JP2008018649A - Manufacturing method for sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a sheet which can be employed for avoiding a problem of flaws of a metal thin film due to the contact with a mechanical part during cleaning, which has been a problem in a conventional cleaning method. <P>SOLUTION: In the manufacturing method for a sheet, a water-soluble coating film is formed on a substrate sheet, and the soluble coating film is removed by water washing a laminated sheet having the metal thin film formed thereon. The product (WT) of an amount of water used W (ml/(min×cm<SP>2</SP>)) per unit area of the substrate sheet and per unit of time, and a water washing time T (min) is 0.02 (ml/cm<SP>2</SP>) or more, and the amount of water used W (ml/(min×cm<SP>2</SP>)) per unit area of the substrate sheet and per unit of time is 5 ml/(min×cm<SP>2</SP>) or more, and 100 ml/(min×cm<SP>2</SP>) or less, and the sheet after being water washed partially has the metal thin film. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a sheet, and more specifically, a water-soluble coating film is formed on a base sheet, and a laminated sheet on which a metal thin film is formed is washed with water to form a water-soluble coating film. The present invention relates to a method for manufacturing a sheet to be removed.

  A metallic luster is applied to the surface to give an excellent beauty to home appliances such as TV, audio, and video, information communication equipment such as mobile phones and personal information terminals, and information communication equipment in automobiles. This has been done conventionally.

  For this purpose, a method of forming a metal thin film by a vacuum deposition method on a transfer material and transferring it to a substrate that requires a beautiful feeling has been performed. It has been proposed to use an insulating metal thin film such as Sn or Pb (see Patent Documents 1 and 2).

  On the other hand, for the purpose of design diversity, there is a disclosure of a patterned metal deposition film having a partially metallic luster, a coating layer having a desired pattern is provided by a water-soluble paint, and a metal deposition layer is formed on the entire surface of the film. And a method for dissolving and removing the metal vapor deposition layer and the coating layer on the coating layer by washing with water (see Patent Document 3).

When the above method is applied to an insulating metal thin film, the insulating metal thin film is scratched and a beautiful metallic luster cannot be obtained. Attempts have been made to protect the surface of the insulating metal thin film with a water-insoluble paint and to prevent scratches by applying the paint and washing it (see Patent Document 4). Furthermore, in order to improve the poor productivity of the washing process and the unclearness of the water-soluble coating pattern, it has been proposed to use a coating soluble in a specific organic solvent instead of the water-soluble coating. (See Patent Document 5).
Japanese Patent Publication No. 3-25353 (Claims) Japanese Patent Laid-Open No. 10-324093 (Claims) JP 49-24255 A (Claims) Japanese Patent Publication No. 7-37111 (Claims) JP-A-61-270186 (Claims)

  In the manufacturing method of the sheet | seat which has these insulating metal thin films partially, there exists a request | requirement of desiring to omit the process of apply | coating a water-insoluble coating material to the surface of an insulating metal thin film.

  In addition, the water-free coating applied on the entire surface serves as a shielding layer for water penetration into the water-soluble paint, and a longer contact time with water for dissolving the water-soluble coating is necessary. As a result, burrs are likely to occur, and it has been common to remove burrs by using auxiliary means such as buffing, brushing, and ultrasonic.

  The present invention avoids the problem of scratches on the metal thin film due to contact with the machine part being cleaned, which has been a problem in the conventional cleaning method, without applying a water-insoluble paint to the metal thin film, and removes a beautiful metal thin film part. The manufacturing method of the sheet | seat which has is presented.

  In order to solve this problem, the present invention has the following configuration.

That is, a sheet manufacturing method in which a water-soluble coating film is formed on a base sheet, and a laminated sheet on which a metal thin film is formed is washed with water to remove the water-soluble coating film. The product (WT) of the amount of water used per unit time W (ml / (min · cm ² )) and the time T (min) of water washing is 0.02 (ml / cm ² ) or more. The amount of water used per sheet unit area per unit time W (ml / (min · cm ² )) is 5 ml / (min · cm ² ) or more and 100 ml / (min · cm ² ) or less, and the sheet after washing with water Is a method for producing a sheet which is a sheet partially having a metal thin film.

In addition, the present invention is preferably the above-described sheet manufacturing method, wherein water droplets remaining on the base sheet after washing with water are blown off with high-pressure air and then dried.
Furthermore, in the present invention, preferably, the metal thin film is an insulating metal thin film made of one or two selected from the group consisting of Sn, In, Sb, Zn, Pb and Bi, Is a metal thin film transfer material in which at least one release layer is formed.

  According to the present invention, the step of applying a water-insoluble paint to a metal thin film can be omitted, and the amount of water required for water washing is reduced by washing directly without applying a water-insoluble paint. It is possible to suppress the occurrence of scratches on the metal thin film. According to the present invention, unnecessary portions of the metal thin film can be efficiently removed with a small amount of water without causing defects such as scratches on the metal thin film.

  In the present invention, preferably, when the metal thin film is an insulating metal thin film made of Sn, In, Sb, Zn, or the like, the insulating metal thin film has a fine island-like structure so that the in-plane bonding force is low. Although it is weak and very easily damaged, it is possible to suppress the generation of scratches, and it is possible to easily obtain a sheet partially having a metal thin film with a beautiful metal part even after washing with water.

The present invention is a sheet manufacturing method in which a water-soluble coating film is formed on a base sheet, and a laminated sheet on which a metal thin film is formed is washed with water to remove the water-soluble coating film. The product (WT) of the amount of water used per sheet unit area W (ml / (min · cm ² )) and the washing time T (min) is 0.02 (ml / cm ² ) or more, The amount W (ml / (min · cm ² )) of water used per unit time per unit area of the base sheet is 5 ml / (min · cm ² ) or more and 100 ml / (min · cm ² ) or less, after washing with water Is a sheet manufacturing method in which the sheet is a sheet partially having a metal thin film.

  In the present invention, the base sheet is not particularly limited, and films and sheets made of polyester resin, polyolefin resin, polycarbonate resin, polyamide resin, acrylic resin, polyvinyl chloride resin, and the like are used. The base sheet may be an unstretched sheet or a stretched film, but in applications that are used for in-mold molding as a metal thin film transfer material, a polyester resin blended with a copolymer component is stretched. A film is preferably used.

  When the base sheet is designed as a metal thin film transfer material, preferably, at least one release layer is formed, and if necessary, a protective resin layer, a metal thin film layer, and an adhesive layer are formed thereon. Are formed into a metal thin film transfer material.

  On this base material sheet, a water-soluble coating film is applied as a target pattern. That is, the water-soluble coating film is not applied to the portion where the metal thin film remains, and the water-soluble coating film is applied to the portion where the metal thin film is removed. The water-soluble coating film is preferably partially formed on the substrate sheet.

  In the present invention, as the water-soluble coating agent, polyvinyl alcohol, ethylene-vinyl alcohol, polyethylene glycol, polyethylene oxide, starch, casein, glue, gelatin, polyacrylamide, hydroxyethyl cellulose, polyvinyl pyrrolidone, polyvinyl methyl ether, vinyl methyl ether Examples thereof include maleic anhydride copolymers, acrylic acid esters, methacrylic acid esters and the like as main components. These coating agents are dissolved in water and printed in a desired pattern by a method such as gravure printing or silk screen printing. In order to improve solubility in water, particles such as silica, alumina, titanium oxide, calcium carbonate, and barium sulfate may be mixed in an amount of 5 to 30 wt% with respect to the solid content of the water coating material. The thickness of the water-soluble coating film is preferably selected from about 0.2 to 2 μm. If the thickness of the water-soluble coating film is less than 0.2 μm, patterning tends to be unclear due to printing blur, and if the thickness is 2 μm or more, the level difference of the film tends to be large. About 2 μm is selected as the upper limit.

  A water-soluble coating film is formed on the base sheet as described above, and a metal thin film is formed thereon. The metal thin film is preferably formed on the entire surface of the water-soluble coating film.

  As a method for forming the metal thin film, general vacuum deposition, sputtering, ion plating, chemical vapor deposition, or the like can be used, but vacuum deposition is more preferably used from the viewpoint of productivity. The thickness of these metal thin film layers is preferably about 10 to 100 nm in order to obtain a beautiful metallic luster, and the thickness is appropriately selected according to the metal species and purpose. The light transmittance of the metal thin film is preferably selected in the range of 1% or more and less than 10% according to the purpose.

  In the present invention, the metal thin film is preferably an insulating metal thin film made of one or two selected from the group consisting of Sn, In, Sb, Zn, Pb, and Bi.

By making the metal thin film layer a metal selected from the group consisting of Sn, In, Sb, Zn, Pb and Bi, the metal thin film can be made insulative, and this sheet can be used as a metal thin film transfer foil, for example, as an electronic device. When used as a part of the housing, it is possible to prevent the phenomenon that the electronic device is destroyed by receiving a spark from the high-voltage part of the internal electronic device, and it is also possible to communicate between the inside and outside of the housing by passing radio waves A function of not causing trouble can be provided. The surface resistance value of the metal thin film for this purpose is preferably 10 ⁵ Ω / □ or more, more preferably 10 ¹⁰ Ω / □ or more.

  In the present invention, the water-soluble coating film is then removed by washing with water. By removing the water-soluble coating film by washing with water, the metal thin film is removed together with the water-soluble coating film, and a sheet in which a portion of the metal thin film not forming the water-soluble coating film is left is manufactured. When the water-soluble coating film is removed by washing with water, the water-soluble coating film is preferably dissolved and removed.

  The condition for removing the water-soluble coating film by washing with water is an important requirement of the present invention.

That is, the product (WT) of the amount W (ml / (min · cm ² )) of water used per unit area per unit time of the base sheet and the time T (min) of water washing is 0.02 (ml / cm ² ). The amount of water used per unit sheet unit area W (ml / (min · cm ² )) is 5 ml / (min · cm ² ) or more and 100 ml / (min · cm ² ) or less. is there.

The amount W (ml / min / cm ² ) of water used per unit time per unit area of the base sheet is 5 ml / (min · cm ² ) or more and 100 ml / (min · cm ² ) or less. If W is less than 5 ml / (min · cm ² ), removal of the water-soluble coating film is insufficient. When W is larger than 100 ml / (min · cm ² ), the momentum of water is too strong, and a necessary metal thin film portion is peeled off to inhibit a beautiful metallic luster. The amount W (ml / min / cm ² ) of water used per unit area of the substrate sheet is preferably 10 (ml / (min · cm ² )) <W <50 (ml / (min · cm ^2). )).

Furthermore, when the washing time is T (minutes), the product (WT) of the amount of water used W (ml / (min · cm ² )) per unit time of the base sheet unit area and the washing time T (min) ) Must satisfy 0.02 (ml / cm ² ) or more. If the WT is less than 0.02, the cleaning is insufficient. There is no particular upper limit for WT, but if WT is too large, the amount of water to be used becomes enormous and a heavy load may be applied to the wastewater treatment facility, so WT <1 is preferable.

The water is preferably mist. By making the water into a mist rather than a high-pressure spray or shower, water can be uniformly incident on the surface with a constant striking force (N / cm ² ), and the water-soluble coating film can be efficiently dissolved. it can. As a method for generating mist, a so-called two-fluid nozzle method in which water and air are mixed and blown out is common, but other methods may be used.

  The diameter of the mist is preferably in the range of 20 to 500 μm, and if it is 20 μm or less, the dissolving ability may be low, and if it is 500 μm or more, the amount of water required for the treatment may be excessive.

The mist hitting force is preferably in the range of 0.02 to 0.5 N / cm ² . If it is 0.02 N / cm ² or less, the dissolving and cleaning ability may be low, and if it is 0.5 N / cm ² or more, the momentum is too strong, and in some cases, the necessary metal thin film part is peeled off. In addition, the metal thin film transfer sheet is not preferable because it may be peeled off from the release layer.

  In the present invention, when the substrate sheet is continuously washed with water in the longitudinal direction, the substrate is wet with water during the process from washing to drying, and the metal thin film surface is in contact with the mechanical part. Preferably there is no contact. In the conventional method, when a washing bath is used, in order to immerse the sheet in water for a long time, the film path is folded in a zigzag manner through the roll. As a result, there is a problem that the film and the roll are slippery, and the metal surface is damaged due to the peripheral speed difference from the roll contacting the metal thin film surface. In the prior art, since the water-insoluble paint is provided on the metal thin film, the penetration of water is hindered, so that the cleaning surface is rubbed with a sponge or buff to enhance the cleaning effect.

  In the present invention, it is preferable that the metal thin film surface is not in contact with the mechanical part in the wet state, and a beautiful sheet can be obtained without causing scratches on the metal thin film surface, and more preferable.

  According to the present invention, it is preferable that the water droplets remaining on the base sheet after washing with water be blown off by high-pressure air and then dried. If it is dried with water droplets on it, it may stain and impair the metallic luster, and the heat load for drying will increase. As the high-pressure air, a method is generally used in which air is blown out from a slit-like outlet in a sheet shape to drain water. It is more preferable that the water droplets be blown off simultaneously on both sides of the sheet in order to prevent the water droplets from entering the back surface.

  In this invention, the sheet | seat after water washing is a sheet | seat which has a metal thin film partially. In the present invention, unnecessary portions of the metal thin film can be efficiently removed with a small amount of water without causing defects such as scratches on the metal thin film.

  In the present invention, it is preferable that the base sheet is a metal thin film transfer material in which at least one release layer is formed. As a release layer. Phospholipid (lecithin), cellulose acetate, wax, fatty acid, fatty acid amide, fatty acid ester, rosin, acrylic resin, silicone, fluororesin, and the like are appropriately selected and used depending on the degree of ease of peeling. These release layers are preferably used in a thickness of 0.01 to 2 μm, and more preferably in a thickness of 0.5 to 1 μm.

  In the present invention, a protective resin layer is provided on the release layer as needed to protect the metal thin film layer after transfer. As the resin for the protective resin layer, a thermosetting resin, a thermoplastic resin, or a photo-curing resin such as an ultraviolet ray having good adhesiveness is used for both the release layer and the metal thin film layer. Specifically, the protective resin layer can be appropriately selected depending on the type of vapor deposition metal and various performances required for the application (mechanical characteristics, heat resistance, solvent resistance, optical characteristics, weather resistance, etc.), for example, One type or two or more types selected from acrylic resins, melamine resins, urethane resins, epoxy resins, alkyd resins, cellulosics, polyvinyl chlorides, and the like can be used. In general, the thickness is preferably about 0.2 to 5 μm, more preferably 1 to 3 μm. These resins are preferably those having good transparency, but can also be colored by adding dyes, pigments or matting agents. Further, an iris color or a hologram effect can be imparted by performing hologram processing on the surface of the protective resin layer.

  The sheet manufactured by the sheet manufacturing method of the present invention is suitably used as a metal thin film transfer material.

  When used as a metal thin film transfer material, an adhesive layer for adhering to the resin molding may be applied after washing with water. As the adhesive layer, for example, a resin adhesive having good adhesiveness can be used for both the metal thin film layer and the resin molded body to be transferred. Adhesive layers include, for example, acrylic ester, polyester, synthetic rubber, epoxy, polyurethane, ethylene-vinyl acetate, polyamide, polyvinyl chloride, halogenated polyolefin, nitrocellulose and copolymers thereof. Can generally be used. Depending on the application of the metal thin film transfer material, various known adhesives or hot melt sheets that can be bonded by heating can be used. As the hot melt sheet, those of polyurethane, polyamide and polyvinyl chloride are preferably used. The thickness of the adhesive layer is preferably in the range of 2 to 100 μm, more preferably 5 to 30 μm in the case of an adhesive, and preferably 20 to 200 μm, more preferably 50 to 100 μm in the case of a hot melt sheet. Each is chosen.

  The sheet manufactured by the sheet manufacturing method of the present invention is excellent in housings for home appliances such as televisions, audios and videos, information communication devices such as mobile phones and personal information terminals, and information communication devices in automobiles. It is preferably used for giving a beautiful feeling. In particular, the sheet metal thin film manufactured by the sheet manufacturing method of the present invention is preferably used for a housing of home appliances and information communication devices, and the sheet metal thin film manufactured by the sheet manufacturing method of the present invention is It is preferably used as a sheet for a metal thin film transfer material.

  The embodiment of the present invention will be specifically described with reference to examples, but the present invention is not limited thereto.

  Below, the evaluation method used for evaluation of this invention is demonstrated.

(1) Use amount W of water per unit time of sheet unit area (ml / min / cm ² )
Receiving a reagent bottle with a known diameter of the opening at the mouth of the base sheet at the position of the water washing at a right angle, dividing the amount of water accumulated in 1 minute (ml) by the area of the opening (cm ² ) , W was determined.

(2) Time T (minute) exposed to water incidence
The passage time of the film was calculated from the line speed of the film and the width in the longitudinal direction of the film where the mist was sprayed.

(3) WT (ml / cm ² )
The WT was calculated by multiplying the above W and T.

(4) State of missing metal thin film The quality was judged visually.

(5) Scratch state of the metal thin film The state of the scratch was visually confirmed, and the quality was judged.

(Example 1)
A release layer (cellulose acetate resin, thickness 0.5 μm) was applied to a biaxially stretched polyethylene terephthalate film having a thickness of 25 μm and a width of 500 mm using a gravure coater and dried. Next, a toluene solution containing methacrylic acid, 2-hydroxyethyl methacrylate, n-butyl methacrylate, and melamine resin was applied on the release layer, dried and cured with the coater, and the thickness was 1 μm. A protective resin layer was obtained. Subsequently, a water-soluble resin layer of polyvinyl alcohol was pattern-printed with a thickness of 0.5 μm on the upper surface of the protective resin layer by a gravure printing method.

Next, Sn metal vapor deposition was performed using a semi-continuous winding type vacuum vapor deposition apparatus under the conditions of vacuum degree: 2 × 10 ⁻⁴ Torr, cooling can temperature: −10 ° C., and total light transmittance of 5%. The Sn vapor deposition sheet was obtained.

  In the continuous processing apparatus having the roll arrangement shown in FIG. 1, the film is sprayed from two sets of two fluid nozzles arranged 11 at 50 mm intervals, the distance between the nozzles is 5 cm, and mist is sprayed onto the metal thin film deposition surface. The water was drained by spraying, dried in an oven and wound up. The sheet speed was 10 m / min.

The water pressure at this time is 0.13 MPa, the air pressure is 0.12 MPa, the area of the portion where the mist enters is 50 (sheet width) × 2 = 100 cm ² per set, W is 25, WT Was 0.10.

  The state of the Sn thin film being removed was visually checked, and it was confirmed that there was no scratch and that the Sn thin film was in an excellent state.

(Example 2)
The same Sn vapor deposition sheet as in Example 1 was used, and the water washing treatment was performed at a water pressure of 0.25 MPa, an air pressure of 0.2 MPa, and a line speed of 20 m / min. W was 60 and WT was 0.12.

  The state of the Sn thin film being removed was visually checked, and it was confirmed that there was no scratch and that the Sn thin film was in an excellent state.

(Comparative Example 1)
The same Sn vapor deposition sheet as in Example 1 was used, and the water washing treatment was performed at a water pressure of 0.03 MPa, an air pressure of 0.05 MPa, and a line speed of 10 m / min. W was 3.5 and WT was 0.015. The state of missing of the Sn thin film was visually checked. There was much omission and the pattern was not good.

(Comparative Example 2)
The same Sn vapor deposition sheet as in Example 1 was used, and the water washing treatment was performed at a water pressure of 0.5 MPa, an air pressure of 0.4 MPa, and a line speed of 10 m / min. W was 130 and WT was 0.5. Peeling occurred from the release layer, and the product became unusable.

(Comparative Example 3)
The same Sn vapor deposition sheet as in Example 1 was used, the water pressure was 0.13 MPa, the air pressure was 0.12 MPa, and the line speed was 100 m / min. W was 25 and WT was 0.01. The state of missing of the Sn thin film was visually checked. There was much omission and the pattern was not good.

An example of the apparatus which injects water into a base material sheet in the shape of a mist and wash | cleans is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base sheet 2 Fog generating nozzle 3 Fog 4 Water 5 Compressed air 6 Pressure gauge 7 Pressure gauge 8 Waste liquid pan 9 Air nozzle 10 Compressed air 11 To drying oven

Claims (4)

A method for producing a sheet in which a water-soluble coating film is formed on a base sheet, and a laminated sheet on which a metal thin film is formed is washed with water to remove the water-soluble coating film. The product (WT) of the amount of water used per hour W (ml / (min · cm ² )) and the washing time T (min) is 0.02 (ml / cm ² ) or more, and is a base sheet unit The amount of water used per unit time W (ml / (min · cm ² )) is 5 ml / (min · cm ² ) or more and 100 ml / (min · cm ² ) or less. The manufacturing method of the sheet | seat which is a sheet | seat which has a metal thin film partially.   The method for producing a sheet according to claim 1, wherein water droplets remaining on the base sheet after washing with water are blown off by high-pressure air and then dried.   The metal thin film is an insulating metal thin film made of one or two selected from the group consisting of Sn, In, Sb, Zn, Pb and Bi, and at least one release layer is formed on the base sheet. 3. The sheet manufacturing method according to claim 1, wherein the sheet is a metal thin film transfer material.   The manufacturing method of the sheet | seat for metal thin film transfer materials in which the metal thin film of Claim 1 to 3 is used for the housing | casing of household appliances and information communication equipment.

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