CN102176082A - Method for manufacturing reflecting film with micro-prism array structure - Google Patents

Method for manufacturing reflecting film with micro-prism array structure Download PDF

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Publication number
CN102176082A
CN102176082A CN2010106058332A CN201010605833A CN102176082A CN 102176082 A CN102176082 A CN 102176082A CN 2010106058332 A CN2010106058332 A CN 2010106058332A CN 201010605833 A CN201010605833 A CN 201010605833A CN 102176082 A CN102176082 A CN 102176082A
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China
Prior art keywords
resin
array structure
hot melt
microprism array
film
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CN102176082B (en
Inventor
王宏
蓝庆东
吴伟斌
胡智彪
胡智雄
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Zhejiang Daoming Optics & Chemical Co ltd
Zhejiang Daoming Optoelectronics Technology Co ltd
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ZHEJIANG DAOMING OPTICS& MATERIAL CO Ltd
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Priority to CN2010106058332A priority Critical patent/CN102176082B/en
Priority to PCT/CN2011/079399 priority patent/WO2012088921A1/en
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    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/04Prisms
    • G02B5/045Prism arrays

Abstract

The invention relates to a method for manufacturing a reflecting film with a micro-prism array structure. In the prior art, a photosensitive resin is used as a micro-prism forming material, which has the disadvantages of small material selection range, high production cost, poor subsequent processing property of the reflecting film and small application range. In the invention, an annular die capable of reciprocally moving along a closed loop is adopted to manufacture the reflecting film, and a recessed continuous micro-prism array structure is arranged on the outer surface of the annular die. The manufacturing method comprises the following steps: applying hot-melt resin on one side surface of a resin film; synchronously molding the resin film, the hot-melt resin and the annular die; and synchronously cooling the resin film with the hot-melt resin and the annular die, so that the resin film with the hot-melt resin and the micro-prism array structure on the hot-melt resin layer form a laminated film. The manufacturing method has the advantages of wide selection range of the micro-prism forming material and low production cost, and is beneficial to the subsequent processing and use of the reflecting film; and the reflecting film has the advantages of wide application range, and the like.

Description

A kind of production method with reflective membrane of microprism array structure
Technical field
The present invention relates to a kind of production method of reflective membrane, relate in particular to a kind of production method with reflective membrane of microprism array structure.
Background technology
Reflectorized material with microprism array structure is owing to its remarkable reflex reflection performance, the fields such as different kinds of roads traffic safety facilities, vehicle passive security protective device, sign board and personal security's protective articles that are applied to more and more widely.
Open day is on October 21st, 2009, application number is CN200910098915.X, the application for a patent for invention that name is called " production method with reflective membrane of microprism array structure " has disclosed a kind of production method of utilizing the reflective membrane of optical light sensitive adhesive moulding microprism, the key step that this production method comprises is: apply photosensitive resin on resin film, drying, the heating mould, solidify fast by the UV rayed again, make the resin film that applied photosensitive resin and the microprism array structure mutual group on the photosensitive resin layer become laminated film, the final layer press mold is cooled, and this laminated film is the reflective membrane with microprism array structure.
The reflective membrane that makes by this method, need through evaporation layer of metal reflection horizon, perhaps pass through existing solder technology such as ultrasound wave, high frequency or hot melt behind its microprism one side surface involution one hypoglyph, pressure sensitive adhesive on metallic reflector or counterdie one side are compound more just can be made into the micro-prism type reflective membrane in fields such as being used for traffic safety sign or personal security's protective articles.And there is metallic reflector different ranges of application and field to be arranged with the micro-prism type reflective membrane that a hypoglyph is arranged through involution through evaporation.
Though the micro-prism structure that forms by said method has excellent hardness and scratch resistance, reaches heat-resisting, solvent resistance, and good product consistency, because the kind of optical light sensitive adhesive is fewer, performance is special, price general charged is all very high; And optical light sensitive adhesive is after curing, be cross-linked into netted between the molecule, surface compact, polarity is very low, though can be in microprism one side surface evaporation layer of metal reflection horizon, but be difficult to utilize existing solder technology such as ultrasound wave, high frequency or hot melt at described laminated film microprism one side surface involution one hypoglyph, therefore be unfavorable for the following process and the use of reflective membrane, the range of application of reflective membrane also can be restricted.
Summary of the invention
Technical matters to be solved by this invention be overcome that the moulding material that utilizes optical light sensitive adhesive to exist as the microprism moulding material in the above-mentioned prior art selects that face is narrow, production cost is high, reflective membrane properties for follow difference and the narrow defective of range of application, a kind of production method of new reflective membrane is provided, in this production method the moulding material of microprism select extensively and production cost low, more help the following process of reflective membrane and use and make reflective membrane have range of application widely.
In order to solve technique scheme, the present invention is achieved by the following technical solutions:
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating ring mould of loop, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, said method comprising the steps of:
(1) side surface at the resin film applies one deck hot melt resin;
(2) side surface that is coated with the hot melt resin on the resin film is close to the outside surface of ring mould, then resin film, hot melt resin and ring mould are carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array architecture of depression under pressure;
(3) under engagement, the coating that to handle through step (2) the resin film of hot melt resin and ring mould synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer and become laminated film, this laminated film is the reflective membrane with microprism array structure.
The invention provides a kind of method of utilizing the production reflective membrane of hot melt resin moulding microprism.Because the molecule of hot melt resin is linear structure, active degree height, polarity is strong, be easy in microprism one side surface evaporation layer of metal reflection horizon or utilize existing solder technology such as ultrasound wave, high frequency or hot melt, therefore utilize the micro-prism type reflective membrane of hot melt resin moulding that more excellent properties for follow and range of application are widely arranged at microprism one side surface involution one hypoglyph; In addition, the selection face of hot melt resin is wider, and production cost is also lower.
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating ring mould of loop, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, said method comprising the steps of:
(1) side surface at the resin film applies one deck hot melt resin;
(2) side surface that is coated with the hot melt resin on the resin film is close to the outside surface of ring mould, opposite side surface at the resin film attaches the last layer backing film, then resin film, hot melt resin and the ring mould that is pasted with backing film carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array architecture of depression under pressure;
(3) under engagement, to be pasted with backing film, applied the resin film of hot melt resin and ring mould through what step (2) was handled synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, be pasted with backing film and applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer becomes laminated film, this laminated film is the reflective membrane with microprism array structure.
The use of backing film can effectively prevent the deformation of resin film in heating process, and avoids a side surface of the uncoated hot melt resin of resin film to be scratched.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, in the described step (1), before a side surface of resin film is coated on the hot melt resin, this side surface at the resin film applies one deck coupling agent earlier, coupling agent and resin film form secure bond, being coated with coating one deck hot melt resin on the side surface of coupling agent, make hot melt resin and coupling agent bonding then.The use coupling agent can increase adhesive property and the cohesive strength between resin film and hot melt resin.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described ring mould is endless belt-shaped mould.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, endless belt-shaped mould is the flexible metal band.Because therefore described endless belt-shaped mould must need flexible preferably along the loop to-and-fro movement; In addition, peel off from mould after laminated film completes for homogeneity, the microprism array structure that guarantees to cool off accurately duplicates and be convenient to, described mould should have dimensional stability and good antistick characteristic, so should select metal material to make this mould.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, endless belt-shaped mould adopt the nickel metal material to make.Nickel has excellent size stability, when endless belt-shaped mould is cooled, can effectively reduce the variation of die size, thereby guarantees accurately duplicating of on tree resin layer micro-prism structure.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described ring ring mould is a cylinder mould.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described cylinder mould is the rigid roller of hollow, is made by steel or copper material.The cylinder mould of hollow, its inside can lead to heat eliminating medium.
The continuous microprism array structure that above-mentioned a kind of production method with reflective membrane of microprism array structure, the outside surface of described cylinder mould are recess is to form with chemical corrosion, laser engraving or with the diamond cutter cutting.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, the outside surface of described cylinder mould is assembled by the nickel sheet that a side surface has the continuous microprism array structure that is recess.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described resin film adopts the compound substance of acrylate material, makrolon material, polyester material, pvc material, polyurethane material, polyvinyl alcohol material, polypropylene material, polythene material, polyamide material, polystyrene material, above-mentioned two or more material.Carry out total internal reflection in order to make the incident optical energy maximum probability pass surface tree ester film arrival microprism, thereby guarantee that reflective membrane has excellent reflex reflection performance, the resin film of selecting for use need have excellent light transmission, so the carrier that the present invention preferentially selects for use above-mentioned material to adhere to as the hot melt resin.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described hot melt resin adopts the potpourri of acrylate resin, polycarbonate resin, polyester resin, Polyvinylchloride resin, polyurethane resin, polyvinyl alcohol (PVA) resin, polypropylene resin, polyethylene resin, polyamide resin, polystyrene resin, vinyl chloride vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resins, above-mentioned two or more resin.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, what coating hot melt resin was adopted is the mode that heat seeling coating or hot melt are extruded.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, the melt index (MI) of hot melt resin is 3~40g/10min.Because the hot melt resin of melt index (MI) in 3~40g/10min scope applies than the mode that is easier to so that heat seeling coating or hot melt are extruded.
Above-mentioned a kind of production method with reflective membrane of microprism array structure, described backing film adopts polyester material, polypropylene material, polyamide material, polythene material or fluorine material.Because above-mentioned material has good temperature tolerance and dimensional stability, so use these materials as backing film, can prevent the deformation of resin film in mould and cooling procedure better, and avoid a side surface of the uncoated hot melt resin of resin film to be scratched.
The present invention has following beneficial effect:
1, the selection face of microprism moulding material is more extensive: be to adopt optical light sensitive adhesive to make the moulding material of microprism in the prior art, but optical light sensitive adhesive all has the requirement of comparison harshness to construction and storage, so comparatively speaking, alternative kind is few; And the hot melt resin is as long as be fit to that hot melt applies or hot melt is extruded operation and just be can be used as microprism moulding material in the inventive method, so select wide general.
2, production cost is lower: because the optical light sensitive adhesive kind is few, performance is special, and price is all very high, surpasses 100 yuan/kg usually, and the price of hot melt resin is then relatively more cheap, generally is no more than 50 yuan/kg.
3; more help the following process and the use of reflective membrane: a side that has microprism array structure at reflective membrane; if metallic reflector that does not shield or counterdie; behind dust stratification or other any foreign substance pollutions; the capital influences its reflective function; therefore after reflective membrane strips down from ring mould; need be with the mode of evaporation in microprism one side surface evaporation layer of metal reflection horizon or utilize ultrasound wave; existing solder technology such as high frequency or hot melt is at microprism one side surface involution one hypoglyph; form the cellular sealing airbag structure between counterdie and the microprism array structure, this micro-prism type reflective membrane just can be used to fields such as traffic safety sign or personal security's protective articles like this.And optical light sensitive adhesive is after curing, be cross-linked between the molecule netted, surface compact, polarity is very low, is difficult to use existing solder technology formed honeycomb shape pressure bladder structures such as ultrasound wave, high frequency or hot melt thereon.And utilize the micro-prism structure of hot melt resin moulding, because the molecule of resin is linear structure, active degree height, polarity is strong, then be easy between microprism array structure and counterdie, form the cellular sealing airbag structure, so the reflective membrane of making by the inventive method with microprism array structure has more excellent properties for follow.
4, has range of application widely: have metallic reflector different ranges of application and field to be arranged with the micro-prism type reflective membrane that a hypoglyph is arranged through involution through evaporation.The available technology adopting optical light sensitive adhesive is as the moulding material of microprism, though can be in microprism one side surface evaporation layer of metal reflection horizon, but be difficult to utilize existing solder technology such as ultrasound wave, high frequency or hot melt at described laminated film microprism one side surface involution one hypoglyph, so the reflective membrane of making by the inventive method with microprism array structure has range of application and field widely.
Embodiment
Below in conjunction with embodiment the present invention is described in further detail, but they are not limitations of the present invention:
Embodiment 1
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating endless belt-shaped mould of loop, the flexible metal band that endless belt-shaped mould preferentially selects for use the nickel metal material to make, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, said method comprising the steps of:
(1) apply one deck hot melt resin at a side surface of resin film with the mode of heat seeling coating, resin film preferred acrylate material, the hot melt resin adopts polycarbonate resin, and the melt index (MI) of described hot melt resin is 3g/10min;
(2) side surface that is coated with the hot melt resin on the resin film is close to the outside surface of endless belt-shaped mould, then resin film, hot melt resin and endless belt-shaped mould are carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array structure of depression under pressure;
(3) under engagement, the coating that to handle through step (2) the resin film of hot melt resin and endless belt-shaped mould synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer and become laminated film, this laminated film is the reflective membrane with microprism array structure.
Embodiment 2
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating cylinder mould of loop, the hollow rigid roller that cylinder mould is preferably made with steel material, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, the described continuous microprism array structure that is recess adopts the mode of chemical corrosion to make, and said method comprising the steps of:
(1) mode of extruding with hot melt at a side surface of resin film applies one deck hot melt resin, resin film optimization polycarbonate material, and the hot melt resin adopts the acrylate resin, and the melt index (MI) of described hot melt resin is 40g/10min;
(2) side surface that is coated with the hot melt resin on the resin film is close to the outside surface of ring mould, opposite side surface at the resin film attaches the last layer backing film, then resin film, hot melt resin and the ring mould that is pasted with backing film carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array architecture of depression under pressure, described backing film preferentially adopts polyester material;
(3) under engagement, to be pasted with backing film, applied the resin film of hot melt resin and ring mould through what step (2) was handled synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, be pasted with backing film and applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer becomes laminated film, this laminated film is the reflective membrane with microprism array structure.
Embodiment 3
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating cylinder mould of loop, the hollow rigid roller that cylinder mould is preferably made with copper material, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, the described continuous microprism array structure that is recess adopts the mode of laser engraving or diamond cutter cutting to make, and said method comprising the steps of:
(1) side surface at the resin film applies one deck coupling agent, make coupling agent and resin film form secure bond, there is the mode that adopts hot melt to extrude on the side surface of coupling agent to apply one deck hot melt resin in the resin thin film coated then, makes hot melt resin and coupling agent bonding.Described resin film is preferentially selected the compound substance of acrylate material and makrolon material for use, and the hot melt resin adopts the potpourri of acrylate resin and polycarbonate resin, and the melt index (MI) of described hot melt resin is 10g/10min;
(2) side surface that is coated with coupling agent and hot melt resin on the resin film is close to the outside surface of ring mould, then resin film, hot melt resin and ring mould are carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array structure of depression under pressure;
(3) under engagement, the coating that to handle through step (2) the resin film of hot melt resin and ring mould synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer and become laminated film, this laminated film is the reflective membrane with microprism array structure.
Embodiment 4
A kind of production method with reflective membrane of microprism array structure, described method includes along the reciprocating cylinder mould of loop, the hollow rigid roller that cylinder mould is preferably made with copper material, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, the described continuous microprism array structure that is recess is assembled by the nickel sheet that is had the continuous microprism array structure that is recess by a side surface, said method comprising the steps of:
(1) side surface at the resin film applies one deck coupling agent, make coupling agent and resin film form secure bond, have in the resin thin film coated then and adopt the mode of heat seeling coating to apply one deck hot melt resin on the side surface of coupling agent, make hot melt resin and coupling agent bonding.Described resin film is preferentially selected polyester material for use, pvc material, polyurethane material, polyvinyl alcohol material, polypropylene material, polythene material, polyamide material, polystyrene material, the compound substance of above-mentioned two or more material, the hot melt resin can be selected polyester resin for use, the Polyvinylchloride resin, the polyurethane resin, the polyvinyl alcohol (PVA) resin, the polypropylene resin, polyethylene resin, polyamide resin, the polystyrene resin, vinyl chloride vinyl acetate copolymer resin, the ethylene-vinyl acetate copolymer resins, the potpourri of above-mentioned two or more resin, the melt index (MI) of described hot melt resin are 20g/10min;
(2) side surface that is coated with coupling agent and hot melt resin on the resin film is close to the outside surface of ring mould, opposite side surface at the resin film attaches the last layer backing film, then resin film, hot melt resin and the ring mould that is pasted with backing film carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array architecture of depression under pressure, described backing film can adopt polypropylene material, polyamide material, polythene material or fluorine material;
(3) under engagement, to be pasted with backing film, applied the resin film of hot melt resin and ring mould through what step (2) was handled synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, be pasted with backing film and applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer becomes laminated film, this laminated film is the reflective membrane with microprism array structure.
In a word, the above only is preferred embodiment of the present invention, and all equalizations of doing according to the scope of the present patent application patent change and modify, and all should belong to covering scope of the present invention.

Claims (15)

1. production method with reflective membrane of microprism array structure, described method includes along the reciprocating ring mould of loop, this mould has an inside surface and an outside surface, its outside surface has the continuous microprism array structure that is recess, said method comprising the steps of:
(1) side surface at the resin film applies one deck hot melt resin;
(2) side surface that is coated with the hot melt resin on the resin film is close to the outside surface of ring mould, then resin film, hot melt resin and ring mould are carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array structure of depression under pressure;
(3) under engagement, the coating that to handle through step (2) the resin film of hot melt resin and ring mould synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer and become laminated film, this laminated film is the reflective membrane with microprism array structure.
2. a kind of production method according to claim 1 with reflective membrane of microprism array structure, it is characterized in that: in the described step (2) except a side surface that is coated with the hot melt resin on the resin film is close to the outside surface of ring mould, also attach the last layer backing film on the opposite side surface of resin film, then resin film, hot melt resin and the ring mould that is pasted with backing film carried out mold pressing synchronously, make the hot melt resin that is molten condition fill up the gap of the microprism array architecture of depression under pressure; In the described step (3), under engagement, to be pasted with backing film, apply the resin film of hot melt resin and ring mould synchronously through supercooling, cooled hot melt resin, one side surface and resin film form secure bond, the microprism array structure on opposite side surface is simultaneously by moulding, be pasted with backing film and applied the resin film of hot melt resin and the microprism array structure mutual group on the hot melt tree resin layer becomes laminated film, this laminated film is the reflective membrane with microprism array structure.
3. a kind of production method according to claim 1 and 2 with reflective membrane of microprism array structure, it is characterized in that: in the described step (1), before a side surface of resin film is coated on the hot melt resin, this side surface at the resin film applies one deck coupling agent earlier, coupling agent and resin film form secure bond, being coated with coating one deck hot melt resin on the side surface of coupling agent, make hot melt resin and coupling agent bonding then.
4. a kind of production method with reflective membrane of microprism array structure according to claim 1 and 2 is characterized in that: described ring mould is endless belt-shaped mould.
5. a kind of production method with reflective membrane of microprism array structure according to claim 4 is characterized in that: described endless belt-shaped mould is the flexible metal band.
6. a kind of production method with reflective membrane of microprism array structure according to claim 5 is characterized in that: described endless belt-shaped mould adopts the nickel metal material to make.
7. a kind of production method with reflective membrane of microprism array structure according to claim 1 and 2 is characterized in that: described ring mould is a cylinder mould.
8. a kind of production method with reflective membrane of microprism array structure according to claim 7 is characterized in that: described cylinder mould is the rigid roller of hollow, is made by steel or copper material.
9. a kind of production method with reflective membrane of microprism array structure according to claim 8 is characterized in that: the continuous microprism array structure that the outside surface of described cylinder mould is recess is to form with chemical corrosion, laser engraving or with the diamond cutter cutting.
10. a kind of production method with reflective membrane of microprism array structure according to claim 8 is characterized in that: the outside surface of described cylinder mould is assembled by the nickel sheet that a side surface has the continuous microprism array structure that is recess.
11. a kind of production method with reflective membrane of microprism array structure according to claim 1 is characterized in that: described resin film adopts the compound substance of acrylate material, makrolon material, polyester material, pvc material, polyurethane material, polyvinyl alcohol material, polypropylene material, polythene material, polyamide material, polystyrene material, above-mentioned two or more material.
12. a kind of production method with reflective membrane of microprism array structure according to claim 1 is characterized in that: described hot melt resin adopts the potpourri of acrylate resin, polycarbonate resin, polyester resin, Polyvinylchloride resin, polyurethane resin, polyvinyl alcohol (PVA) resin, polypropylene resin, polyethylene resin, polyamide resin, polystyrene resin, vinyl chloride vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resins, above-mentioned two or more resin.
13. a kind of production method with reflective membrane of microprism array structure according to claim 1 is characterized in that: what coating hot melt resin was adopted is the mode that heat seeling coating or hot melt are extruded.
14. a kind of production method with reflective membrane of microprism array structure according to claim 1 and 2 is characterized in that: the melt index (MI) of described hot melt resin is 3~40g/10min.
15. a kind of production method with reflective membrane of microprism array structure according to claim 2 is characterized in that: described backing film adopts polyester material, polypropylene material, polyamide material, polythene material or fluorine material.
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