JP2003117460A - Method and apparatus for manufacturing pattern sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and apparatus for manufacturing a pattern sheet capable of continuously manufacturing the pattern sheet at a low cost without being restricted by ink. SOLUTION: The apparatus for manufacturing the pattern sheet is equipped with a partition wall forming part 20 for continuously forming a plurality of partition walls, which extend in the feed direction of a sheet 100, to the surface of the sheet 100 fed in the direction shown by an arrow A and coating dies 32R, 32G and 23B having a plurality of nozzles for discharging inks and also equipped with an ink coating part 30 injecting the inks in a plurality of the recessed grooves formed to the surface of the fed sheet 100 having the partition walls formed on the surface thereof from a plurality of the nozzles of the coating dies 32R, 32G and 32B to fill the recessed grooves with the inks and a drying part 40 for drying the inks on the surface of the sheet 100 coated with the inks by the ink coating part 30 to be fed to form the ink layers to the recessed grooves.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a color filter,
The present invention relates to a method and an apparatus for manufacturing a pattern sheet used as an electronic display material such as an organic EL.

[0002]

2. Description of the Related Art Conventionally, as a material for an electronic display such as a color filter or an organic EL, a single color or a plurality of colors such as R (red), G (green) and B (blue) are formed on a transparent sheet.
A pattern sheet is used in which three-color micron-order fine stripe-shaped patterns are formed.

As a method for producing this pattern sheet, 1) photolithography method: a transparent sheet is patterned by applying a resist on the surface of the transparent sheet, exposing it with a mask, developing, and etching.

2) Sand blast method: A resist is applied to the surface of a transparent sheet, a mask is applied, and then a sand is sprayed to remove the pattern other than the mask portion.

3) Screen printing method: Ink is placed on a stripe pattern screen and printing is performed with a squeegee. And other methods have been proposed.

[0006]

However, since none of these pattern sheet manufacturing methods are continuous processes, it is difficult to improve productivity and reduce manufacturing costs. Therefore, as a method of manufacturing a pattern sheet by a continuous process, a method of continuously applying ink to a running transparent sheet using a die coater for stripe application having a large number of ink jet nozzles has been proposed.

FIG. 20 is a diagram showing an example of a conventional pattern sheet manufacturing method.

FIG. 20 shows an example of a conventional method of manufacturing a pattern sheet disclosed in Japanese Patent Laid-Open No. 5-11105. In this manufacturing method, a coating die 92 having a plurality of slits formed on a transparent substrate 91.
The ink 93 containing a resin, a dye and a solvent is extruded therethrough to form an ink layer 94 having a desired pattern.

However, the pattern sheet manufacturing method shown in FIG. 20 cannot be realized without using a high-viscosity ink, and thus there is a problem that the product specifications of the pattern sheet are restricted by the ink used. Further, since it is not a completely continuous process, it is difficult to continuously manufacture a patterned sheet at low cost.

FIG. 21 is a diagram showing another example of a conventional method of manufacturing a pattern sheet.

FIG. 21 shows another example of the conventional method of manufacturing a pattern sheet disclosed in Japanese Patent Laid-Open No. 5-11105. In this manufacturing method, three or more rows of coating material discharge holes 97, each of which is composed of a plurality of nozzles 96 having an equal pitch in the coating width direction Y, are provided in the lip tip portion 95 of the coating die 92 in the support body traveling direction X, and each coating material is discharged. The hole rows 97 are arranged at positions shifted by one-third of the pitch of the nozzles 96 in the coating width direction Y, and each paint discharge hole row 97 is run by an ink application device 99 having its own paint supply passage 98. A method for producing a pattern sheet for a liquid crystal display device, in which three or more kinds of paints are applied in a stripe pattern on a support, is disclosed.

However, the pattern sheet manufacturing method shown in FIG. 21 cannot be manufactured unless high-viscosity ink is used. Therefore, there is a problem that the product specifications of the pattern sheet are restricted by the ink used.

In addition, in Japanese Unexamined Patent Publication No. 2000-48716, a table for fixing a base material, a nozzle having a plurality of discharge holes provided facing the base material, and a coating liquid are supplied to the nozzle. There is disclosed an ink coating device including a coating liquid supply unit and a moving unit that relatively moves the table and the nozzle three-dimensionally. However, this Japanese Patent Laid-Open No.
The ink application device disclosed in Japanese Patent Application Laid-Open No. 00-48716 is a method of forming a stripe pattern by moving an ink ejection nozzle on a table, and is not a continuous process, and therefore a pattern sheet is continuously manufactured at low cost. Is difficult to do.

In view of the above circumstances, it is an object of the present invention to provide a pattern sheet manufacturing method and manufacturing apparatus capable of continuously manufacturing a pattern sheet at low cost without being restricted by ink.

[0015]

According to a first method for producing a patterned sheet of the present invention which achieves the above object, a partition wall is provided, wherein a plurality of partition walls extending in a transport direction are formed on a surface of a substrate made of a transported web or sheet. A forming die and a coating die having a plurality of nozzles for ejecting ink, injecting ink into a plurality of concave grooves formed between partition walls,
And an ink layer forming step of forming an ink layer by drying or curing the ink injected into the concave groove.

According to the first method for producing a pattern sheet of the present invention, the pattern sheet can be continuously produced at a low cost without being restricted by the viscosity of the ink used.

Further, in the second method for producing a patterned sheet of the present invention which achieves the above object, a step of forming a plurality of partition walls extending in the transport direction is formed on the surface of a material to be transported comprising a web or sheet to be transported. And an ink layer by injecting ink into a plurality of concave grooves formed between the partition walls with a coating die having a plurality of nozzles for ejecting ink and drying or curing the ink injected into the concave grooves. The ink layer forming step of forming the ink layer and the material to be conveyed on which the ink layer is formed are overlapped and pressed against a substrate made of a web or sheet to be conveyed so that the ink layer faces the substrate side. And a transfer step of transferring the ink layer on the transport material onto the substrate.

According to the second method for producing a pattern sheet of the present invention, by selecting a material to be conveyed suitable for forming an ink layer on the surface and a substrate suitable for the properties of the pattern sheet to be a product, A pattern sheet having desired properties can be continuously manufactured at low cost.

Here, in the ink layer forming step, a plurality of colors of ink are injected into the groove formed between the partition walls, and the injected ink is dried or cured to thereby form a plurality of colors of ink. It is preferably a step of forming a layer.

In the case of the above construction, a pattern sheet having a desired number of colors can be continuously manufactured at low cost without being greatly restricted by the ink used.

Further, a partition wall reducing step of reducing at least the height of the partition wall on the transported material on which the partition wall is formed may be provided between the ink layer forming step and the transfer step. preferable.

With the above structure, it is possible to prevent the height of the partition walls of the material to be conveyed from interfering with the transfer of the ink layer in the next step.

Further, the first pattern sheet manufacturing apparatus of the present invention which achieves the above object is to form a plurality of barrier ribs extending in the conveying direction on the surface of a substrate made of a web or sheet conveyed in a predetermined direction. Section, and a coating die having a plurality of nozzles for ejecting ink, and an ink application section for injecting ink from a plurality of nozzles of the coating die into a plurality of concave grooves formed between partition walls. And an ink layer forming section for forming an ink layer by drying or curing the ink on the surface of the substrate.

According to the first pattern sheet manufacturing apparatus of the present invention, the pattern sheet can be continuously manufactured at low cost without being greatly restricted by the viscosity of the ink used.

Further, the second pattern sheet manufacturing apparatus of the present invention which achieves the above object, forms a plurality of partition walls extending in the transport direction on the surface of the material to be transported which is a web or a sheet transported in a predetermined direction. A partition wall forming section and a coating die having a plurality of nozzles for ejecting ink,
An ink application section for injecting ink from a plurality of nozzles of the coating die and an ink layer is formed by drying or curing the ink on the surface of the material to be conveyed in a plurality of concave grooves formed between the partition walls. By pressing the ink layer forming portion and the material to be conveyed on which the ink layer has been formed on a substrate made of a web or sheet to be conveyed so that the ink layer faces the substrate, And a transfer portion for transferring the ink layer on the material to be conveyed onto the substrate.

According to the second pattern sheet manufacturing apparatus of the present invention, by selecting a material to be conveyed suitable for forming an ink layer on the surface and a substrate suitable for the properties of the pattern sheet to be a product, It is possible to continuously manufacture a patterned sheet having the above properties at low cost.

Here, the ink application section includes a plurality of coating dies having a plurality of nozzles for ejecting a plurality of colors of ink, and the coating dies fill the concave grooves with inks of different colors. It is preferable.

In the case of the above construction, the pattern sheet having a desired number of colors can be continuously manufactured at low cost without being greatly restricted by the viscosity of the ink used.

Further, it is preferable that a partition wall reducing portion for reducing at least the height of the partition wall formed on the material to be transported is provided between the ink layer forming portion and the transfer portion.

In the case of the above construction, it is possible to prevent the height of the partition walls of the material to be conveyed from becoming an obstacle during the transfer of the ink layer in the next step.

The coating die has a diameter of the nozzle of A and a width of the concave groove of W, and is 0.2 × W.
It is preferable to have a plurality of nozzles satisfying the relationship of << A << 0.8 × W.

In the case of the above construction, the ink pressure inside the coating die is properly maintained and the ink can be applied uniformly.

The coating die has a size of 5 × A, where A is the diameter of the nozzle and B is the length of the nozzle.
It is preferable to have a plurality of nozzles satisfying the relationship of <B <100 × A.

In the case of the above-mentioned constitution, the ink pressure inside the coating die is properly maintained, and the ink can be applied uniformly.

It is preferable that the coating die has a plurality of nozzles for ejecting ink downward from the horizontal plane.

With the above structure, it is possible to prevent the ink from dripping from the lip portion of the coating die.

Further, the coating die has a gap of 0.5 between the tip end portions of the plurality of nozzles and the surface of the coating material to which ink is applied by the coating die.
It is preferably deployed in a position that is less than or equal to mm.

With the above structure, it is possible to prevent the ink from dripping from the lip portion of the coating die.

[0039]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below.

First, a first embodiment of the present invention will be described. This first embodiment corresponds to the first pattern sheet manufacturing method of the present invention and the first pattern sheet manufacturing apparatus of the present invention.

FIG. 1 is a schematic configuration diagram of a pattern sheet manufacturing apparatus according to the first embodiment of the present invention.

In FIG. 1, a delivery roll 10 for delivering the sheet 100 as an example of the substrate according to the present invention, and a partition wall having a predetermined pattern on the surface of the sheet 100 delivered from the delivery roll 10 and conveyed in the direction of arrow A. Ink for continuously filling the partition wall forming unit 20 and the surface of the sheet 100 having the partition wall formed thereon by continuously applying the ink to fill the ink in the concave groove formed between the partition walls. The coating unit 30 includes: a coating unit 30; a drying unit 40 that forms an ink layer in the groove by drying the ink on the surface of the sheet 100 that has been coated with the ink by the ink coating unit 30 and conveyed; A patterned sheet manufacturing apparatus 1 is shown.

In the first embodiment, the web-shaped sheet 1 is used.
As 00, for example, a polyurethane film having a water-repellent surface and a thickness of about 300 μ can be used.

The water repellency of the sheet 100 is not an essential requirement of the present embodiment, but when ink is applied to the concave grooves formed between the partition walls and dried, it is easy to obtain an ink layer having a uniform film thickness. Therefore, it is preferable to use a sheet having water repellency.

As the water-repellent sheet, a resin sheet or the like which is originally water-repellent may be used, or
A method of applying water-repellent treatment such as applying a water-repellent resin to the surface of the sheet in advance may be adopted. As the water-repellent resin, for example, a silicon-based resin or a fluorine-based resin can be used.

As the material of the sheet 100, metal or the like can be used in addition to resin. Further, it is preferable to use a material having a shape memory characteristic as the material of the sheet. The use of a sheet having shape memory characteristics has the advantages that patterning is easy and restoration to the original shape after patterning is easy.

Such a sheet 100 is supplied to the partition wall forming section 20 of the pattern sheet manufacturing apparatus 1 shown in FIG.

The partition wall forming section 20 is provided with a hot pressing device comprising a pattern roll 21 having a convex pattern of a predetermined pattern on the surface and a backup roll 22 arranged so as to face the pattern roll 21. The pressing force of this hot press machine is about 100 kg / cm ² , and the pattern roll temperature is about 110 ° C.

In the partition wall forming section 20, a partition wall having a predetermined pattern is continuously formed on the surface of the sheet 100 conveyed to the hot press machine (partition wall forming step).

FIG. 2 is a side view of the pattern roll used in the pattern sheet manufacturing apparatus shown in FIG.

As shown in FIG. 2, a plurality of ridges 2 extending along the circumferential direction of the roll are formed on the surface of the pattern roll 21.
1a is formed, and a groove 21b is formed between the ridges 21a.
Are formed.

As the method of forming the partition wall, in addition to the above-mentioned forming method using the hot press device, for example, a method using a curable resin or a casting method can be adopted.

FIG. 3 is a cross-sectional view of a sheet in which partition walls are formed by the partition wall forming process of the first embodiment.

By the partition wall forming step of the first embodiment, as shown in FIG. 3, a plurality of stripe-shaped partition walls 101 arranged in the sheet conveying direction are formed on the surface of the sheet 100, and between the partition walls 101. The concave groove 102 is formed.

FIG. 4 is a cross-sectional view of a partition wall and a concave groove formed on the surface of the sheet.

As shown in FIG. 4, the dimensions of the partition wall 101 and the concave groove 102 formed on the surface of the sheet 100 are as follows.
The length L1 of the bottom side of the concave groove 102 is 90 μ, the length L2 of the upper side of the concave groove 102 is 100 μ, and the length L3 of the upper side of the partition wall 101.
Is 30 μ, the length L4 of the bottom of the partition 101 is 40 μ, and the height H of the partition 101 is 30 μ.

In this embodiment, the reason why the partition wall 101 has a trapezoidal sectional shape is that the partition wall can be easily formed by heat as compared with a rectangular shape. The sectional shape of the partition wall 101 is not limited to the trapezoidal shape shown in FIG. 4, and may be rectangular or any other shape.

Now, the influence of the presence or absence of water repellency of the sheet used in this embodiment on the process will be described.

FIG. 5 is a diagram showing an ink layer formed on the surface of the sheet in the ink layer forming step.

By the ink layer forming step following the partition wall forming step, as shown in FIG. 5, the concave groove 10 on the surface of the sheet 100 is formed.
The ink layer 103 is formed on the surface 2.

When a sheet having water repellency is used as the sheet 100, as shown in FIG. 5A, the ink layer 103 formed in the concave groove 102 has a uniform film thickness, but is water repellent. When using a sheet without
As shown in (b), the ink liquid surface in the portion in contact with the partition wall 101 is pulled upward along the partition wall 101 due to the surface tension, and the thickness of the dried ink layer 103 becomes uneven. Therefore, in the present invention, it is preferable to use a sheet having water repellency.

Next, the ink layer forming step will be described.

The sheet 100 having the partition wall formed on the surface by the partition wall forming section 20 (see FIG. 1) is next processed by the ink coating section 3
Transported to 0.

A roll 31 for stretching the sheet 100 and R (red), G (green), and B (blue) inks arranged to face the roll 31 are ejected to the ink application section 30. Coating die 32 having a plurality of nozzles
R, 32G, 32B are provided.

FIG. 6 is a view showing an example of the coating die 32 used in this embodiment.

As shown in FIG. 6, in this coating die, a plurality of nozzles 32a for ejecting ink of a predetermined color are arranged in a line, and ink 3 of the same color is ejected from each nozzle 32a.
3 is discharged. As shown in FIG. 1, such a coating die 32 has R (red) and G
By arranging three units corresponding to each color of (green) and B (blue), a stripe pattern of three colors of RGB can be formed.

FIG. 7 is a diagram showing another example of the coating die used in this embodiment.

FIG. 7 shows a coating die 32 having a plurality of nozzles 32a_1 for ejecting R color ink 33R, a plurality of 32a_2 for ejecting G color ink 33G, and a plurality of 32a_3 for ejecting B color ink 33B. 'It is shown.

By using the coating die 32 'shown in FIG. 7 in place of the coating die 32 shown in FIG. 6, it is possible to form a stripe pattern of RGB three colors by one coating die.

FIG. 8 is a diagram showing an ink application section when the coating die shown in FIG. 7 is incorporated in the pattern sheet manufacturing apparatus of the present invention.

As shown in FIG. 8, this ink applying section 3
The 0'is provided with only one coating die 32 '(see FIG. 7) arranged opposite the roll 31.
With only one coating die 32 ', it is possible to form a stripe pattern of RGB three colors.

The coating die 32 shown in FIG. 6 or the coating die 32 'shown in FIG. 7 is used to apply the ink to the plurality of concave grooves 102 on the surface of the sheet 100 conveyed to the ink applying section 30 (see FIG. 1). Groove 10 by continuous injection
Fill 2 with ink. The height of the liquid film of the ink injected into the concave groove 102 is adjusted to be about 25 μ, for example.

As the ink, three types of inks are prepared by mixing and dispersing a binder of each color of RGB, an alcohol, and a coating aid. The viscosity of the ink is about 30
It is preferably about mPa · s.

It is also possible to mix a curable material in the ink and, after injecting the ink, cure the ink by UV light or the like.

Here, the structure of the coating die used in the method and apparatus for manufacturing the pattern sheet of the present invention will be described.

FIG. 9 is a side view (a), a bottom view (b), and a sectional view (c) of the coating die used in this embodiment.

As shown in FIG. 9, the coating die 32 includes a plurality of nozzles 32a for ejecting ink, an ink pocket 32b for storing ink, and a die block 32c having the nozzle 32a and the ink pocket 32b accommodated therein. Consists of.

FIG. 10 is a diagram showing the dimensions of the nozzle of the coating die used in this embodiment.

As shown in FIG. 10, the coating die 32 used in this embodiment has a nozzle 32a whose diameter is A,
When the width of the recessed groove 102 is W (see FIG. 5), it is preferable to have a plurality of nozzles that satisfy the relationship of 0.2 × W <A <0.8 × W. When the diameter A of the nozzle 32a is 0.2 × W or less, the pressure in the nozzle 32a may be too high and the ink may be excessively ejected, and when it is 0.8 × W or more, the ink may be protruded from the concave groove. .

As shown in FIG. 10, the coating die 32 used in this embodiment has a diameter of the nozzle 32a of A and a length of the nozzle 32a of B, 5 × A <B <100 × A. It is also preferable to have a plurality of nozzles that satisfy the following relationship. When the length B of the nozzle 32a is shorter than 5 × A, it is difficult to uniformly eject the ink, and when the length B of the nozzle 32a is longer than 100 × A, the pressure inside the die is high and the ink is still normal. Cannot be applied.

The tip shape of the nozzle 32a from which ink is ejected may be circular as shown in FIG. 10, but may be any other shape such as an ellipse, a rectangle, and a round rectangle.

FIG. 11 is a diagram showing the positional relationship between the coating die used in this embodiment and the material to be coated.

As shown in FIG. 11, the coating die 32 used in this embodiment preferably has a nozzle 32a for ejecting ink downward from the horizontal plane. When the coating die 32 is arranged so as to eject the ink upwards from the horizontal plane, the ink ejected from the nozzle 32a will drop along the lip portion of the coating die 32, and stable ink ejection is difficult. Is.

Further, as shown in FIG. 11, the coating die 32 used in the present embodiment is a tip end portion of the nozzle 32a and an applied material (sheet 100 or substrate 60) to which the ink 33 is applied by the coating die 32. It is also preferable that the gap G with the surface is arranged at a position of 0.5 mm or less. Gap G is 0.5mm
In the above case, the ejected ink is the coating die 3
It is difficult for stable ink ejection because it drips along the second lip portion 32d.

An example of the dimensions of the coating die 32 is shown below as an example. (Example) Nozzle shape = Circular nozzle pitch = 0.39 mm Nozzle diameter A = 0.05 mm Nozzle length B = 0.2 mm Gap between nozzle and surface of material to be coated G = 0.1 mm Width W = 0.1 mm Next, a second embodiment of the present invention will be described.

The second embodiment corresponds to the second pattern sheet manufacturing method of the present invention and the second pattern sheet manufacturing apparatus of the present invention.

FIG. 12 is a schematic block diagram of the pattern sheet manufacturing apparatus of the second embodiment.

In FIG. 12, a partition wall forming portion for continuously forming a plurality of partition walls extending in the transport direction on the surface of the material 60 to be transported, which is made of a web or sheet that is transported from the delivery roll 10 and transported in the direction of arrow A. 20, an ink application unit 30 that fills the recessed groove formed between the partition walls with the ink by continuously applying the ink to the surface of the transported material 60 having the partition wall formed thereon. The drying unit 40 that forms an ink layer in the concave groove by drying the ink on the surface of the transported material 60 that has been coated with the ink and transported by the coating unit 30, and the transported substrate that has been formed with the ink layer and transported. The conveyance material 60 is superposed on the conveyed sheet 100 as an example of the substrate according to the present invention so that the ink layer faces the sheet 100 side and is pressed so as to be conveyed. Sheet ink layer on wood 60 100
A pattern sheet manufacturing apparatus 2 including a transfer unit 70 that transfers images continuously is shown.

As the transported material 60 used in the second embodiment, a resin sheet, a resin film, a metal sheet or the like is used. The transported material 60 has water repellency. The water repellency of the transported material 60 is not an essential requirement of the present embodiment, but when ink is applied to the concave grooves formed between the partition walls and dried, it is easy to obtain an ink layer having a uniform film thickness. It is preferable to use a material to be transported having water repellency. As the water-repellent material to be transported, a material that is originally water-repellent may be used, or a method of applying a water-repellent treatment such as applying a water-repellent resin to the surface of the material to be transported may be adopted. Good. As the water-repellent resin, for example, a silicon-based resin or a fluorine-based resin can be used.

As the sheet 100 used in the second embodiment, a resin sheet, a resin film, a metal sheet, a glass substrate or the like is used. The sheet may have a web-like shape or a sheet cut into a predetermined length.

As the partition wall forming section 20, the ink applying section 30, and the drying section 40 of the second embodiment, those substantially the same as those of the first embodiment shown in FIG. 1 are used.

Next, the operation of the pattern sheet manufacturing apparatus 2 according to the second embodiment will be described.

Patterned sheet manufacturing apparatus 2 shown in FIG.
The web-shaped material 60 to be transported sent from the delivery roll 10 is supplied to the partition wall forming portion 20.

In the partition wall forming section 20, a partition wall having a predetermined pattern is continuously formed on the surface of the conveyed material 60 (partition wall forming step).

The transported material 60 having the partition walls formed on the surface thereof by the partition wall forming section 20 is then transported to the ink applying section 30.

In the ink application section 30, a roll 31 for stretching a material 60 to be conveyed, and R (red), G (green), and B (blue) inks arranged facing the roll 31, respectively. Coating die 32 having a plurality of nozzles for discharging
R, 32G, 32B are provided.

The transported material 60 on which the stripe patterns of three colors of RGB are formed by the ink application section 30 is then transported to the drying section 40 and dried, and RGB is transferred onto the transported material 60.
An ink layer having a stripe pattern of three colors is formed. This ink layer is transferred to the transfer roll 71 provided in the transfer section 70.
And by the action of the pressure roll 72, it is transferred to the sheet 100 conveyed in the direction of arrow B. The transported material 60 that has passed through the transfer section 70 is wound up by the winding roll 73.

FIG. 13 is a cross-sectional view of the material to be conveyed having partition walls formed on the surfaces thereof in the partition forming step of the second embodiment.

As shown in FIG. 13, a plurality of stripe-shaped partition walls 61 arranged in the transported material transport direction are formed on the surface of the transported material 60 in the partition forming step, and recesses are formed between the partition walls 61. The groove 62 is continuously formed.

FIG. 14 is a sectional view of a partition wall and a concave groove formed on the surface of the material to be conveyed.

As shown in FIG. 14, the dimensions of the partition wall 61 and the concave groove 62 formed on the surface of the material 60 to be conveyed are as follows: the length L1 of the bottom side of the concave groove 62 is 90 μ, and the length of the upper side of the concave groove 62 is 90 μm. The length L2 is 100 μ, and the length L3 of the upper side of the partition wall 61 is 30
μ, the length L4 of the bottom of the partition wall 61 is 40 μ, and the height H of the partition wall 61 is 30 μ.

The barrier layer may be formed after the cushion layer is applied to the surface of the material 60 to be conveyed. By doing so, the partition wall having a desired size can be easily formed.

The material 60 to be transported after the transfer process is
When it is desired to restore the original shape before forming the partition wall, it is preferable to use a material having a shape memory characteristic as the transported material 60. For materials with shape memory characteristics,
In addition to easy patterning, restoration to the original shape is easy, and the transported material 60 can be repeatedly used multiple times without requiring a special process.

Next, in the ink layer forming step, the ink is applied by the ink applying section 30 (see FIG. 12) and the ink is dried by the drying section 40. That is, ink is applied to the surface of the conveyed material 60 (see FIG. 6) having the partition walls 61 formed and conveyed to the ink applying section 30, and the drying section 40 dries the ink to form a space between the partition walls 61. An ink layer 63 is formed in the formed concave groove 62.

As the ink, the same ink as in the first embodiment can be used.

FIG. 15 is a diagram showing the ink layer formed on the surface of the material to be conveyed.

As shown in FIG. 15, an ink layer 63 is formed in the concave groove 62 on the surface of the material 60 to be conveyed.

Here, when the transported material 60 having water repellency is used, as shown in FIG. 15A, the ink layer 63 formed in the concave groove 62 of the transported material 60 having water repellency. When the transported material 60 having a uniform film thickness but no water repellency is used, as shown in FIG. 15B, the ink surface of the portion in contact with the partition wall 61 runs along the partition wall 61 due to surface tension. And the ink layer 63 after being dried is made to have an uneven thickness.

Next, in the second embodiment, the conveyed material 60 having the ink layer formed by the drying section 40 and conveyed to the transfer section 70 is conveyed to the drying section 40 at the same timing. 100, the ink layer is the sheet 10
By overlapping and pressing so as to face the 0 side, the ink layer on the transported material 60 is continuously transferred onto the sheet 100. As the transfer unit 70, a roll-type transfer device including a transfer roll 71 and a pressure roll 72 arranged so as to face the transfer roll 71 can be used. Transfer pressure is about 10 kg / cm ² , transfer roll temperature is about 140 ° C.
Is.

FIG. 16 is a diagram showing a transfer process in which the ink layer on the material to be conveyed is transferred onto the sheet, and FIG. 17 is a diagram showing a state in which the ink layer is transferred onto the sheet.

The material to be conveyed 60 (see) having the ink layer 63 formed on the surface is conveyed to the transfer portion 70 shown in FIG. 15, and the sheet 100 is moved from the direction of arrow B at the same timing as the material to be conveyed 60. The ink layer 63 is conveyed to the transfer unit 70, and as shown in FIG.
The conveyed material 60 and the sheet 100 are superposed so as to face the 0 side and are pressed by the pressure roll 72.

Thus, as shown in FIG. 17, the sheet 1
The ink layer 63 is transferred onto the ink.

As the sheet 100, a resin sheet, a glass substrate or the like is used.

As described above, a pattern sheet having a desired pattern formed on its surface can be obtained.

Next, a third embodiment of the present invention will be described.

The third embodiment corresponds to a modification of the second pattern sheet manufacturing method of the present invention and the second pattern sheet manufacturing apparatus of the present invention.

In the method of manufacturing a pattern sheet according to the third embodiment, at least the height of the partition wall on the material to be transported having the partition wall formed and transported between the ink layer forming step and the transfer step is set. It is configured to have a partition wall reduction step of reducing. Further, the pattern sheet manufacturing apparatus of the third embodiment is configured to include a partition wall reduction portion that reduces at least the height of the partition wall formed on the substrate between the drying portion and the transfer portion. .

FIG. 18 is a diagram showing a partition wall reducing step in the third embodiment of the present invention, and FIG. 19 is a diagram showing a substrate after the partition wall reducing step in the third embodiment of the present invention.

As the partition wall reducing portion, a press is used in this embodiment. As shown in FIG. 18, the partition wall 61 on the transported material 60 is crushed by the press 80, and the height of the partition wall 61 is reduced as shown in FIG. By doing so, it is possible to improve the transfer efficiency of the ink layer 62 to the transparent sheet in the next transfer step.

As the partition wall reducing step, a step of crushing the partition wall, a step of scraping the partition wall, a step of deleting the partition wall,
Alternatively, any of the steps of dissolving the partition walls may be used.

[0121]

As described above, according to the first method and apparatus for manufacturing a patterned sheet of the present invention, a plurality of partition walls extending in the transport direction are continuously formed on the surface of a substrate made of a web or a sheet. By using a coating die having a plurality of nozzles for ejecting ink, the ink is injected into the plurality of concave grooves formed between the partition walls, and the ink injected into the concave grooves is dried or cured. Since the ink layer is formed, it is possible to realize a pattern sheet manufacturing method and a manufacturing apparatus capable of continuously manufacturing a pattern sheet at low cost without being greatly affected by ink.

Further, according to the second pattern sheet manufacturing method and manufacturing apparatus of the present invention, the material to be conveyed on which the ink layer has been formed as described above is transferred to the conveyed sheet, and the ink layer is formed on the sheet. By overlapping and pressing to face the side, the ink layer on the material to be transported is transferred onto the sheet, so a pattern sheet can be continuously manufactured at low cost without being restricted by ink. A sheet manufacturing method and a sheet manufacturing apparatus can be realized.

[Brief description of drawings]

FIG. 1 is a schematic configuration diagram of a pattern sheet manufacturing apparatus according to a first embodiment of the present invention.

FIG. 2 is a side view of a pattern roll used in the pattern sheet manufacturing apparatus shown in FIG.

FIG. 3 is a cross-sectional view of a sheet in which partition walls are formed by the partition wall forming process of the first embodiment.

FIG. 4 is a cross-sectional view of a partition wall and a concave groove formed on the surface of the sheet.

FIG. 5 is a diagram showing an ink layer formed on a sheet surface by an ink layer forming step.

FIG. 6 is a diagram showing an example of a coating die used in the present embodiment.

FIG. 7 is a diagram showing another example of the coating die used in the present embodiment.

FIG. 8 is a diagram showing an ink application unit when the coating die shown in FIG. 7 is incorporated in the pattern sheet manufacturing apparatus of the present invention.

FIG. 9 is a side view (a), a bottom view (b), and a sectional view (c) of a coating die used in this embodiment.

FIG. 10 is a diagram showing dimensions of a nozzle of a coating die used in this embodiment.

FIG. 11 is a layout view of a coating die used in this embodiment.

FIG. 12 is a schematic configuration diagram of a pattern sheet manufacturing apparatus of a second embodiment.

FIG. 13 is a cross-sectional view of a material to be conveyed having a partition wall formed on the surface thereof in the partition wall forming step of the second embodiment.

FIG. 14 is a cross-sectional view of a partition wall and a concave groove formed on the surface of a material to be conveyed.

FIG. 15 is a diagram showing an ink layer formed on the surface of a material to be conveyed.

FIG. 16 is a diagram showing a transfer step in which an ink layer on a material to be conveyed is transferred onto a sheet.

FIG. 17 is a diagram showing a state in which an ink layer is transferred onto a sheet.

FIG. 18 is a diagram showing a partition wall reducing step according to the third embodiment of the present invention.

FIG. 19 is a diagram showing a material to be conveyed after a partition wall reducing step in the third embodiment of the present invention.

FIG. 20 is a diagram showing an example of a conventional pattern sheet manufacturing method.

FIG. 21 is a diagram showing another example of a conventional method of manufacturing a pattern sheet.

[Explanation of symbols]

1, 2 pattern sheet manufacturing apparatus 10 delivery roll 20 partition wall forming part 21 pattern roll 21a convex ridge 21b concave groove 22 backup roll 30, 30 'ink applying part 31 roll 32, 32', 32R, 32G, 32B coating die 32a, 32a_1 , 32a_2, 32a_3 Nozzle 32b Ink pocket 32c Die blocks 33, 33R, 33G, 33B Ink 40 Drying part 50 Winding roll 60 Conveying material 61 Partition wall 62 Groove 63 Ink layer 70 Transfer part 71 Transfer roll 72 Pressure roll 80 Press 91 Transparent Substrate 92 Coating Die 93 Ink 94 Ink Layer 95 Lip Tip 96 Nozzle 97 Paint Ejection Hole Array 98 Paint Supply Channel 99 Ink Coating Device 100 Sheet 101 Partition 102 Groove 103 Ink Layer

Continued front page    (72) Inventor Tadahiro Kigazawa             200, Onakazato, Fujinomiya City, Shizuoka Prefecture Fuji Photo             Within Film Co., Ltd. (72) Inventor Ryuichi Katsumoto             200, Onakazato, Fujinomiya City, Shizuoka Prefecture Fuji Photo             Within Film Co., Ltd. F-term (reference) 2H048 BA02 BA11 BA55 BA64 BB02                       BB41 BB42                 4D075 AC06 AC07 AC41 AC72 AC80                       AC93 AC95 BB24Z BB26Z                       CA35 DA03 DA04 DA06 DB01                       DB13 DB31 DB39 DB54 DC24                       EA07 EA33                 4F041 AA11 AA12 AB02 BA12 BA13                       BA36 CA02 CA03

Claims (12)

[Claims] 1. A partition wall forming step of forming a plurality of partition walls extending in a transport direction on a surface of a substrate made of a web or sheet to be transported, and a space between the partition walls by a coating die having a plurality of nozzles for ejecting ink. An ink layer forming step of forming an ink layer by injecting ink into the plurality of concave grooves formed in the groove and drying or curing the ink injected into the concave grooves. . 2. A partition wall forming step of forming a plurality of partition walls extending in the transport direction on a surface of a material to be transported, which is composed of a web or a sheet to be transported, and a plurality of concave grooves formed between the partition walls. An ink layer forming step of forming an ink layer by injecting ink with a coating die having a plurality of nozzles for ejecting, and drying or curing the ink injected into the groove; Transfer that transfers the ink layer on the material to be conveyed onto the substrate by pressing the material to be conveyed onto a substrate made of a web or sheet so that the ink layer faces the substrate. A method for manufacturing a pattern sheet, comprising: 3. The ink layer forming step comprises injecting a plurality of colors of ink into a groove formed between the partition walls,
The method for producing a pattern sheet according to claim 1, which is a step of forming ink layers of a plurality of colors by drying or curing the injected ink. 4. Between the ink layer forming step and the transfer step, the partition on the material to be conveyed on which the partition is formed,
The method for manufacturing a pattern sheet according to claim 2, further comprising a partition wall reduction step of reducing at least the height of the partition wall. 5. A partition wall forming section for forming a plurality of partition walls extending in the transport direction on a surface of a substrate composed of a web or a sheet transported in a predetermined direction, and a coating die having a plurality of nozzles for ejecting ink. An ink application part for injecting ink from a plurality of nozzles of the coating die into a plurality of concave grooves formed between the partition walls, and an ink layer is formed by drying or curing the ink on the surface of the substrate. A patterned sheet manufacturing apparatus, comprising: an ink layer forming unit. 6. A coating die having a partition wall forming portion for forming a plurality of partition walls extending in the transport direction and a coating die having a plurality of nozzles for ejecting ink on a surface of a material to be transported, which is composed of a web or a sheet transported in a predetermined direction. An ink application section for injecting ink from a plurality of nozzles of the coating die into a plurality of concave grooves formed between the partition walls; and an ink by drying or curing the ink on the surface of the material to be transported. The ink layer forming portion for forming a layer and the material to be conveyed on which the ink layer is formed are superimposed and pressed on a substrate made of a web or sheet to be conveyed so that the ink layer faces the substrate side. Accordingly, the pattern sheet manufacturing apparatus is provided with a transfer unit for transferring the ink layer on the material to be conveyed onto the substrate. 7. The ink applying section includes a coating die having a plurality of nozzles for ejecting a plurality of colors of ink, and the coating die fills the concave grooves with inks of different colors. The pattern sheet manufacturing apparatus according to claim 6. 8. The partition wall reducing portion for reducing at least the height of the partition wall formed on the material to be transported is provided between the ink layer forming portion and the transfer portion. The described patterned sheet manufacturing apparatus. 9. The coating die has a plurality of nozzles satisfying a relationship of 0.2 × W <A <0.8 × W, where A is a diameter of the nozzle and W is a width of the groove. The pattern sheet manufacturing apparatus according to claim 5, 6, or 7, which is a thing. 10. The coating die has a plurality of nozzles satisfying a relationship of 5 × A <B <100 × A, where A is a diameter of the nozzle and B is a length of the nozzle. The pattern sheet manufacturing apparatus according to claim 5, 6, or 7. 11. The pattern sheet manufacturing apparatus according to claim 5, wherein the coating die has a plurality of nozzles for ejecting ink downward from a horizontal plane. 12. The coating die has a gap of 0.5 mm between the tip end portions of the plurality of nozzles and the surface of the coating material to which ink is applied by the coating die.
The pattern sheet manufacturing apparatus according to claim 5, 6, or 7, wherein the pattern sheet manufacturing apparatus is arranged at the following position.