparatus which can cope with such a large size.

[0045]

In order to solve the above-mentioned conventional problems, the present invention takes the following measures. That is,
A rotary type apparatus for forming a cured convex pattern of an ionizing radiation-curable resin composition on the surface of a rigid plate is characterized in that it has at least the following mechanisms and structures. (See Fig. 5)

An intaglio rotary roll having an intended convex pattern as a concave pattern having a releasable surface is provided. An ionizing radiation curable resin is interposed between the intaglio rotary roll and an ionizing radiation transmitting film having releasability. A mechanism for continuously sandwiching the composition while maintaining a predetermined thickness. A mechanism for irradiating ionizing radiation while sandwiching the composition. A mechanism for peeling the ionizing radiation transmitting film from the surface of the intaglio rotary roll after curing. A mechanism for supplying a rigid plate onto the intaglio rotary roll, superimposing the ionizing radiation-curable resin composition cured by ionizing radiation irradiation while maintaining a predetermined alignment accuracy, and providing a pressurized state. And a mechanism for releasing the rigid plate from the surface of the intaglio rotary roll after the pressurized state.

That is, as a method of filling the ink into the concave portions of the intaglio, a method was employed in which an ionizing radiation curable resin was sandwiched between an intaglio rotary roll and an ionizing radiation transmitting film, and ionizing radiation was irradiated in that state.

Next, in the above-mentioned apparatus, the releasable surface material of the intaglio roller was made of silicone resin.

There was provided a mechanism for supplying a rigid plate coated with an adhesive or an adhesive so as to come into contact with the surface of the intaglio rotary roll. If the curing of the ionizing radiation-curable resin composition is not complete and there is still some tackiness, even if nothing is applied to the rigid plate, if both are contacted and pressed, the cured product will peel off from the intaglio. To transfer to a rigid plate. However, as the curing progresses and the tackiness decreases, it becomes necessary to use the help of other adhesive materials. The adhesive / adhesive is applied to the rigid plate in advance.

In the case where it is inconvenient to apply an adhesive or a release agent on the entire surface of the rigid plate, the adhesive resin for transfer is applied to the surface of the cured resin composition in the apparatus according to claim 1. A mechanism is provided. In this case, the transfer adhesive or adhesive is applied only to the portion where the cured product of the ionizing radiation-curable resin composition is present.
The adhesive is applied and the other parts are ink-repellent surfaces, so there is no adhesive or adhesive on it.

The width of the ionizing radiation transmitting film having releasability to be supplied to the apparatus of claim 1 is wider than the width of the intaglio rotary roll. By doing so, when the sandwiched ionizing radiation-curable resin composition spreads around, it does not hang down from the side surface of the intaglio rotary roll, but gets on the edge of the film. The ionizing radiation-curable resin composition does not spread around the apparatus, and can be reused.

An ionizing radiation curable resin composition was previously applied to the surface of an ionizing radiation transmitting film having releasability to be supplied to the apparatus of claim 1, and then superposed on an intaglio rotary roll. It is easier to control the supply amount and to prevent air bubbles from mixing than supplying and applying the ionizing radiation-curable resin composition to the plate or supplying the ionizing radiation-curable resin composition to the contact point between the intaglio rotary roll and the film. It becomes easier to do. In some cases, air bubbles are left at the interface during bonding and air bubbles in the original ionizing radiation-curable resin composition. For the former, it is common to vacuum degas the ionizing radiation-curable resin composition. For the latter, a method for forming a liquid layer on the bonding surface described later is effective.

The present invention provides a method for forming a convex pattern, wherein a transfer adhesive or adhesive is previously formed on the surface of an ionizing radiation transmitting film having releasability.

The apparatus according to claim 1, further comprising a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start contacting. Elimination of bubbles during lamination is eliminated.

Similarly, there is provided the apparatus according to the first aspect, further comprising a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the rigid plate start contacting.

The apparatus according to claim 1, wherein the moving mechanism of the rigid plate is an XY-θ table that moves according to a guide rail having a mechanism for fixing the rigid plate.

For high-precision alignment, claim 1
In an apparatus having a mechanism of 0, alignment marks are formed at corresponding positions on both the intaglio and the rigid plate,
An XY-θ table in which the intaglio alignment mark is transferred to the rigid plate in advance, the positional deviation between the intaglio alignment mark transferred to the rigid plate and the alignment mark of the rigid plate is measured, and the rigid plate is fixed accordingly. And adjusting the position and alignment of the two.

According to a first aspect of the present invention, there is provided a rotary type apparatus for forming a cured concavo-convex pattern of an ionizing radiation-curable resin composition on the surface of a rigid plate, which has at least the following mechanisms and structures. Pattern forming apparatus.

An intaglio rotary roll having an intended concavo-convex pattern as an uneven pattern having a releasable surface. An ionizing radiation-curable resin composition between the intaglio rotary roll and an ionizing radiation transmitting film having releasability. A mechanism for continuously sandwiching an object while maintaining a predetermined thickness A mechanism for irradiating ionizing radiation in a sandwiched state After the ionizing radiation-curable resin composition is cured, the ionizing radiation transmitting film is peeled off from the surface of the intaglio rotary roll. Mechanism A mechanism in which a rigid plate is supplied onto the intaglio rotary roll, and is superimposed on the ionizing radiation-curable resin composition cured by ionizing radiation irradiation while maintaining a predetermined alignment accuracy, and is in a pressurized state. Then, a mechanism for peeling the rigid plate from the surface of the intaglio rotary roll

According to a second aspect of the present invention,
2. The uneven pattern forming apparatus according to claim 1, wherein the surface material of the “intaglio rotary printing roll having an uneven pattern having a releasable surface” is a silicone resin. 3.

According to a third aspect of the present invention, there is provided a mechanism for applying an adhesive or an adhesive to the rigid plate to be supplied onto the intaglio rotary roll according to the first aspect in advance. Or the uneven pattern forming apparatus according to any one of 2.

According to a fourth aspect of the invention, there is provided a mechanism for applying a transfer resin to the surface of the cured ionizing radiation-curable resin composition according to the first aspect. An uneven pattern forming apparatus according to any one of the above.

According to a fifth aspect of the present invention, the width of the ionizing radiation transmitting film having releasability according to the first aspect is wider than the width of the intaglio rotary roll. 3. An uneven pattern forming apparatus according to item 1.

According to a sixth aspect of the present invention, there is provided:
The "mechanism for continuously sandwiching the ionizing radiation-curable resin composition between the intaglio rotary roll and the ionizing radiation transmitting film having releasability while maintaining a predetermined thickness" is an ionization having releasability. The uneven pattern forming apparatus according to any one of claims 1 to 5, wherein the apparatus is a mechanism in which an ionizing radiation-curable resin composition is applied to the surface of the radiation transmitting film in advance, and is superposed on an intaglio rotary roll.

According to a seventh aspect of the present invention, there is provided an ionizing radiation transmitting film having releasability according to the first aspect, further comprising a mechanism for applying an adhesive or an adhesive in advance to the surface. 7. The uneven pattern forming apparatus according to any one of 1 to 6.

According to an eighth aspect of the present invention, there is provided the uneven pattern forming apparatus according to the first aspect, further comprising a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start to contact. An uneven pattern forming apparatus according to any one of claims 1 to 7.

According to a ninth aspect of the present invention, in the uneven pattern forming apparatus according to the first aspect, a mechanism is provided for supplying a liquid to a portion where the intaglio rotary roll and the rigid plate start contacting. An uneven pattern forming apparatus according to any one of claims 1 to 8.

According to a tenth aspect of the present invention, in the uneven pattern forming apparatus according to the first aspect, the XY-θ table in which the rigid plate moving mechanism has a mechanism for fixing the rigid plate and moves according to the guide rail. The uneven pattern forming apparatus according to any one of claims 1 to 9, wherein

According to the eleventh aspect of the present invention, there is provided a method for forming a concavo-convex pattern of a rotary type for forming a cured concavo-convex pattern of an ionizing radiation-curable resin composition on the surface of a rigid plate, wherein at least the following mechanisms are provided. This is a method for forming a concavo-convex pattern that is a feature. A predetermined thickness of the ionizing radiation-curable resin composition between an “intaglio rotary roll having an intended concavo-convex pattern as a concave-convex pattern composed of a releasable surface” and an ionizing radiation transmitting film having releasability. A mechanism for continuously sandwiching while maintaining a mechanism for irradiating ionizing radiation in a sandwiched state A mechanism for peeling off the ionizing radiation-permeable film from the surface of the intaglio rotary roll after curing the ionizing radiation-curable resin composition The rigid plate is rotated in the intaglio rotary A mechanism for superimposing the ionizing radiation-curable resin composition supplied on a roll and curing it by irradiation with ionizing radiation and superimposing it while maintaining a predetermined alignment accuracy. Mechanism to peel off from the surface of the rotary roll

A twelfth aspect of the present invention is characterized in that the surface material of the "intaglio rotary roll having an irregular pattern having a releasable surface" of the eleventh aspect is a silicone resin. Item 12. An uneven pattern forming method according to Item 11.

According to a thirteenth aspect of the present invention, in any one of the eleventh and twelfth aspects, a pressure-sensitive adhesive or an adhesive is previously applied to the rigid plate to be supplied onto the intaglio rotary roll. And a method of forming a concavo-convex pattern.

According to a fourteenth aspect of the present invention, a transfer resin is applied to the surface of the cured ionizing radiation-curable resin composition according to the eleventh aspect. The method for forming a concavo-convex pattern described in 1. above.

According to a fifteenth aspect of the present invention, the width of the ionizing radiation transmitting film having releasability according to the eleventh aspect is wider than the width of the intaglio rotary roll.
15. The method for forming a concavo-convex pattern according to any one of claims 14 to 14.

According to a sixteenth aspect of the present invention, there is provided an intaglio rotary roll having an intended concavo-convex pattern as a concave-convex pattern having a releasable surface according to the eleventh aspect, and ionizing radiation having releasability. A mechanism for continuously sandwiching the ionizing radiation-curable resin composition between the films while maintaining a predetermined thickness applies the ionizing radiation-curable resin composition in advance to the surface of the ionizing radiation-transmitting film having releasability. The method according to any one of claims 11 to 15, wherein the mechanism is a mechanism for superimposing an intaglio rotary roll.

The invention of claim 17 is characterized in that a pressure-sensitive adhesive or an adhesive is previously applied to the surface of the ionizing radiation transmitting film having releasability according to claim 11. An uneven pattern forming method according to any one of the above.

According to an eighteenth aspect of the present invention, in the method of forming an uneven pattern according to the eleventh aspect, the liquid is supplied to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start to contact. Item 18. An uneven pattern forming method according to any one of Items 11 to 17.

According to a nineteenth aspect of the present invention, in the method of forming an uneven pattern according to the eleventh aspect, the liquid is supplied to a portion where the intaglio rotary roll and the rigid plate start contacting. An uneven pattern forming method according to any one of the above.

According to a twentieth aspect of the present invention, in the method of forming an uneven pattern according to the eleventh aspect, the moving mechanism of the rigid plate includes:
20. The method according to claim 11, wherein the XY-θ table has a mechanism for fixing the rigid plate and moves along a guide rail.

According to a twenty-first aspect of the present invention, in the method of forming a concavo-convex pattern having the rigid plate moving mechanism according to the twentieth aspect, an alignment mark is formed at a corresponding position on both the intaglio and the rigid plate. The intaglio alignment mark is transferred to the rigid plate, and the positional deviation between the intaglio alignment mark transferred to the rigid plate and the alignment mark of the rigid plate is measured, and the rigid plate is fixed accordingly.
21. The method for forming a concavo-convex pattern according to claim 11, wherein the position of the table is adjusted and alignment is performed.

[0080]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS According to an embodiment of the present invention, the ionizing radiation is an ultraviolet ray, an X-ray, an electron beam, or the like.
Radiation having the ability to excite air and molecules into an ionized state. The ionizing radiation-curable resin composition refers to a composition containing a resin that undergoes a curing reaction by ionizing radiation.

The release surface is a surface from which the cured product of the ionizing radiation-curable resin composition can be released from the mold very easily. For example, silicone resin, fluorine resin, polyolefin resin, polyester resin. These resins only need to be formed on the surface of the intaglio plate.In practice, a metal plate such as aluminum, stainless steel, or invar alloy, or a plastic film such as polyester resin is used as a base plate, and the above A concave pattern of the release material is formed. As a method of forming an intaglio, there are a lift-off method and a casting method using a matrix. Here, the lift-off method is to form a target intaglio by forming a pattern opposite to a desired pattern on a printing material, applying and curing a release material over the entire surface, and finally peeling the reverse pattern. Is the way.

The thickness of the elastic layer for following the rigid plate varies depending on the thickness irregularity of the rigid plate (between lots, between substrates, within the substrate), but at least in the range of the thickness irregularity. It is necessary to be in a certain state. Usually, (range width of thickness unevenness) + (thickness of 2 to 5 times the plate depth) is appropriate as a range in which the deformation of the intaglio pattern is not hindered. Numerically, it is about 0.5 to 2 mm for decorative plywood, and 0.5 to 3 mm for PDP substrate.

As a method for making the surface of the intaglio mold releasable,
A method of forming a silicone resin uneven pattern directly on an intaglio rotary roll base material, and forming a silicone resin uneven pattern on a flexible substrate and winding it over an intaglio rotary roll base material There is a way. The method of winding is a method of sticking with an adhesive or an adhesive, a method of adsorbing with magnetic force, electric force, vacuum, etc., a method used in a rotary printing press, but a method of biting with a jig. .

The type of the ionizing radiation transmitting film includes polyester, polyamide and the like. Thickness is 30 μm to 100
μm is easy to use. Silicone resin is preferred as the material of the film having releasability formed on the surface of the film. Release films in which a silicone resin is coated on the surface of a polyester film are commercially available and can be used in many cases.

The composition of the ionizing radiation-curable resin composition is different depending on the use, and is shown in Examples. However,
The viscosity and fluidity need to be such that the intaglio can be filled.

As a mechanism for continuously sandwiching the ionizing radiation-curable resin composition while maintaining a predetermined thickness, as shown in FIG. It is common to set up a backup roll. Further, a tension adjusting roll or the like is required to adjust the tension of the film.

As a mode related to the implementation of the mechanism for irradiating ionizing radiation while being sandwiched, first, as the ultraviolet irradiation device, it is desirable that the illuminance in the width direction of the intaglio rotary roll is uniform, and for example, an ultraviolet curable ink is used. For example, an ultraviolet irradiation device installed in an offset printing machine for performing the operation or a non-polar ultraviolet irradiation device manufactured by Fusion is suitable. The arrangement shown in FIG. 5 is common.

A mechanism for peeling the cured ionizing radiation transmitting film from the surface of the intaglio rotary roll is usually a backup roll.

A mechanism for supplying a rigid plate onto the intaglio rotary roll and superimposing it with an ionizing radiation-curable resin composition cured by irradiation with ionizing radiation while maintaining a predetermined alignment accuracy to form a pressurized state is described below. The mechanism changes greatly depending on the alignment accuracy. When almost no alignment is required, as in the case of decorative plywood, a simple timing delivery mechanism may be used. A backup roll may be provided at the contact portion between the intaglio rotary roll and the plywood substrate, and the plywood substrate may be a mechanism that wraps around the intaglio rotary roll. If running becomes unstable, install guide rails. On the other hand, a mechanism for a case where precise alignment is required is provided in claim 11.

A guide rail is generally used as a mechanism for peeling the rigid plate from the surface of the intaglio rotary roll after pressing.

An embodiment according to the second aspect of the present invention relates to an "intaglio rotary roll characterized in that the releasable surface material of the intaglio rotary roll is a silicone resin". Room temperature curing type rubber used for
The formation of an intaglio plate is also very preferable because it can be made by injecting it into a matrix and curing it. In the description of the prior art, a room temperature curing type silicone rubber material used in the production of decorative plywood, for example, TSE354 of Toshiba Silicone Co., Ltd.
0 is preferable, but other room temperature-curable rubbers, and further, a millable silicone rubber can be used. Note that it does not swell due to the ionizing radiation curable resin composition used.

In the embodiment according to the third aspect relating to "applying an adhesive or an adhesive on the rigid plate in advance", first, it is assumed that the adhesive material is formed on the entire surface. Sex remains. Use this for another purpose,
It is sufficient if the adhesiveness is eliminated, but it is usually inconvenient because dust adheres. to solve this problem,
It is preferable to use an adhesive that cures with ultraviolet light or the like.
As the chemical composition, there is an ultraviolet curable pressure-sensitive adhesive. In the case of an adhesive, it is necessary to perform a treatment such as heating or solvent spraying before bonding so that a cured product of the ionizing radiation-curable resin composition can have sufficient adhesive strength to be pulled out from the intaglio. There is.

The embodiment relating to the fourth aspect of the "mechanism for applying a transfer resin to the surface of a cured resin composition" includes, for example, a roll coating structure shown in FIG. The transfer resin composition does not adhere to the silicone rubber, but adheres only to the portion where the ionizing radiation-curable resin composition is cured. The transfer resin described above can be used as the transfer resin.

According to the fifth embodiment, the method for forming a convex pattern characterized in that the width of the ionizing radiation transmitting film is wider than the width of the intaglio rotary roll, the minimum is about 5 cm from the width of the intaglio rotary roll. A wide one up to about 15 cm is easy to use. If the ionizing radiation-curable resin composition extruded on the upper surface is configured not to be irradiated with ionizing radiation, it can be collected and reused.

The object of the present invention is to prevent the introduction of the ionizing radiation-curable resin composition on the surface of the ionizing radiation-transmitting film having releasability to be supplied to the apparatus in advance and to prevent the incorporation of bubbles and supply an appropriate amount of paste. It is.

In the embodiment, as a coating method, roll coating, die coating, and knife coating are preferable. In any case, the type in which the ionized radiation-curable resin composition deaerated in vacuum is directly applied is more preferable. As a method of preventing air bubbles from being mixed at the interface between the film and the paste when applying a high-viscosity paste, a method of forming a thin, low-viscosity liquid layer on the film surface before application is preferable. As a low viscosity liquid,
For example, there is water (FIG. 5).

The amount of application is adjusted so that the amount of paste that protrudes to both sides of the ionizing radiation transmitting film is as small as possible.

In the seventh aspect, "applying an adhesive or an adhesive in advance on the surface of an ionizing radiation transmitting film having releasability" is an alternative to applying an adhesive or an adhesive to a rigid plate. It is. An ionizing radiation-curable resin composition may be further applied on the adhesive / adhesive. In this case, if the pressure-sensitive adhesive / adhesive layer is in a liquid state, mixing of bubbles therebetween is prevented. Roll application,
Die coating and knife coating are preferred. After the application, the solvent may be dried or irradiated with ultraviolet rays to be polymerized to improve the adhesive strength and the adhesive strength.

In the eighth aspect, "a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start to contact" is a mechanism for preventing air bubbles from being mixed in this portion. It is. As the type of liquid, a liquid that does not swell or dissolve the intaglio surface is required. The ionizing radiation-curable resin composition may be one that swells and dissolves to some extent, and in some cases, it is better. Actually, there are water, water to which methyl alcohol, ethyl alcohol and isopropyl alcohol are added, and alcohols.

The object of the present invention is to provide a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the rigid plate start contacting.
It is the same as claim 8. However, depending on the type of the rigid plate, it is also possible to supply the rigid plate to form a film and combine it with the intaglio.

According to the tenth aspect, "the rigid plate moving mechanism is an XY-θ table having a mechanism for fixing the rigid plate and moving along the guide rail", it is necessary to lift the rigid plate upward. Yes, X- with vacuum suction mechanism
A Y-θ table is preferred. As a type of the guide rail, a linear guide is preferable. In addition, a driving force such as a ball screw and an air slider is used for the movement. In addition, although the accuracy is slightly lowered, a timing belt can be used.

Claim 21 provides an alignment method when precise alignment is required. Of the alignment marks formed at the corresponding positions on both the intaglio plate and the rigid plate, the alignment marks formed on the intaglio plate can be transferred to the rigid plate. Specifically, it is desirable that the recessed portion can be formed in the same step as the desired concave pattern portion. Further, the material to be filled in the concave portion of the alignment mark is an ionizing radiation-curable resin composition, and it is preferable that the material is cured and then transferred, because the shape is firm. However, since it is important that the planar shape is solid, only the alignment mark portion, for example, a plate for offset printing without water may be used. The ionizing radiation-curable resin composition is also suitable for forming a fine pattern, and it is possible to use a resin whose color is suitable for measurement.

In the alignment method, an intaglio alignment mark is transferred to a rigid plate in advance, the positional deviation between the intaglio alignment mark transferred to the rigid plate and the rigid plate alignment mark is measured, and the rigid plate is fixed accordingly. X
This is a method of adjusting the position of the -Y-θ table and performing alignment.

In the case where alignment accuracy is not so required as in the case of a decorative plywood, there is a method in which the substrate is sandwiched between rubber roll rows and sequentially moved. Further, there is a method in which the paper is fed into a backup roll at a good timing, and then the paper is moved in accordance with the rotational speed of the intaglio, that is, in a so-called swinging state.

<Function> The rigid substrate to which the present invention is applied is a so-called veneer plate that has not been subjected to surface processing, or a plastic plate that has not been subjected to surface processing (it does not matter if it has been processed). No), a glass plate, a substrate for a printed circuit, and a substrate on which a preliminary coat or a pattern is formed as a preliminary treatment may be used. Air bubbles can be completely prevented by sealing with a liquid. In this case, it is structurally very advantageous to use the rotary method.
After curing by irradiation with ionizing radiation, leaving the cured resin on the intaglio is achieved by using a peelable film. An adhesive is used for the transfer, but since the surface of the intaglio is silicone rubber, the adhesive is transferred to the rigid plate together with the cured resin without adhering to the silicone rubber.

[0106]

<Example 1> Plasma display (hereinafter referred to as P
DP) will be described. The apparatus had the following mechanism. (1) Claim 1 correspondence: 300m in diameter of the intaglio rotary roll
m, width 1000 mm. Intaglio plate winding set method (2) According to claim 6, a slot coater head is used as a device for applying a partition wall paste on a release film. (3) Ionizing radiation irradiation device → UV irradiation device. Manufacturer is Fusion, 5kW type. Includes a light-blocking wall to prevent light from irradiating other than specified parts. (4) Corresponding to claim 10: The XY-θ table has a vacuum suction device. Equipped with alignment mark position detection mechanism and automatic set position correction mechanism based on the data. With position offset function. Alignment accuracy ± 3μm. (5) Glass substrate moving transfer mechanism: XY-θ table for setting the glass substrate position (consisting of a moving belt and a table fixed on the belt, the table fixing and releasing the glass substrate Receiving the glass substrate set in position),
A belt mechanism that sticks, passes through the transfer unit, moves to the receiving unit, and releases the sticking at the receiving unit. The required parts move on the linear guide. The driving force is a gear-chain mechanism that is set so that the intaglio intaglio rotary roll and belt are at the same speed. A backup roll that can apply the required pressure is installed at the transfer location. Accuracy specification of the distance between the electrode and the partition is ± 5μm
Since the accuracy specification of the transfer start position is about ± 100 μm, meandering of the belt in the width direction is strictly prohibited. Therefore, the belt moves on the linear guide in the required part.

Materials Used (1) Release Film: Polyester Film Thickness 30
μm, silicone resin release material coating. (2) Claims 8 and 9: Liquid to be supplied to the mechanism for preventing air bubbles from mixing → water (3) Rigid plate: glass substrate for PDP Asahi Glass PD-
200 Size 850 x 650mm (4: 3 type, 40 inch) 3mm thick. Electrode part, alignment already formed.
Adhesive applied to desired transfer area (acrylic thickness 50μ)
m) Laminated protective film (4) Intaglio plate: Plane intaglio winding method compatible → substrate 42
Alloy Thickness 300μm Intaglio Silicone Rubber For room temperature curing type molding (Toshiba Silicone TSE3540) Cast product.
2mm thick. Alignment mark part TAP version. A rubber plate is used for the underlay (thickness: 0.5 mm). The partition wall width is 70 μm, height is 180 μm, and pitch is 430 μm. The direction of the partition is set in a direction parallel to the rotation direction of the intaglio printing. This makes it easier to fill the concave portion with the paste, reduces the incorporation of bubbles, smoothes the transfer, and makes it much easier to ensure positional accuracy. (5) UV-curable paste for partition walls: Table 1 shows the composition.

[0108]

[Table 1]

The vacuum-cured UV-curable paste for partition walls was fed under pressure to the head of a slot coater, and was extruded and applied onto a release film. The thickness is 80 μm, and this thickness is appropriate for the amount to be inserted. The interval between the sandwiching roll and the intaglio rotary roll is 5
It was set to 0 μm. The tension was adjusted to 0.5 kg / cm using a tension adjusting roll of a release film. This tension value is a value for setting the thickness of the paste to be inserted to 50 μm, and was determined by experiments. The sandwiching speed, that is, the rotational peripheral speed of the intaglio is 5 cm / sec. The amount of ultraviolet irradiation is 1000 mJ. The pressure of the backup roll for bonding to the rigid plate is 2kg / cm
It is. In addition, the protective film on the rigid material was peeled off immediately before bonding to minimize the adhesion of dust. The liquid according to claim 9 is water, and the supply method is spray.

Alignment Method A spare substrate is set, and an alignment mark (described as an electrode alignment mark) formed at the same time as the electrodes is placed in the field of view of the CCD observation system, and is used as a temporary origin. Transfer is started in this state. In other words, the vacuum suction is applied to the XY-θ table while the vacuum suction is applied to the XY-θ table (at this time, the movement belt is stationary). (With pin)
Let it rise by 1-2 mm. Then, the movement of the belt is started, and the glass substrate passes through the transfer unit and moves to the substrate receiving unit. The partition wall alignment mark is transferred to the preliminary substrate. Return the spare substrate to the start position, measure the misalignment between the electrode alignment mark (temporary origin) and the partition alignment mark (true origin), and adjust the offset amount so that the temporary origin moves to the true origin every time. Set. Set the production board. The mechanism first detects an electrode alignment mark and moves it to a temporary origin. next,
Move it by the offset amount. In this way, the true origin (partition wall alignment mark) and the electrode alignment mark overlap. In this state, as in the case of the spare substrate, the production substrate is fixed to the transport belt, and when the transfer process is performed, the partition is transferred to a predetermined position. Thereafter, the production substrates are sequentially passed.

Post-Treatment The cured paste may be peeled off from the roll on the part of the substrate after transfer where no adhesive is applied. This was peeled off using an adhesive roll for dust removal. Then it was fired.

Results Shape: Matches the shape of the intaglio. However, the thickness of the dielectric portion was 10 ± 5 μm. Defects: No defects in the partition walls and other parts due to air bubbles, insufficient filling, and poor transfer. Alignment accuracy with electrodes Direction parallel to transfer ± 20μm Direction perpendicular to transfer Within ± 5μm Meander of partition wall → R ± 5μm

The formation of the partition on the back plate of the plasma addressed liquid crystal display (PALC) can also be manufactured using the apparatus of the present invention and the method described herein. Further, it can also be used for forming paste wiring and electrodes of PDP and PALC.

<Example 2> A case where the present invention is used for forming an etching resist pattern on a copper-clad laminate in the manufacture of a printed circuit board will be described. The apparatus had the following mechanism. (1) Claim 1 correspondence: 300m in diameter of the intaglio rotary roll
m, width 800 mm. Intaglio plate wrapping set method (2) According to claim 6: A head of a knife coater is used as a device for applying a paste for partition walls on a release film. Ionizing radiation irradiation device → UV irradiation device. Manufacturer is Fusion, 5kW type. Includes a light-blocking wall to prevent light from irradiating other than specified parts. (5) Corresponding to claim 10: The XY-θ table has a vacuum suction device. Equipped with alignment mark position detection mechanism and automatic set position correction mechanism based on the data. With position offset function. Alignment accuracy ± 10μm. (6) Copper-clad laminate transfer mechanism: Receives and fixes the copper-clad laminate set on the XY-θ table, passes through the transfer section, moves to the receiving section, and releases the fixed section at the receiving section. Belt mechanism. The fixing method is vacuum adsorption. The required parts move on the linear guide. The driving force is a gear-chain mechanism set so that the intaglio rotary roll and belt are at the same speed. A backup roll that can apply the required pressure is installed at the transfer location. The position accuracy specification of the etching resist pattern is ± 50 μm with respect to the center of the pin hole,
The meandering of the belt in the width direction is strictly prohibited. Therefore, the belt moves on the linear guide in the required part of lamination.

Materials Used (1) Release Film: Polyester Film Thickness 30
μm, silicone resin release material coating. Manufacturer: Tocelo Co., Ltd., number SP-PET (2) Claims 8 and 9: Liquid supplied to the mechanism for preventing air bubbles from mixing → water (3) Rigid board: copper-clad laminate for printed circuit board Size 6
00 × 600 0.5 mm thick. Pre-formed alignment pin holes. (4) Intaglio plate: Compatible with flat intaglio winding method → Integral board and intaglio portion polyethylene. Created by pressing the mold into the mother die. 2mm thick. Alignment mark part TA
P version. Rubber plate is used for underlay (0.5mm thickness) Resist pattern specification: Design rule 70μm. Thickness 10μ
m (5) Material of resist pattern: PMER manufactured by Tokyo Ohkasha
N-HC600

The tension was adjusted to 1.0 kg / cm by using a tension adjusting roll for the release film. The pinching speed, that is, the rotational peripheral speed of the intaglio is 100 mm / sec. The amount of ultraviolet irradiation is 100 mJ. The pressure of the backup roll for bonding to the rigid plate is 5 kg / cm
It is. Under these conditions, the curing is not complete, the surface of the cured resist ink is tacky and adheres to the surface of copper.

Procedure The vacuum-cured UV-curable etching resist was pressure-fed to the head of a knife coater and extruded and applied onto a release film. The thickness was 15 μm, and most of the solvent was evaporated by irradiating infrared rays before being sandwiched between the intaglio plate made of polyethylene and the release film. The thickness has been reduced to 10 μm. Water was used to prevent air bubbles from entering. Although the depth of the intaglio is as small as 10 μm, this water is necessary because it is absolutely necessary to avoid air bubbles. The interval between the interposing roll and the intaglio rotary roll is adjusted to -20 by using the interval adjusting mechanism.
μm. That is, the contact portion between the sandwiching roll and the intaglio rotary roll was pressurized to prevent the resist ink from protruding beyond the concave portion as much as possible. However, a very thin film may be formed on the upper surface of the release film and the intaglio,
By setting the releasability of the release film to be slightly lower, the thin cured film of the resist is taken not to the substrate side but to the release film. Even if it is left unremoved and placed on the copper-clad laminate, the effect of the etching resist is completely negligible because the thickness is extremely small, so that there is no problem.
If the film becomes a problem, prior to etching, a so-called plasma assembling process or a degreasing process is performed to remove the thin film.

Alignment Method Stock with pins passed through the pin holes, and lift only one from there with a table that can be suctioned under reduced pressure Move the table and place it on the conveyor belt. The transport belt has claws, and the table is pushed at that position, and the transport table (one unit) itself moves left and right on the linear guide beyond the transfer unit. Be careful not to catch your nails when returning. An electromagnetic nail was used.

Post-treatment The substrate after the transfer is cured by irradiating it with UV, and the adhesion to the copper-clad laminate is improved. If necessary, remove the resist thin film. Etching with iron solution under normal conditions Stripping, washing and drying. Result Open short test → It was within the standard. Visual inspection → passed

<Example 3> A case of manufacturing a decorative plywood with wood grain unevenness will be described. The apparatus had the following mechanism. (1) Corresponding to claim 1: diameter of the intaglio rotary roll 600 m
m, width 1000 mm. A method in which the master is eaten by the cylinder roll eating part and set. (2) Corresponding to claim 6: A head of a knife coater was used as an apparatus for applying the paste for partition walls on the release film. Ionizing radiation irradiation equipment → Metal halide lamp 80W / c
m. 6 lights. Includes a light-blocking wall to prevent light from irradiating other than specified parts (5) Corresponding to claim 10: Positioning is performed by sending and moving with a hook. (6) Plywood moving transfer mechanism: A method in which stacked plywood is sucked and moved from above by a reduced-pressure suction platen. The vacuum platen is moved by the hook. A chain mechanism that passes through the transfer unit and releases the vacuum suction at the receiving unit. The driving force is a gear-chain mechanism set so that the intaglio rotary roll and belt are at the same speed. A backup roll that can apply the required pressure is installed at the transfer location.

Materials Used (1) Release Film: Polyester Film Thickness 30
μm, silicone resin release material coating. (2) Corresponding to claims 8 and 9: Mechanism for preventing air bubble mixing → not used (3) Rigid board: Thin paper obtained by printing a wood grain pattern on unprocessed plywood having a width of 3 and a length of 6 is urea-acetic acid Adhered with an adhesive obtained by adding ammonium chloride as a curing agent to a vinyl mixed system. (4) Intaglio plate: The mother die has no frame. The manufacturing method is the conventional method. The base film is a biaxially stretched polyester film having a thickness of 30 μm. The room temperature curing release silicone rubber is TSE3540 manufactured by Toshiba Silicone and has a thickness of about 0.5 mm. (5) UV-curable polyester resin: 100 parts of Polyvest 23 (registered trademark) manufactured by Otani Paint Co., Ltd. was treated with 1.5 parts of a benzoin ethyl ether-based UV-curing initiator PS8A manufactured by Kanto Chemical.
(6) Adhesive: UV-cured polyester resin described in (5). After the transfer is completed, it is cured by irradiating ultraviolet rays from the resin surface. That is, the rotational peripheral speed of the intaglio is 10 m / min.

Procedure The vacuum-cured UV-cured polyester resin was pressure-fed to the head of a knife coater and extruded and applied onto a release film. The thickness is 300 μm, and the thickness sandwiched between the mold on the silicone rubber surface and the release film is 300 μm.
The gap between the sandwiching roll and the intaglio rotary roll was adjusted using a gap adjusting mechanism so as to obtain m. The tension was adjusted to 0.1 kg / cm by using a tension adjusting roll of a release film. Although this tension value is almost free, the pressure between the rolls is high, and the sandwiching condition is determined thereby, so it is important that no adverse effect is exerted. Since the amount of ultraviolet irradiation was again irradiated with ultraviolet rays later, the feeding speed was adjusted to be 10 m / min by increasing the feeding speed as far as possible without hindering the transfer.
The application of the adhesive was performed using the roll of claim 4, and the applied thickness was 200 μm. No water sealing device was used to prevent air bubbles from entering, but air bubbles of a size that would cause defects were not introduced due to the bonding by the roll method.

Alignment method Store in stock locations with frames at the four corners. From there, move to the table with only one arm that can absorb under reduced pressure. Position set with 3 pins on the table. The table moves and stops at a position below the surface plate where vacuum suction is possible from above. Adsorbed on a surface plate capable of vacuum adsorption and transported. There is a transfer chain hook, and the table is pushed at that position, and the transfer table (one unit) itself moves left and right on the linear guide beyond the transfer unit. Be careful not to catch your nails when returning. An electromagnetic nail was used.

Post-Treatment The substrate after the transfer was irradiated with ultraviolet rays to completely cure the ultraviolet-curable polyester resin and the adhesive.

Result Bubble contamination → Within standard → Pass

[0126]

According to the present invention, it is possible to directly produce a defect-free convex pattern on a rigid plate by a rotary method by variously combining conventionally known techniques. A specific apparatus and method for forming a convex pattern free of air bubbles have been provided. Usually, in order to avoid air bubbles, the viscosity of the ink (paste) is reduced. Then, it becomes difficult to increase the thickness. Also, a desired shape cannot be formed. The method of the present invention has solved this point.

[Brief description of the drawings]

FIG. 1 A method for manufacturing a master mold of a wood-grained decorative plywood.

Fig. 2 Manufacturing method of decorative plywood with wood grain

FIG. 3 shows a method of forming a PDP partition and a shape of the partition disclosed in Japanese Patent Application Laid-Open No. 8-32258.

FIG. 4 is a method for forming a PDP partition disclosed in Japanese Patent Application Laid-Open No. 10-101373.

FIG. 5 is a structural view of an apparatus (-corresponds to (1) of claim 1).

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2H113 AA01 AA05 BA03 BA27 BB07 BB09 BB10 BB22 BB32 CA05 CA17 DA57 DA64 FA10 FA43

Claims (21)

[Claims] An apparatus for forming a concavo-convex pattern for forming a cured concavo-convex pattern of an ionizing radiation-curable resin composition on the surface of a rigid plate, wherein the apparatus has at least the following mechanisms and structures: apparatus. An intaglio rotary roll having an intended concavo-convex pattern as a concave-convex pattern composed of a releasable surface. A predetermined ionizing radiation-curable resin composition is placed between the intaglio rotary roll and an ionizing radiation transmitting film having releasability. A mechanism for continuously sandwiching while maintaining the thickness of the mechanism A mechanism for irradiating with ionizing radiation in a state of being sandwiched A mechanism for peeling the ionizing radiation transmitting film from the surface of the intaglio rotary roll after curing the ionizing radiation-curable resin composition Is supplied onto the intaglio rotary roll, and the ionizing radiation-curable resin composition cured by irradiation with ionizing radiation is overlapped with a predetermined pressure while maintaining a predetermined alignment accuracy. Mechanism for peeling a plate from the surface of the intaglio rotary roll 2. The surface material of the “intaglio rotary roll having a concave-convex pattern having a releasable surface” according to claim 1, wherein the surface material is a silicone resin. An uneven pattern forming device. 3. A mechanism according to claim 1, further comprising a mechanism for applying an adhesive or an adhesive to the rigid plate to be supplied onto the intaglio rotary roll in advance. 3. The uneven pattern forming apparatus according to item 1. 4. The method according to claim 1, further comprising a mechanism for applying a transfer resin to the surface of the cured ionizing radiation-curable resin composition according to claim 1. An uneven pattern forming device. 5. The uneven pattern according to claim 1, wherein a width of the ionizing radiation transmitting film having releasability according to claim 1 is wider than a width of the intaglio rotary roll. Forming equipment. 6. The method according to claim 1, wherein the ionizing radiation curable resin composition is continuously provided between the intaglio rotary roll and the ionizing radiation transmitting film having releasability while maintaining a predetermined thickness. 6. The method of claim 1, wherein the "mechanism for sandwiching between" is a mechanism in which an ionizing radiation-curable resin composition is previously applied to the surface of an ionizing radiation transmitting film having releasability, and is superposed on an intaglio rotary roll. An uneven pattern forming apparatus according to any one of the above. 7. The ionizing radiation transmitting film having releasability according to claim 1, further comprising a mechanism for previously applying a pressure-sensitive adhesive or an adhesive to a surface of the film. An apparatus for forming an uneven pattern according to any one of the first to third aspects. 8. The uneven pattern forming apparatus according to claim 1, further comprising a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start to contact. 8. The uneven pattern forming apparatus according to any one of claims 1 to 7. 9. The uneven pattern forming apparatus according to claim 1, further comprising a mechanism for supplying a liquid to a portion where the intaglio rotary roll and the rigid plate start contacting each other. 3. The uneven pattern forming apparatus according to item 1. 10. The uneven pattern forming apparatus according to claim 1, wherein the rigid plate moving mechanism has a mechanism for fixing the rigid plate, and is an XY-θ table that moves according to a guide rail. The uneven pattern forming apparatus according to any one of claims 1 to 9. 11. A method for forming a concave-convex pattern of a rotary printing method for forming a cured concave-convex pattern of an ionizing radiation-curable resin composition on the surface of a rigid plate, comprising at least the following mechanisms: Forming method. A predetermined thickness of the ionizing radiation-curable resin composition between an “intaglio rotary roll having an intended concavo-convex pattern as a concave-convex pattern composed of a releasable surface” and an ionizing radiation transmitting film having releasability. A mechanism for continuously sandwiching while maintaining a mechanism for irradiating ionizing radiation in a sandwiched state A mechanism for peeling off the ionizing radiation-permeable film from the surface of the intaglio rotary roll after curing the ionizing radiation-curable resin composition The rigid plate is rotated in the intaglio rotary A mechanism for superimposing the ionizing radiation-curable resin composition supplied on a roll and curing it by irradiation with ionizing radiation and superimposing it while maintaining a predetermined alignment accuracy. Mechanism to peel off from the surface of the rotary roll 12. The surface material of the "intaglio rotary roll having a concave-convex pattern formed of a releasable surface" according to claim 11, wherein the surface material is a silicone resin. An uneven pattern forming method. 13. The unevenness according to claim 11, wherein a pressure-sensitive adhesive or an adhesive is previously applied to the rigid plate to be supplied onto the intaglio rotary roll. Pattern formation method. 14. The uneven pattern according to claim 11, wherein a transfer resin is applied to the surface of the cured ionizing radiation-curable resin composition according to claim 11. Forming method. 15. The uneven pattern according to claim 11, wherein the width of the ionizing radiation transmitting film having releasability according to claim 11 is wider than the width of the intaglio rotary roll. Forming method. 16. An ionizing radiation-transmissive film having a releasable property, comprising: an intaglio rotary roll having an intended concavo-convex pattern as an uneven pattern having a releasable surface according to claim 11. A mechanism for continuously sandwiching the radiation-curable resin composition while maintaining a predetermined thickness is to apply the ionizing radiation-curable resin composition in advance on the surface of the ionizing radiation-transmitting film having releasability, and the intaglio rotary roll and 16. A mechanism for superimposing.
The method for forming a concavo-convex pattern according to any one of the above. 17. The method according to claim 11, wherein a pressure-sensitive adhesive or an adhesive is applied to the surface of the ionizing radiation transmitting film having releasability according to claim 11 in advance. An uneven pattern forming method. 18. The method according to claim 11, wherein the liquid is supplied to a portion where the intaglio rotary roll and the ionizing radiation-curable resin composition start contacting. The method for forming an uneven pattern according to any one of the above. 19. The method according to claim 11, wherein the liquid is supplied to a portion where the intaglio rotary roll and the rigid plate start contacting each other. An uneven pattern forming method. 20. The method according to claim 11, wherein the moving mechanism of the rigid plate has a mechanism for fixing the rigid plate and is an XY-θ table that moves according to the guide rail. The method for forming a concavo-convex pattern according to any one of claims 11 to 19. 21. An uneven pattern forming method having a rigid plate moving mechanism according to claim 20, wherein an alignment mark is formed at a corresponding position on both the intaglio and the rigid plate, and the intaglio alignment mark is set in advance. The displacement between the intaglio alignment mark transferred to the rigid plate and the intaglio alignment mark transferred to the rigid plate and the alignment mark of the rigid plate are measured, and the position of the XY-θ table fixing the rigid plate is adjusted accordingly to align. 21. The method for forming a concavo-convex pattern according to any one of claims 11 to 20, wherein