JP2002205311A - Method for producing embossed endless belt, embossed endless belt, apparatus for producing embossed sheet, and embossed sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing an embossed endless belt which can be produced simply and promptly at a low cost, can transfer a precise pattern surely, and has a good mold release property during the processing of an embossed sheet, the embossed endless belt produced by using the method, an embossed sheet producing apparatus having the embossed endless belt, and the embossed sheet produced by using the apparatus. SOLUTION: An application process in which a liquid polyimide 10B is applied on the outer surface of the endless belt 10A, a semi-curing process in which the polyimide 10B applied on the outer surface of the endless belt 10A is heated to be semi-dried or semi-cured, a transfer process in which a film-shaped transfer material is pressed/stuck to the semi-dried or semi-cured polyimide 10B, a curing process in which the polyimide 10B to which the transfer material is stuck is heated and cured, and peeling process in which the transfer material is peeled off from the cured polyimide 10B are provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed endless belt manufacturing method, an embossed endless belt, an embossed sheet manufacturing apparatus, and an embossed sheet having an embossed pattern on the surface and used for manufacturing an embossed sheet.

[0002]

2. Description of the Related Art Conventionally, a so-called embossed sheet in which a three-dimensional uneven pattern (embossed pattern) is formed on the surface of a resin sheet or film has been manufactured. Generally, in the production of such an embossed sheet, a method in which an emboss is formed on a surface of a metal roll or a metal flat plate and then transferred to the surface of a resin sheet or a film, or a belt wound around a plurality of rolls. A method of forming an emboss pattern on the surface of a resin sheet or a film by a so-called belt process in which an emboss is formed on the surface of a resin sheet is adopted.

The following is a conventional method using a belt process. Using a metal belt with a pattern formed on the belt surface by engraving etc. with an embossed pattern,
A method of forming embosses continuously by heat and pressure (prior art 1 US Pat. No. 4,740,258). Further, in forming an uneven groove in the polyimide resin thin film on the metal substrate, a method of transferring the uneven groove to the surface by pressing with a transfer roll while the thin film is in a molten state (prior art 2-
337806).

[0004]

However, each of the above-described prior arts has the following problems. That is, in the method according to the prior art 1, there is a problem that it is difficult or time-consuming to form a three-dimensional pattern on the metal belt surface by means such as engraving of a fine pattern such as a grain of wood or a texture, which is uneconomical. Further, when embossing the resin sheet on the surface of the metal belt, the sheet softened by heating is welded to the surface of the belt, so that there is a problem that the peeling becomes difficult and the sheet is damaged if it is forcibly peeled. Also,
In the method according to the prior art 2, since the reproducibility of the mold at the time of transfer to the polyimide surface is poor, it is necessary to increase the pressure at the time of applying a fine pattern, and there is a problem that processing is difficult. Further, in order to improve the mold reproducibility, when the polyimide is softened and pressed, there is a problem that the polyimide adheres to the transfer roll and transfer efficiency is deteriorated.

An object of the present invention is to provide a method for manufacturing an embossed endless belt which can be manufactured simply, quickly and at low cost, can transfer a precise pattern reliably, and has good releasability during embossed sheet processing. An object of the present invention is to provide an embossed endless belt manufactured by using this manufacturing method, an embossed sheet manufacturing apparatus provided with the embossed endless belt, and an embossed sheet manufactured by using this apparatus.

[0006]

The method of manufacturing an embossed endless belt according to claim 1 is a method of manufacturing an embossed endless belt having an outer surface provided with an embossed pattern and used for manufacturing an embossed sheet. An application step of applying a thermosetting resin to the outer surface of the endless belt, and a semi-curing step of heating the thermosetting resin applied to the outer surface of the endless belt and semi-drying or semi-curing,
A transfer step of pressing and attaching a film-like transfer material to the semi-dried or semi-cured thermosetting resin, and a curing step of heating and curing the thermosetting resin with the transfer material adhered,
A separating step of separating the transfer material from the cured thermosetting resin.

Here, a metal material such as steel, stainless steel or copper can be used for the endless belt. The number of rolls around which the endless belt is wound is arbitrary as long as it is two or more, and the type of rolls can be appropriately selected, such as a heating roll or a cooling roll. As the thermosetting resin used in the coating step, a polyimide resin, an epoxy resin, an unsaturated polyester resin, a phenol resin, a urea melamine resin, a polyurethane resin, a silicone resin, or the like can be used. Among them, a polyimide resin is preferable. As the polyimide resin, non-thermoplastic polyimide, thermoplastic linear polyimide, thermosetting polyimide, modified polyimide, polyamide imide, polyether imide,
Polyester imide or the like can be employed.

[0008] Further, a heating means is required in a semi-curing step for bringing the thermosetting resin into a semi-dry or semi-cured state. The heating means is inside the endless belt,
When performing from the outside or from both sides,
Although it can be selected appropriately, it is preferable to heat from inside the belt. By heating from the inside of the belt, the sheet fixed to the heated endless belt can be directly heated, and the heating efficiency can be improved.

Here, as the heating means from the inside of the endless belt, for example, a method of using at least one of a plurality of rolls around which the belt is wound as a heating roll,
A method of heating with an electric heater or the like installed inside the belt may be used. On the other hand, as a heating means from the outside of the belt, for example, a method of heating with an electric heater or the like installed outside, a method of directly heating the sheet with a heating roll or the like that also serves as a nip roll provided outside the belt, and the like are given. Can be In addition, it is also possible to improve heating efficiency by appropriately combining heating with hot air or the like.

In the transfer step, various materials such as cloth, lace, embossed paper, bark, wire netting, leaves, tatami mats, etc. may be used as the transfer material having a pattern to be transferred to the thermosetting resin. Can be. Further, as a pressing means for pressing the transfer material against the thermosetting resin film in the transfer step, for example, a method of pressing the sheet toward the endless belt by a nip roll provided outside the endless belt is employed. it can.

In the curing step, a heating means is required in the same manner as in the semi-curing step. However, if the temperature can be set higher than in the semi-curing step, the same heating means as described above can be employed.

In the peeling step, the transfer material must be peeled off from the embossed thermosetting resin. As means for cooling, the cooling means for cooling the endless belt is provided, and the thermosetting resin is cooled by the cooling means. And a method in which a transfer material located on the cooled thermosetting resin is wound up and peeled off by using a peeling roll provided outside the endless belt.
As the cooling means, for example, a method of using a roll around which a metal endless belt is wound as a cooling roll, a method of providing a cooling roll outside the belt, or the like can be adopted.

According to the present invention, the emboss pattern is transferred to the semi-dried or semi-cured thermosetting resin, so that the emboss pattern can be easily held on the thermosetting resin. Can be transferred to In addition, since a method of transferring and embossing a transfer material onto a thermosetting resin coated on an endless belt by applying and pressing a transfer material is employed, engraving directly on an endless belt or on coated polyimide is not necessary. In comparison, an embossed endless belt can be manufactured simply, quickly, and at low cost.

According to a second aspect of the present invention, in the method for producing an embossed endless belt according to the first aspect, the thermosetting resin is preferably a liquid polyimide. According to the present invention, since the emboss pattern is transferred to the semi-dried or semi-cured liquid polyimide, it is easy to hold the emboss pattern on the polyimide. By cooling the polyimide as it is, a precise pattern can be reliably transferred.

According to a third aspect of the present invention, in the method for producing an embossed endless belt according to the second aspect, the solid concentration of the liquid polyimide is 33% by weight or more.

Here, as the solvent for the liquid polyimide, any solvent can be adopted as long as the solvent disperses the polyimide. When the solid content is less than 33% by weight, the solvent is too much, and the residual solvent is volatilized, whereby the interface between the polyimide and the endless belt is peeled off, resulting in poor transferability. Further, since the viscosity of the solution becomes low, it becomes difficult for the polyimide to hold the transferred emboss pattern. However, when the solid concentration is 33% by weight or more, there is no possibility that the interface between the polyimide and the endless belt is peeled off and the transferability is deteriorated because the amount of the solvent is small. In addition, since the viscosity of the solution is high without volatilization of the solvent, the transferred emboss pattern can be held by the polyimide, and transferability can be improved.

According to a fourth aspect of the present invention, there is provided an embossed endless belt obtained by the method for producing an embossed endless belt according to any one of the first to third aspects.

According to the present invention, the embossed pattern of the cured thermosetting resin is transferred to the sheet to be processed, so that the embossed sheet adheres to the thermosetting resin when the embossed sheet is peeled off during the embossed sheet processing. It is possible to provide an embossed endless belt capable of peeling off the embossed sheet without performing the process and transferring a precise embossed pattern to the sheet.

According to a fifth aspect of the present invention, there is provided an embossed sheet manufacturing apparatus comprising: a plurality of rolls; an embossed endless belt according to the fourth aspect wound around these rolls;
It is characterized by having.

Here, each of the plurality of rolls is one roll.
More than one heating roll and cooling roll can be employed. As a pressing means, a means using a nip roll, a means for pressing with another belt provided in parallel with the embossed endless belt, or the like may be employed outside the embossed endless belt wound around these rolls.

According to the present invention, since the endless belt coated with the thermosetting resin formed on the emboss pattern is used, the releasability is improved and the high value-added emboss sheet having a precise emboss pattern is used. Can be provided.

According to a sixth aspect of the present invention, there is provided an embossed sheet manufactured by using the embossed sheet manufacturing apparatus according to the fifth aspect.

As the thermoplastic resin constituting the sheet to be processed according to the present invention, any thermoplastic resin can be adopted. For example, polyolefin resins such as polyethylene and polypropylene, and two or more olefin resins can be used. Copolymers, ethylene-acrylic acid copolymers, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, polyesters, polyvinyl chloride, ionomers and the like can be employed. The thermoplastic resin may contain a filler (calcium carbonate, talc, etc.), a lubricant, an antistatic agent, a plasticizer, a coloring agent, a pyrolytic foaming agent, and the like, if necessary. .

The above-mentioned sheet may be embossed by laminating two or more kinds of sheets, or a pre-laminated sheet may be supplied onto an endless belt. In addition, as a method of laminating in advance, for example, a laminating method such as heat lamination or dry lamination, a coextrusion method, a calendar method, or the like can be used. In addition, the sheet in the present invention is a concept including a relatively thin film.

According to the present invention, the thermosetting resin having the embossed pattern is adhered to the sheet to be processed, and the embossed pattern is transferred to the sheet. Therefore, when the completed sheet is peeled, it is easily peeled off. can do. Further, various high-precision embossed sheets such as a cube corner prism type can be provided.

[0026]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a manufacturing apparatus 1 used for manufacturing an embossed endless belt 10 according to an embodiment of the present invention. The manufacturing apparatus 1 includes a first heating roll 110, a second heating roll 111, and a cooling roll 120 arranged at predetermined intervals, and each of these rolls 1.
Endless belt 1 wound around 10, 111, 120
OA, a bar coater 30, an extruder 40, a nip roll 50 and a peeling roll 60.

Here, the heating rolls 110 and 111 have a built-in heating means such as a heater, and the surface temperature thereof is
It is adjustable. The cooling roll 120 has a built-in cooling means such as a water-cooling type, and its surface temperature is adjustable. In addition, at least one of these rolls is connected to rotation driving means such as a motor and is rotatable.

The endless belt 10A is formed of stainless steel, and the surface thereof is coated with a polyimide 10B that forms an embossed pattern having irregularities. This polyimide 10B is made of polyimide dispersed in a solvent, and its concentration is preferably 33% by weight or more. Also,
The viscosity is preferably from 40 to 700 Poise. If the viscosity is less than 40 Poise, there is a risk that the polyimide 10B becomes too soft and cannot be retained even when the embossed pattern is transferred. There is a fear that extra force is required for pressing.

At the time of coating the polyimide 10B, the liquid polyimide 10B is extruded from the extruder 40 or, if the viscosity is low, poured and adjusted to a predetermined thickness by the bar coater 30. It is preferable that the extruder 40 has a function of extruding when the viscosity of the object is high. In the present embodiment, an extruder 40 having a function of extruding the polyimide 10B is used. The bar coater 30 is preferably made of a material such as plastic or rubber to adjust the thickness of the polyimide 10B to a predetermined thickness. In this embodiment, a plastic bar coater 30 is used.
You are using

The nip roll 50 is formed of rubber, and a silicone rubber surface material is mounted on the outer peripheral surface thereof. The nip roll 50 is connected to the first heating roll 11.
It is adjusted so that it is pressed to zero with an appropriate pressure. Here, the nip roll 50 and the first heating roll 110
A pressure step is performed at the time of emboss pattern transfer. In addition,
The pressing force can be appropriately set according to the thickness and width of the resin sheet, the material of the resin, and the like. Further, the peeling roll 60 is also formed of rubber, and a surface material made of silicone rubber is mounted on the outer peripheral surface thereof.

A method for manufacturing the embossed endless belt 10 according to this embodiment using the manufacturing apparatus 1 shown in FIG. 1 will be described. A method of manufacturing the embossed endless belt 10 by the above-described manufacturing apparatus 1 will be described with reference to FIGS. (1) The extruder 40 applies the liquid polyimide 10B onto the endless belt 10A operating in the direction of the arrow. At this time, the thickness of the polyimide 10B is adjusted to about 300 μm by the bar coater 30 (coating step). (2) The temperatures of the first heating roll 110 and the second heating roll 111 are increased, and the cooling roll 120 turns off the cooling function.
To adjust the rotation speed of the endless belt 10A,
The endless belt 10A is rotated for a time, and the polyimide 10B coated on the endless belt 10A
Was dried and semi-cured (semi-curing step).

FIG. 2 shows a nip roll 5 in addition to FIG.
On the 0 side, a delivery roll 51 for delivering the transfer material 70 is provided, and on the release roll 60 side, the transfer material 70 attached to the polyimide 10B coated on the endless belt 10A from the delivery roll 51 is wound. A take-up roll 61 for taking up is provided.

(3) The transfer material 70 provided on the embossed surface with the embossed pattern sent from the feed roll 51 to the semi-cured polyimide 10B is transferred to the nip roll 50.
And between the endless belt 10A and pressed and adhered (transfer step).

(4) Thereafter, the temperatures of the first heating roll 110 and the second heating roll 111 are further increased, the rotation speed of the endless belt 10A is adjusted, the endless belt 10A is rotated for one hour, and the endless belt 10A is rotated. The polyimide 10B coated thereon is cured (curing step).

(5) Further, cured polyimide 10B
The transfer material 70 attached from above is peeled off by being inserted between the peeling roll 60 and the endless belt 10A (peeling step).

In FIG. 3, the bar coater 30 and the extruder 40 are removed from FIG. After the peeling step is completed, the bar coater 30 and the extruder 40 are removed from the manufacturing apparatus 1.

(6) Then, the temperatures of the first heating roll 110 and the second heating roll 111 are raised, the rotation speed of the endless belt 10A is adjusted, and the endless belt 10A is rotated for one hour, and Is completely cured. As described above, the embossed endless belt 10 in which the polyimide 10B having the embossed pattern formed thereon is coated on the endless belt 10A is completed.

The embossed endless belt 10 manufactured as described above is used as it is as an embossed sheet manufacturing apparatus. FIG. 4 shows a manufacturing apparatus 1 including the embossed endless belt 10. In the following description of the embodiments, the same components will be denoted by the same reference numerals, and the description thereof will be omitted or simplified. The manufacturing apparatus 1 includes a first heating roll 110, a second heating roll 111, and a cooling roll 120 arranged at predetermined intervals, an embossed endless belt 10 wound around these rolls 110, 111, 120, and a nip roll 50. , A delivery roll 52, a peeling roll 60, and a winding roll 62.

Here, a sheet 71 to be processed according to the present invention is wound around the delivery roll 52, from which the sheet 71 is inserted between the nip roll 50 and the embossed endless belt 10 and pressed to form the embossed endless belt. The emboss pattern on the belt 10 is transferred to the sheet 71. In the present embodiment, the sheet 71 employs a polypropylene sheet. Further, the winding roll 62 includes
The sheet 71 on which the emboss pattern is transferred is inserted between the peeling roll 60 and the emboss endless belt 10,
Further, peel off.

A method for manufacturing the embossed sheet 72 according to this embodiment using the manufacturing apparatus 1 shown in FIG. 4 will be described. (7) First, the temperatures of the first heating roll 110 and the second heating roll 111 are increased, and the first heating roll 110 and the second heating roll 111 are cooled by the cooling roll 120.
The rotation speed of the embossed endless belt 10 is adjusted. (8) After that, the sheet 71 wound around the delivery roll 52 is inserted between the nip roll 50 and the embossed endless belt 10 and pressed, so that the embossed pattern on the embossed endless belt 10 is changed to the sheet 71.
Transfer to (9) Further, the sheet 7 on which the emboss pattern has been transferred
1 is inserted between the peeling roll 60 and the embossed endless belt 10 and peeled off. With the above, the embossed sheet 72
Is completed. As shown in FIG. 5, the obtained embossed sheet 72 has an embossed surface 72A forming an embossed pattern with irregularities.

According to the above-described embodiment, the following effects can be obtained. First, since the embossed pattern is transferred to the semi-cured polyimide 10B, the embossed pattern can be easily held on the polyimide 10B, and a precise pattern can be reliably transferred. Further, the transfer material 70 is attached and
Since the method of pressing and transferring the emboss pattern to the polyimide 10B coated on the endless belt 10A is adopted, it is simpler and faster than engraving directly on the endless belt 10A or the coated polyimide. The embossed endless belt 10 can be manufactured at low cost.

Furthermore, since the embossed pattern of the cured polyimide 10B is transferred to the sheet 71, which is a workpiece, the embossed sheet 72 is not adhered to the polyimide 10B when the embossed sheet 72 is peeled off during the embossed sheet processing. An embossed sheet 72 with a high product value, from which the embossed sheet 72 can be peeled off, can be manufactured. Then, most of the components (the heating rolls 110 and 111, the cooling roll 120, and the like) of the manufacturing device 1 for the embossed endless belt 10 can be continuously used as the manufacturing device 1 for the embossed sheet 72. The embossed sheet 72 can be manufactured simply, quickly, and at low cost as compared with manufacturing and attaching to an embossed sheet manufacturing apparatus.

It should be noted that the present invention is not limited to the above embodiment, and modifications and improvements as long as the object of the present invention can be achieved are included in the present invention. For example, stainless steel is used as the endless belt 10A in the above embodiment, but the present invention is not limited to this, and a metal material such as steel or copper can be used. Further, as the thermosetting resin, in the above embodiment, polyimide 10
B was adopted, but not limited to this, epoxy resin,
Other thermosetting resins such as an unsaturated polyester resin, a phenol resin, a urea melamine resin, a polyurethane resin, and a silicone resin can be employed.

In the above-described embodiment, the heating rolls 110 and 111 employ the heating rolls having the built-in electric heaters. However, the present invention is not limited to this. The sheet 7 is heated by a heating roll or the like which also serves as a nip roll 50 provided outside the belt.
A method of directly heating 0 can be adopted.

Further, as the sheet 71 to be processed, in each of the above-described embodiments, a polypropylene sheet is employed. However, the present invention is not limited to this. Another thermoplastic resin sheet such as polyethylene or the above-mentioned thermoplastic sheet is used. A resin sheet or the like in which a plurality of resins are laminated can be employed. In addition, the specific structure, shape, and the like at the time of carrying out the present invention may be other structures and the like as long as the object of the present invention can be achieved.

[0046]

EXAMPLES In the above embodiment, specific conditions for producing an embossed endless belt and an embossed sheet were as follows. Manufacture of embossed endless belt Perimeter of endless belt 10A: 2000 mm Inner diameter of heating roll and cooling roll: 250 mm Polyimide 10B to be applied: FS-5 manufactured by Ube Industries, Ltd.
10T Viscosity of polyimide 10B to be applied 10B: 351 Pois
e Solid concentration of polyimide 10B to be applied: 66.3% by weight Temperature of heating rolls 110 and 111 (FIG. 1): 80 ° C. Temperature of heating rolls 110 and 111 (FIG. 2): 150 ° C. Temperature of heating rolls 110 and 111 (FIG. 3): 170 ° C. Rotational speed of the endless belt 10A (FIGS. 1, 2 and 3): 1 m / min Embossed pattern transferred: floral lace pattern

On the surface of the obtained embossed endless belt 10 on the polyimide 10B side, a floral lace pattern was accurately transferred.

Manufacture of embossed sheet Sheet 71 to be used: polypropylene (F-744NP manufactured by Idemitsu Petrochemical Co., Ltd.) Temperature of heating roll 110 (FIG. 4): 170 ° C. Temperature of heating roll 111 (FIG. 4): 200 ° C. Cooling Temperature of the roll 120 (FIG. 4): cooling with normal temperature water Rotation speed of the embossed endless belt 10 (FIG. 4): 2
m / min

On the embossed surface side of the obtained embossed sheet 72, a floral lace pattern was accurately transferred.

[0050]

According to the present invention, since the emboss pattern is transferred to the semi-dried or semi-cured thermosetting resin, the emboss pattern can be easily held on the thermosetting resin, and the precise pattern can be transferred reliably. Can be. In addition, the method of transferring the embossed pattern to the thermosetting resin coated on the endless belt by sticking and pressing the transfer material is adopted, so that it is possible to engrave directly on the endless belt or coated polyimide. In comparison, there is an effect that an embossed endless belt can be manufactured simply, quickly, and at low cost. Furthermore, in order to transfer the embossed pattern of the cured thermosetting resin to the sheet which is the workpiece, when the embossed sheet is peeled off during the embossed sheet processing, the embossed sheet is peeled off without attaching the embossed sheet to the thermosetting resin. It is possible to provide an embossed endless belt capable of manufacturing an embossed sheet having a high product value.

[Brief description of the drawings]

FIG. 1 is a view showing a coating step and a semi-curing step of a method for producing an embossed endless belt according to the present invention.

FIG. 2 is a view showing a transfer step, a curing step, and a peeling step of the method for manufacturing an embossed endless belt according to the present invention.

FIG. 3 is a view showing a completed state of the embossed endless belt according to the present invention.

FIG. 4 is a diagram showing an embossed sheet manufacturing apparatus according to the present invention.

FIG. 5 is a view showing an embossed sheet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 10 Embossed endless belt 10A Endless belt 10B Polyimide 30 Bar coater 40 Extruder 50 Nip roll 60 Release roll 70 Transfer material 71 Sheet 72 Embossed sheet 110,111 Heating roll 120 Cooling roll

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B29K 79:00 B29K 79:00 105: 20 105: 20 B29L 29:00 B29L 29:00 F term ( Reference) 2H113 AA01 BA28 DA54 3F024 BA01 BA02 BA04 CA04 4F202 AA11 AC03 AG01 AG05 AJ03 AJ09 CA01 CB02 CD01 CD22 CD30 4F204 AA11 AC03 AG01 AG05 AJ03 AJ09 EA05 EB01 EB11 EF23 EK04 EK13 EK17 4J09P06 A0603

Claims (6)

[Claims] 1. A method for producing an embossed endless belt having an embossed pattern applied to an outer surface and used for producing an embossed sheet, comprising: a coating step of applying a thermosetting resin to an outer surface of the endless belt; A semi-curing step of heating and semi-drying or semi-curing the thermosetting resin applied to the outer surface of the resin, and a transferring step of pressing and attaching a film-like transfer material to the semi-dry or semi-cured thermosetting resin An embossing endless belt, comprising: a curing step of heating and curing the thermosetting resin with the transfer material adhered thereto; and a peeling step of peeling the transfer material from the cured thermosetting resin. Manufacturing method. 2. The method for producing an embossed endless belt according to claim 1, wherein said thermosetting resin is a liquid polyimide. 3. The method for producing an embossed endless belt according to claim 2, wherein the solid concentration of the liquid polyimide is 33% by weight or more. 4. An embossed endless belt obtained by the method for producing an embossed endless belt according to any one of claims 1 to 3. 5. An embossed sheet manufacturing apparatus comprising: a plurality of rolls; an embossed endless belt according to claim 4, wound around these rolls; and a pressing means. 6. An embossed sheet manufactured using the embossed sheet manufacturing apparatus according to claim 5.