JP2009233957A - Method for manufacturing release paper and apparatus for manufacturing release paper - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing, with high production efficiency, release paper transferring a pattern having excellent contrast. <P>SOLUTION: The method for manufacturing release paper 10 by forming an irregular pattern 12 on a rolled web 20 comprises steps of: roughening a surface 20a of the rolled web by spray-coating the surface of the rolled web with a resin 15; and forming the irregular pattern on the roughened surface of the rolled web by embossing. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a production method for producing a release paper by forming a concavo-convex pattern on an original fabric, and more particularly to a production method for producing a release paper capable of transferring a pattern having excellent contrast. The present invention also relates to a manufacturing apparatus for manufacturing a release paper by forming a concavo-convex pattern on an original fabric, and particularly to a manufacturing apparatus for manufacturing a release paper capable of transferring a pattern having excellent contrast.

Sheet-like materials used for synthetic leather products, decorative sheets, interior materials and the like can be manufactured by transferring a concavo-convex pattern formed on a release paper using the release paper as a pattern paper. The release paper can be generally produced by embossing an original fabric (for example, Patent Document 1).
JP 2002-205311 A

  By the way, when producing release paper by embossing, since a big pressure is easy to be applied during embossing, the recessed part of release paper can be formed accurately. On the other hand, since the processing pressure tends to be relatively small, it is difficult to accurately form the convex portion of the release paper. Therefore, there is a limit to increasing the gap between the concave portion and the convex portion on the release paper. As a result, there arises a problem that the contrast (brightness difference) of the sheet-like material produced using the release paper is not sufficient, that is, the pattern of the sheet-like material is flattened and visually recognized.

  Also, by increasing the processing pressure, the gap between the concave and convex portions on the release paper can be somewhat increased. However, when the processing pressure is increased, the production efficiency is deteriorated, and the load on the processing apparatus and the raw material is also increased.

  The present invention has been made in consideration of such points, and is a manufacturing method for manufacturing a release paper by forming a concavo-convex pattern on an original fabric, and is a release paper that can transfer a pattern having excellent contrast An object of the present invention is to provide a production method capable of producing a product with high production efficiency. Furthermore, the present invention is an apparatus for manufacturing a release paper for transferring a concavo-convex pattern to a raw fabric, and an apparatus for manufacturing a release paper capable of manufacturing a release paper capable of transferring a pattern having excellent contrast with high production efficiency. The purpose is to provide.

  By the way, in recent years, in order to manufacture a release paper (typically, a release paper that can withstand severe use conditions) according to a special application, a base material, a resin layer bonded on the base material, An original fabric having s may be used. Such an original fabric is usually produced by coating a resin on a substrate, and the resin layer becomes glossy. And when a sheet-like material is produced with the release paper obtained using such an original fabric, the above-mentioned problem that the contrast of the sheet-like material is insufficient tends to appear remarkably. It would be advantageous if a release paper capable of transferring a pattern having excellent contrast could be manufactured from such an original fabric by the release paper manufacturing method and the release paper manufacturing apparatus according to the present invention.

  A method for producing a release paper according to the present invention is a method for producing a release paper by forming a concavo-convex pattern on the original fabric, and the surface of the original fabric is roughened by spray coating a resin on the original fabric. And a step of forming the concavo-convex pattern on the roughened surface of the raw material by embossing.

  In the release paper manufacturing method according to the present invention, the roughening step may include a step of spraying a resin on the original fabric and a step of drying the resin sprayed on the original fabric.

  In the roughening step of the release paper manufacturing method according to the present invention, the resin to be spray-coated may be sprayed on the original fabric at a spraying distance of 20 cm or more.

  Further, in the release paper manufacturing method according to the present invention, the original fabric has a base material and a synthetic resin layer laminated on the base material, and the surface of the synthetic resin layer side is roughened. You may do it.

  Furthermore, the method for producing a release paper according to the present invention further includes a step of producing the original fabric, and the step of producing the original fabric comprises a resin that forms the synthetic resin layer on one surface of the base material. You may make it have the process of coating on the top, and drying the resin coated on the said base material, and forming the said synthetic resin layer on the said base material.

  Furthermore, in the release paper manufacturing method according to the present invention, the resin spray-coated on the original fabric may be the same as the resin forming the synthetic resin layer.

  Further, in the roughening step of the release paper manufacturing method according to the present invention, the glossiness value on the roughened surface of the original fabric is the glossiness on the surface of the embossing mold used in embossing. The resin may be spray coated so as to be smaller than the value.

  Further, in the roughening step of the release paper manufacturing method according to the present invention, the resin may be spray-coated so that the glossiness on the roughened surface of the raw material is 4 or more and 8 or less. Good. In the roughening step of the method for producing a release paper according to the present invention, the average length Sm on the roughened surface of the original fabric is 30 μm or more and 80 μm or less, and the roughened surface of the original fabric The resin may be spray-coated so that the ten-point average roughness Rz at 5 to 20 μm.

  Furthermore, in the roughening step of the release paper manufacturing method according to the present invention, a region of the surface of the original fabric where the uneven pattern is to be formed may be roughened.

  Furthermore, in the step of forming the concavo-convex pattern of the method for producing a release paper according to the present invention, the concavo-convex pattern is maintained while maintaining the surface of the original fabric that is positioned on the convex portion of the concavo-convex pattern in a roughened state. The roughened surface of the original fabric that comes to be located in the concave portion of the substrate may be smoothed.

  The release paper manufacturing apparatus according to the present invention is a manufacturing apparatus for manufacturing a release paper by forming a concavo-convex pattern on a raw fabric, and spraying a resin on the raw fabric to roughen the surface of the raw fabric It is provided with the coating apparatus and the embossing apparatus which is arrange | positioned in the downstream of the said spray coating apparatus, and forms the said uneven | corrugated pattern in the said original fabric.

  In the release paper manufacturing apparatus according to the present invention, the spray coating apparatus may include a spraying device that sprays the resin onto the original fabric, and a drying device that dries the resin sprayed onto the original fabric. Good.

  Moreover, in the release paper manufacturing apparatus according to the present invention, the spray coating apparatus includes a spraying device that is disposed to face the original fabric and that sprays the resin onto the original fabric, and the spraying device includes the spraying device. The blowing outlet for blowing out the resin may be arranged so as to be separated from the original fabric by 20 cm or more.

  Furthermore, the apparatus for producing release paper according to the present invention is arranged on the upstream side of the spray coating apparatus, and a raw fabric production apparatus for producing a raw fabric having a base material and a synthetic resin layer laminated on the base material The raw fabric production apparatus further comprises: a coating apparatus that coats the resin that forms the synthetic resin layer on one surface of the base material; and the resin coated on the base material is dried. You may make it have a drying apparatus which forms the said synthetic resin layer on the said base material.

  Furthermore, in the release paper manufacturing apparatus according to the present invention, the original fabric includes a base material and a synthetic resin layer laminated on the base material, and the spray coating apparatus is configured to combine the original fabric. The spraying device is disposed so as to face the resin layer and sprays the resin onto the synthetic resin layer, and the embossing device is an uneven portion corresponding to the uneven pattern and comes into contact with the synthetic resin layer You may have an embossing type | mold containing an uneven | corrugated | grooved part.

  Furthermore, in the release paper manufacturing apparatus according to the present invention, the original fabric includes a base material and a synthetic resin layer laminated on the base material, and the spraying device is a resin that forms the synthetic resin layer. You may make it spray the same resin on the surface of the said original fabric.

  Furthermore, in the release paper manufacturing apparatus according to the present invention, the embossing device has an embossing die that includes an uneven portion corresponding to the uneven pattern and comes into contact with the original fabric, and the spray coating The apparatus may roughen the surface of the original fabric so that the gloss value of the surface of the original fabric is smaller than the gloss value of the embossed uneven portion.

  Furthermore, in the release paper manufacturing apparatus according to the present invention, the spray coating apparatus spray-coats the resin so that the glossiness on the roughened surface of the raw material is 4 or more and 8 or less. Good. In the release paper manufacturing apparatus according to the present invention, the spray coating apparatus has an average length Sm of 30 μm or more and 80 μm or less on the roughened surface of the original fabric, and the roughened surface of the original fabric. The resin may be spray-coated so that the ten-point average roughness Rz at 5 to 20 μm.

  Further, in the release paper manufacturing apparatus according to the present invention, the spray coating apparatus may roughen a region of the surface of the original fabric where the uneven pattern is formed by the embossing device. Good.

  Further, in the release paper manufacturing apparatus according to the present invention, the embossing device is disposed opposite to the embossing die having an uneven portion corresponding to the uneven pattern and the embossing die. A back-up body that presses against the back, and the convex part of the concavo-convex part of the embossed type gently presses the raw material between the back-up body and gently roughens the surface of the raw material You may make it.

  According to the present invention, a release paper capable of transferring a pattern having excellent contrast can be manufactured with high production efficiency.

BEST MODE FOR CARRYING OUT THE INVENTION

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  1 to 7 are views for explaining an embodiment of a release paper manufacturing method and a release paper manufacturing apparatus according to the present invention. 1 and 2 are perspective views showing a release paper manufacturing apparatus and a release paper manufacturing method, FIG. 3 is a diagram for explaining the release paper manufacturing method, and FIG. 4 shows a rough surface. FIG. 5 is a diagram for explaining a release paper manufacturing method, FIG. 6 is a cross-sectional view showing a release paper, and FIG. 7 is a release paper shown in FIG. It is a figure for demonstrating the effect | action of the sheet-like member produced using as a pattern paper.

  First, the release paper that can be manufactured in the present embodiment will be described mainly with reference to FIG. As shown in FIG. 6, the release paper 10 includes an original fabric 20 in which an uneven pattern 12 having a recess 12b and a protrusion 12a is formed on at least one surface 20a.

  Further, on the convex portion 12 a of the concavo-convex pattern 12, a fine concavo-convex (also referred to as a fine concavo-convex shape) 16 than the concavo-convex pattern 12 is formed. On the other hand, the bottom surface of the recess 12b of the concavo-convex pattern 12 is formed as a flat surface.

  Such release paper 10 is used as a paper pattern for producing a sheet-like member 30 such as vinyl leather or wallpaper. Specifically, the uneven surface side of the release paper 10 is coated with a paint made of a thermosetting resin or the like, and the base fabric 38 is further laminated. Thereafter, the paint is cured to form a paint layer 37 made of paint, and then the release paper 10 is peeled from the paint layer 37 to obtain the sheet-like member 30 having the base cloth 38 and the paint layer 37. be able to. The concavo-convex pattern 12 and the minute concavo-convex shape 16 of the release paper 10 are transferred to the paint layer 37 of the obtained sheet-like member 30, and the design of the sheet-like member 30 is improved by the transferred concavo-convex pattern 32. ing. In addition, the release paper 10 is used repeatedly and the several sheet-like member 30 can be produced.

  In this Embodiment, the release paper 10 functions as a paper pattern for producing the sheet-like member 30 used as a synthetic leather. In this case, the paint layer 37 of the sheet-like member 30 can be formed by, for example, a paint obtained by blending a polyurethane resin with a colorant. Moreover, in this Embodiment, the release paper 10 has the base material 24 which consists of paper etc., and the synthetic resin layer 22 which is laminated | stacked on the base material 24 and consists of a synthetic resin. As shown in FIG. 6, the concavo-convex pattern 12 and the fine concavo-convex shape 16 are formed from the surface of the release paper 10 on the synthetic resin layer 22 side.

  Next, the operation of the release paper 10 having such a configuration will be described.

  As described above, in such a release paper 10, the minute uneven shape 16 is formed on the convex portion 12 a of the uneven pattern 12. Therefore, when this release paper 10 is used as a pattern paper, as shown in FIG. 7, the release paper 10 is separated into the recesses 32b of the pattern 32 of the sheet-like member 30 formed by transferring the projections 12a of the uneven pattern 12 of the release paper 10. A minute unevenness 36 formed by transferring the minute uneven shape 16 of the pattern paper 10 is formed. For this reason, as shown in FIG. 7, the light L76 incident on the concave portion 32b of the sheet-like member 30 is diffusely reflected and scattered, and the reflected light L77 from the concave portion 32b is visible only with a very small amount of light. It becomes like this.

  On the other hand, as described above, the concave portion 12b of the concavo-convex pattern 12 is formed as a flat surface. Therefore, when this release paper 10 is used as a pattern paper, as shown in FIG. 7, the upper surface of the convex portion 32a of the pattern 32 of the sheet-like member 30 formed by transferring the concave portion 12b of the concave and convex pattern 12 of the release paper 10 is It is formed as a flat surface. For this reason, as shown in FIG. 7, the light L71 incident on the convex portion 32a of the sheet-like member 30 is regularly reflected, and the reflected light L72 from the convex portion 32a is clearly visually recognized.

  As a result, the transferred pattern 32 of the sheet-like member 30 has an extremely high contrast between the convex portion 32a and the concave portion 32b, and the gloss on the convex portion 32a. That is, according to the release paper 10 according to the present embodiment, a pattern having excellent gloss and contrast can be transferred.

  Next, an embodiment of a release paper manufacturing method and a release paper manufacturing apparatus according to the present invention capable of producing the release paper described above will be described mainly with reference to FIGS.

  As shown in FIGS. 1 to 5, the manufacturing apparatus 40 includes a spray coating apparatus 60 that roughens the surface 20 a of the original fabric 20 by spray coating a resin on one surface 20 a of the original fabric 20, and spray coating. And an embossing device 50 which is disposed on the downstream side of the device 60 and forms the uneven pattern 12 on the raw fabric 20. Further, as shown in FIG. 1, the manufacturing apparatus 40 is disposed on the upstream side of the spray coating apparatus 60, and produces a raw fabric 20 having a base material 24 and a synthetic resin layer 22 laminated on the base material 24. An original fabric manufacturing apparatus 70 is further provided. Furthermore, the manufacturing apparatus 40 includes a base material supply device (not shown) that continuously supplies the base material 24 that extends in a strip shape to the original fabric preparation device 70, and a release paper formed by forming the uneven pattern 12 on the original fabric 20. And a release paper collecting device (not shown) that winds and collects 10.

  Among these, first, the raw fabric production apparatus 70 will be described. As shown in FIG. 1, the raw fabric preparation apparatus 70 includes a coating apparatus 71 that coats a surface of one of the base materials 24 with a resin (first resin) 22 a that forms the synthetic resin layer 22. . In the present embodiment, the coating apparatus 71 is configured as a printing unit that prints the resin 22a on the substrate 24, more specifically as a gravure printing unit. As shown in FIG. 1, the printing unit 71 includes a gravure plate cylinder 72 for transferring the resin 22 a to substantially the entire surface of one surface of the substrate 24, and an impression cylinder 74 disposed to face the gravure plate cylinder 72. And have. The gravure plate cylinder 72 is immersed in an ink pan 76 in which the resin (ink) 22a is stored. The base material 24 supplied from a base material supply device (not shown) passes between the gravure plate cylinder 72 and the impression cylinder 74. At this time, the resin (ink) 22a transferred from the ink pan 76 to the surface (gravure plate) of the gravure plate cylinder 72 is transferred to the surface of the substrate 24 facing the gravure plate cylinder 72.

  The printing unit 71 further includes a drive mechanism (not shown) connected to the gravure plate cylinder 72 and the impression cylinder 74. By this drive mechanism, the gravure plate cylinder 72 and the impression cylinder 74 are rotationally driven, and the resin (resin solution) 22 a is transferred onto the surface of the base material 24.

  The resin 22a stored in the ink pan 76 contains a solvent, and is given a certain degree of fluidity. As shown in FIG. 1, the raw fabric production apparatus 70 further includes a drying device (first drying device) 78 that dries the resin 22 a applied on the base material 24. The dried film 78 made of the resin 22 a on the substrate 24 is fixed on the substrate 24 to form the synthetic resin layer 22.

  In addition, as such an original fabric preparation apparatus 70, it is not restricted to the above structure, Various raw materials 20 which can produce the original fabric 20 which has the base material 24 and the synthetic resin layer 22 laminated | stacked on the base material 24 are shown. A device can be employed.

  Next, the spray coating apparatus 60 will be described. As shown in FIG. 1, the spray coating apparatus 60 includes a spraying device 62 that sprays a resin (second resin) 15 on the original fabric 20, and a drying device (second drying device) that dries the resin 15 sprayed on the original fabric 20. 66). As shown in FIG. 3, the spray coating apparatus 60 further includes a cover 64 that restricts the flight direction of the resin 15 sprayed from the spraying apparatus 62 and prevents the resin 15 from scattering. According to such a spray coating apparatus 60, the granular resin 15 can be sprayed by the spraying apparatus 62, and the resin 15 can be adhered on the surface 20a of the raw fabric 20. Further, the resin 15 adhered on the surface of the original fabric 20 can be fixed at that position by the drying device 66, and the surface 20a of the original fabric 20 can be roughened.

  As shown in FIGS. 1 and 3, the spraying device 62 is disposed so as to face the synthetic resin layer 22 of the raw fabric 20. The resin (resin solution) 15 sprayed from the spraying device 62 contains a solvent. Thereby, a certain amount of fluidity is imparted to the resin 15, and the resin 15 can be sprayed. Further, in the present embodiment, the resin 15 injected from the spraying device 62 is the same as the resin 22 a forming the synthetic resin layer 22 of the raw fabric 20.

  As shown in FIG. 3, a backup body (first backup body) 68 is disposed at a position facing the spraying device 62 across the raw fabric 20 coated with the resin 15. That is, the raw material 20 is sprayed with the resin 15 while being supported from below by the first backup body 68. In the example shown in FIG. 3, the backup body 68 is configured as a rotatable backup roll (first backup roll). The spray coating apparatus 60 further includes a drive mechanism (not shown) that is connected to the first backup body 68 and rotationally drives the first backup body 68. By this drive mechanism, the first backup body 68 can be rotated at a peripheral speed synchronized with the conveying speed of the original fabric 20.

  As shown in FIG. 3, the spraying device 62 is arranged such that a blowout port 62 a that blows out the resin 15 is separated from the surface 20 a of the original fabric 20 to some extent. Specifically, the distance (spraying distance) d along the normal line of the sheet-shaped original fabric 20 from the outlet 62a of the spraying device 62 to the surface 20a of the original fabric 20 is maintained at 20 cm or more and 100 cm or less. It is preferable. This is because, as will be described in detail later, the surface of the raw fabric 20 can be roughened to a desired degree of accuracy by spray coating the resin 15.

  Next, the embossing device 50 will be described. As well shown in FIG. 2, the embossing device 50 is disposed opposite to the embossing mold 52, an embossing mold 52 having a concavo-convex portion 54 corresponding to the concavo-convex pattern 12 to be formed on the raw fabric 20, A backup body (second backup body) 56 that presses the original fabric 20 with the embossing mold 52. The embossing mold 52 is arranged so that the uneven portion 54 faces the roughened surface 20a side (the synthetic resin layer 22 side) of the raw fabric 20.

  In the present embodiment, the embossing mold 52 is configured as a roll-shaped embossing roll. As well shown in FIG. 5, the embossing roll 52 has a roll body 53 that is driven to rotate, and an uneven portion 54 is formed on the outer peripheral surface of the roll body 53. In this Embodiment, the uneven | corrugated | grooved part 54 is comprised so that a leather pattern can be provided to the surface 20a of the raw fabric 20 so that the release paper 10 for synthetic leather can be produced.

  As shown in FIG. 5, in the present embodiment, the second backup body 56 is disposed so as to face the embossing roll 52 and can be rotated at a circumferential speed synchronized with the moving speed of the raw fabric 20 ( (Second backup roll) 56. The second backup roll 56 sandwiches the raw fabric 20 with the embossing roll 52.

  The embossing device 50 is further connected to a roll main body 53 of the embossing roll 52 and further includes a drive mechanism (not shown) that rotationally drives the roll main body 53. By this drive mechanism, the embossing roll 52 rotates at a peripheral speed synchronized with the conveyance speed of the original fabric 20, and transfers the uneven pattern of the uneven portion 54 to the original fabric 20.

  Next, a method for manufacturing the release paper 10 using the manufacturing apparatus 40 having such a configuration will be described.

  First, as shown in FIG. 1, the base material 24 extending in a strip shape is supplied from a base material supply device (not shown) to the printing unit 71 of the raw fabric preparation device 70. As shown in FIG. 1, the base material 24 is supplied between the gravure printing cylinder 72 and the impression cylinder 74 of the printing unit 71. At this time, the gravure plate cylinder 72 and the impression cylinder 74 are rotationally driven so as to synchronize with the conveyance speed of the original fabric 20. Therefore, the gravure plate cylinder 72 passes through the resin (ink) 22a stored in the ink pan 76, and the resin 22a is placed on the surface (gravure plate) of the gravure plate cylinder 72 that comes into contact with one surface of the substrate 24. Reprinted. As a result, the resin 22a is coated in a planar shape on one surface of the substrate 24 that passes between the gravure plate cylinder 72 and the impression cylinder 74.

  Next, the base material 24 coated with the resin 22 a is supplied to the drying device 78, and the resin 22 a is dried by the drying device 78. As a result, the solvent blended in the resin 22a evaporates and the resin 22a is cured on the substrate 24. The cured resin 22a film is fixed on the substrate 24 to form the synthetic resin layer 22.

  As described above, the resin 22a has a certain degree of fluidity. For this reason, the resin 22a coated in a planar shape extends flat (and is leveled) on the substrate 24 before being dried and cured. Therefore, in the raw fabric 20 produced by such a method, the synthetic resin layer 20 is flattened and has an excellent gloss, and the glossiness of the synthetic resin layer 22 is usually 10 or more.

  Thus, the raw fabric 20 consisting of the base material 24 and the synthetic resin layer 22 laminated on the base material 24 is produced. The resin 22a forming the synthetic resin layer 22 is variously selected according to the requirements for the release paper 10 to be manufactured, such as polypropylene. On the other hand, the substrate 24 is made of paper or the like. The base material 24 promotes plastic deformation of the synthetic resin layer 22, that is, transfer of the uneven pattern, by restraining deformation of the synthetic resin layer 22 in embossing to be described in detail later. In addition, the base material 24 also serves to prevent the unevenness 12 and the minute uneven shape 16 formed on the synthetic resin layer 22 by embossing from being damaged during subsequent handling.

  Next, the produced raw fabric 20 is supplied to the spray coating apparatus 60. The resin 15 is spray-coated on the surface 20a of the original fabric 20 by the spray coating apparatus 60, and the surface 20a of the original fabric 20 is roughened. This roughening step includes a step of spraying the resin 22a on the surface 20a of the original fabric 20 by the spraying device 62 and a step of drying the resin 22a sprayed on the surface 20a of the original fabric 20 by the drying device 66. Have.

  In the spraying process by the spraying device 62, the granular resin 15 is sprayed from the spraying device 62 toward the original fabric 20 supported by the first backup body 68. As shown in FIG. 3, the sprayed resin 15 is guided by the cover 64 and sprayed onto the synthetic resin layer 22 of the raw fabric 20. As a result, the resin 15 adheres on the synthetic resin layer 22 and the synthetic resin layer 22 is coated with the resin 15.

  Thereafter, the original fabric 20 sprayed with the resin 15 is conveyed to the drying device 66. The resin 15 sprayed on the surface 20 a of the raw fabric 20 is dried by the drying device 66. As a result, the solvent mixed in the resin 15 evaporates and the resin 15 is cured on the synthetic resin layer 22 of the raw fabric 20. The cured resin 15 is fixed on the base material 24 to form a surface layer of the original fabric 20.

  As described above, the synthetic resin layer 10 is flat and has an excellent gloss, but the resin 15 adheres to the synthetic resin layer 10 in a granular form. The resin 15 is dried by the drying device 66 before being leveled on the synthetic resin layer 10, that is, before the resin 15 extends and spreads flat on the synthetic resin layer 10. As a result, as shown in FIG. 4, the surface 20 a of the original fabric 20 has minute irregularities 16 formed by the resin 15. In this way, the surface 20a of the raw fabric 20 on the synthetic resin layer 22 side is roughened. As shown in FIG. 4, the roughened surface 20a of the raw fabric 20 scatters and reflects the light L41, and only a small part of the light L42 is regularly reflected (specular reflection).

  By the way, it is effective that the raw fabric 20 is roughened by the spray coating device 41 so that the glossiness on one surface 20a of the raw fabric 20 is 4 or more and 8 or less before embossing. When the inventor conducted various experiments, when the roughened surface 20a of the raw fabric 20 has a glossiness within this range, the finally obtained sheet-like member 30 effectively exhibits the above-described effects. The knowledge that it is possible to perform is obtained. The “glossiness” in this case is a glossiness measured in accordance with JIS 6007.

  Further, as a result of investigation by the present inventor, by managing the average length Sm and the ten-point average roughness Rz of the surface 20a of the original fabric 20 roughened by spray coating, the original fabric 20 is approximately 4 or more and 8 or less. It has been found that a glossiness in the range can be achieved. Specifically, in order to obtain a glossiness of 4 or more and 8 or less on one surface 20a of the original fabric 20, the average length Sm of the surface 20a of the original fabric 20 roughened by spray coating is 30 μm or more and 80 μm or less. Thus, it was found that blasting is effective so that the 10-point average roughness Rz of the surface 20a of the raw fabric 20 roughened by spray coating is 5 μm or more and 20 μm or less. Here, “average length Sm” and “ten-point average roughness Rz” are values measured in accordance with JISB0401.

  The average length Sm and the ten-point average roughness Rz on the surface 20a of the raw fabric 20 are adjusted by appropriately setting the resin 15 spraying method using the spraying device 62, the resin 15 drying method using the drying device 66, and the like. It is possible.

  In particular, in the present embodiment, as described above, the distance d from the outlet 62a of the spraying device 62 along the normal direction of the sheet-shaped original fabric 20 to the surface 20a of the original fabric 20 is 20 cm or more. It has become. That is, the flight distance of the resin 15 to the original fabric 20 is secured to some extent. As a result, the resin 15 blown out from the spraying device 62 is dried to some extent by the time it reaches the original fabric 20, and adheres to the synthetic resin layer 22 of the original fabric 20 in a state where the fluidity is lowered. That is, it is possible to effectively prevent the resin 15 adhering to the raw fabric 20 from extending and spreading on the synthetic resin layer 22, thereby reducing the average length Sm of the desired range, the ten-point average roughness Rz, and the like. It is easy to roughen the raw fabric 20 with high accuracy.

  As described above, the distance d from the outlet 62a of the spraying device 62 along the normal line of the sheet-like original fabric 20 to the surface 20a of the original fabric 20 is 100 cm or less. Therefore, it is possible to effectively prevent the resin 15 blown out from the spraying device 62 from being excessively dried before reaching the raw fabric 20 and being stably adhered to the synthetic resin layer 22.

  In this way, the entire surface 20a on one side of the original fabric 20 is roughened by spray coating, and the fine irregularities 16 are formed (matized) on the entire surface 20a of the original fabric 20. In particular, in the example shown in FIG. 4, one surface 20 a of the raw fabric 20 is almost entirely coated with the granular resin 15, and the surface 20 a of the raw fabric 20 is a resin coated on the synthetic resin layer 20. 15 is constituted.

  Next, the roughened raw fabric 20 is supplied to the embossing device 50. And the uneven | corrugated pattern 12 is formed in the raw fabric 20 from the roughened surface 20a side by the embossing using the embossing apparatus 50. FIG.

  As shown in FIG. 5, the raw fabric 20 is fed between the embossing roll 52 and the second backup body 56 of the embossing device 50 and is sandwiched between the embossing roll 52 and the second backup body 56. As shown in FIG. 5, the synthetic resin layer 22 of the original fabric 20 faces the embossing roll 52 of the embossing device 50, and the base material 24 of the original fabric 20 faces the second backup body 56. As a result, an uneven pattern (skin pattern) 12 corresponding to the shape of the uneven portion 54 of the embossing roll 52 is formed on the surface of the synthetic resin layer 22 of the raw fabric 20.

  By the way, when forming the concavo-convex pattern 12, a large processing pressure is applied to the region where the concave portion 12b of the concavo-convex pattern 12 is formed. That is, the convex part 54a of the uneven part 54 of the embossing roll 52 presses the raw fabric 20 with a large pressure. In general, the concavo-convex portion 54 of the embossed mold (embossed plate) 52 is formed smoothly, and the glossiness of the concavo-convex portion 54 (for example, the convex portion 54a) in accordance with JIS S6007 is usually greater than at least 8. In many cases, it is 15 or more. Therefore, as shown in FIG. 5, the minute uneven shape 16 that has been formed on the surface of the raw fabric 20 where the concave portion 12b of the uneven pattern 12 is formed becomes gentle when pressed. That is, the glossiness on the surface of the raw fabric 20 where the concave portion 12b of the concave / convex pattern 12 is formed increases. In the present embodiment, the bottom surface of the concave portion 12b of the concave-convex pattern 12 on the raw fabric 20 is further flattened.

  In particular, as described above, the average length Sm of the surface 20a of the raw fabric 20 roughened by spray coating is 30 μm or more and the ten-point average roughness Rz of the surface 20a is 20 μm or less. When the glossiness of the surface 20a of the materialized raw fabric 20 is 4 or more, the inside of the concave portion 12b of the concavo-convex pattern 12 on the raw fabric 20 can be sufficiently smoothed. The upper surface of the convex part 32a of the sheet-like member 30 manufactured using the (release paper 10) can be made sufficiently glossy.

  On the other hand, when the concavo-convex pattern 12 is formed, only a relatively small processing pressure is applied to a region where the convex portion 12a of the concavo-convex pattern 12 is formed. Therefore, the minute irregularities 16 that are positioned on the convex portions 12a of the irregular pattern 12 can be left as they are (see FIG. 5) or in a slightly gentle state. In particular, the depth (gap) of the concave portion 54b of the concave-convex portion 54 of the embossing roll 52 is set deep, specifically, as shown in FIG. 5, the height of the convex portion 12a of the concave-convex pattern 12 to be formed. By setting the depth deeper than the value, the minute unevenness 16 positioned on the convex portion 12a of the uneven pattern 12 can be left as it is without being crushed.

  In particular, as described above, the average length Sm of the surface 20a of the raw fabric 20 roughened by spray coating is 80 μm or less, and the ten-point average roughness Rz of the surface 20a is 5 μm or more. When the glossiness of the surface 20a of the original fabric 20 is 8 or less, it is possible to leave an effective micro uneven shape 16 on the convex portion 12a of the uneven pattern 12 on the original fabric 20, Light incident on the concave portion 32b of the sheet-like member 30 manufactured using the original fabric 20 (release paper 10) can be sufficiently scattered.

  In this way, the release paper 10 having the raw fabric 20 on the surface of which the rough concavo-convex pattern 12 having the concave portion 12b and the convex portion 12a is formed, and the minute concavo-convex shape 16 is formed on the convex portion 12a. Thus, the release paper 10 in which the inside of the recess 12b is smoothed can be manufactured. The manufactured release paper 10 is taken up by a collecting device (not shown).

  As described above, according to the present embodiment, first, the resin 15 is spray-coated on the raw fabric 20 by the spray coating apparatus 60, whereby the minute irregularities 16 are formed on the surface 20a. Thereby, even if the glossiness of the surface 20a on which the concavo-convex pattern 12 of the raw fabric 20 is to be formed initially has a large value, the glossiness of the embossed type (embossed plate) 52 is reduced to a predetermined value or less. It can be reduced to a value smaller than the glossiness of the uneven portion (uneven surface, transfer surface) 54. Thereafter, the embossing roll 52 of the embossing device 50 forms the uneven pattern 12 that is coarser than the fine unevenness 16 on one surface 20a of the raw fabric 20. When the concave / convex pattern 12 is formed, a large processing pressure is applied to the region where the concave portion 12b of the concave / convex pattern 12 is formed, while the region where the convex portion 12a of the concave / convex pattern 12 is formed is relatively small. Only processing pressure is applied. Therefore, the minute unevenness 16 that comes to be positioned on the convex portion 12a of the uneven pattern 12 can be left as it is or slightly gently. At the same time, the minute unevenness 16 that comes to be positioned on the recess 12b of the uneven pattern 12 can be made gentle. As a result, when the sheet-like member 30 is produced using the release paper 10 as a pattern paper, the surface of the convex portion 32a of the pattern 32 transferred to the sheet-like member 30 becomes smooth and has excellent gloss. On the other hand, minute irregularities 36 are formed on the bottom surface of the concave portion 32 b of the pattern 32 transferred to the sheet-like member 30. Thereby, the pattern 32 transferred to the sheet-like member 30 has a high contrast between the convex part 32a and the concave part 32b of the pattern 32, and has an excellent gloss on the convex part 32a. That is, according to the present embodiment, the pattern 32 having excellent gloss and contrast can be transferred to the sheet-like member 30. Further, according to the present embodiment, a sheet-like member is formed not by the gap between the concave portion 12b and the convex portion 12a of the concave / convex pattern 12 of the release paper 10 but by the minute concave / convex portions 16 remaining on the convex portion 12a of the concave / convex pattern 12. The contrast of the pattern 32 transferred to 30 is increased. Therefore, it is not necessary to apply a high processing pressure to the raw fabric 20 during the production of the release paper 10. Thereby, while being able to manufacture the release paper 10 with high production efficiency, the damage to the raw fabric 20, especially the base material 24, can be reduced. Moreover, the manufacturing cost and maintenance cost of the manufacturing apparatus 40 can be reduced. Furthermore, according to the present embodiment, the release paper that can transfer the pattern 32 having excellent gloss and contrast to the sheet-like member 30 irrespective of the degree of gloss that the original fabric 20 originally has. Can be manufactured stably.

  Further, according to the present embodiment, the resin 15 to be spray-coated is the same as the resin forming the surface of the raw fabric 20. Therefore, the surface 20a of the raw fabric 20 can be roughened without generating a material interface. In other words, the present embodiment is bonded to the base material 24 and the base material 24, which are used for manufacturing a release paper (typically, a release paper that can withstand severe use conditions) according to a special application. It can be suitably applied to the raw fabric 20 having the resin layer 22 formed.

  Furthermore, according to the present embodiment, the resin 15 to be spray-coated is sprayed onto the original fabric 20 with a spraying distance d of 20 cm or more. Therefore, the resin 15 is dried before adhering to the original fabric 20, and the resin 15 adhering to the original fabric 20 has fluidity. For this reason, it is possible to prevent the resin 15 from spreading gently on the raw fabric 20 and to roughen the surface 20a of the original fabric 20 with a desired degree of accuracy.

  Furthermore, according to the present embodiment, the surface 20 a of the raw fabric 20 is roughened by spray coating using the spray coating apparatus 60. Therefore, the minute irregularities 16 can be formed on the surface 20a of the original fabric 20 easily and quickly.

  Furthermore, according to the present embodiment, the bottom surface of the recess 12b of the concavo-convex pattern 12 is flattened. According to such a release paper, a pattern having extremely excellent gloss can be transferred to the sheet-like member 30.

  Furthermore, according to the present embodiment, in the step of forming the concavo-convex pattern 12, the fine concavo-convex 16 is formed in the entire region where the concavo-convex pattern 12 of the original fabric 20 is formed. . According to this embodiment, it is not necessary to strictly align the arrangement position of the minute unevenness 16 on the original fabric 20 and the uneven pattern 12 on the original fabric 20. Further, the unnecessary minute irregularities 16 formed on the raw fabric 20 are made gentle during the formation of the irregular pattern 12. Therefore, the release paper 10 in which the minute irregularities 16 exist only at the desired position can be manufactured with high production efficiency.

  Various modifications can be made to the above-described embodiment within the scope of the present invention.

  For example, in the above-described embodiment, an example in which the release paper 10 for synthetic leather is manufactured has been shown. However, the present invention is not limited to this, and a release paper (for example, a release paper for wallpaper) used for other purposes is manufactured. You may make it do.

  In the above-described embodiment, the example in which the entire surface 20a on the synthetic resin layer 22 side of the raw fabric 20 is roughened by spray coating has been shown. However, the present invention is not limited thereto. Only the region where 12 is formed or only the region where the convex portion 12a of the concavo-convex pattern 12 on the raw fabric 20 is formed may be roughened by spray coating.

  Further, in the above-described embodiment, the example in which the first backup body 68 facing the spraying device 62 of the spray coating device 60 is configured as the first backup roll is shown, but the present invention is not limited to this. For example, from the spraying device 62 Various devices that can stably support the original fabric 20 to which the resin 15 is sprayed, such as a cradle, can be employed as the first backup body 68.

  Further, in the above-described embodiment, the embossing device 50 has an embossing roll as the embossing die 52. However, the embossing device 50 is not limited thereto, and various known embossing devices can be employed. For example, a press device that presses a belt type or flat plate type embossing die against the workpiece can be employed as the embossing device.

  Furthermore, in the above-described embodiment, the example in which the outer peripheral surface of the second backup roll of the second backup body 56 of the embossing device 50 is formed into a flat curved surface without unevenness has been shown. You may make it have the unevenness | corrugation corresponding to the uneven | corrugated | grooved part 54 of the roll 52. FIG.

  Furthermore, in the above-described embodiment, the example in which the second backup body 56 facing the embossing mold 52 of the embossing device 50 is configured as the second backup roll has been shown. Various devices that can stably support the original fabric 20 between them, for example, a cradle, can be employed as the second backup body 56.

  Furthermore, in the above-described embodiment, the example in which the base material 24 is coated with the resin 22a that forms the synthetic resin layer 22 using the printing unit as the coating apparatus 71 has been described. A resin 22a that forms the synthetic resin layer 22 may be coated on the substrate 24 using a coating apparatus.

  Furthermore, in the above-described embodiment, the example in which the release paper manufacturing apparatus 40 includes the original fabric manufacturing apparatus 70 has been described, but the present invention is not limited thereto. The original fabric production apparatus 70 may be omitted from the manufacturing apparatus 40, and the produced original fabric 20 may be supplied to the production apparatus 40.

  Furthermore, the present invention is not limited to the above-described embodiment, and at least one of the resin 22a forming the synthetic resin layer 22 and the resin 15 to be spray-coated is a radiation curable resin (radiation curable) such as an ultraviolet curable resin (UV resin). Mold resin solution) may be supplied. When a radiation curable resin such as an ultraviolet curable resin (UV resin) is supplied, the manufacturing apparatus 40 may further include a means (curing means) for curing the radiation curable resin. As an example, when the supplied resin is an ultraviolet curable resin, the manufacturing apparatus 40 may be provided with ultraviolet irradiation means for irradiating ultraviolet rays. The curing means such as the ultraviolet irradiation means is a path after the radiation curable resin is supplied, specifically, the downstream side of the drying device 78 of the raw fabric preparation device 70 and the downstream side of the drying device 66 of the spray coating device 60. Etc. Further, the curing means can be disposed on the downstream side of the embossing device 50.

  According to the manufacturing apparatus in which the curing means is arranged on the downstream side of the embossing device 50, the release paper 10 can be manufactured as follows as an example. First, an ultraviolet curable resin solution (UV resin solution) is applied onto the base material 22 as the first resin 22a by the raw fabric forming apparatus 70. Next, the solvent in the applied ultraviolet curable resin solution is blown off by the drying device 78, and the synthetic resin layer 22 made of the ultraviolet curable resin is fixed on the substrate 22. Thereafter, an ultraviolet curable resin solution (UV resin solution) is sprayed on the synthetic resin layer 22 as the second resin 15, and the sprayed ultraviolet curable resin solution is further dried by the drying device 66. Thereby, the raw fabric 20 which consists of the synthetic resin layer 22 which has the micro uneven | corrugated shape 16 on the surface, and the base material 24 is obtained. Next, the concavo-convex pattern 12 is formed on the original fabric 20 by the embossing device 50, and then the synthetic resin layer 22 made of an ultraviolet curable resin is cured by the curing means. Thus, when the release paper 10 is manufactured, since the radiation curable resin has not been cured yet, the embossing device 50 can form the concavo-convex pattern 12 on the original fabric 20 with high accuracy. Further, by curing the radiation curable resin, it is possible to maintain the concavo-convex pattern 12 formed with high accuracy as it is.

  In addition, as an example of the ultraviolet curable resin solution to be supplied, an ultraviolet curable resin (UV resin), a MEK (methyl ethyl ketone) solvent, and PGM (propylene glycol glycol monoethyl ether) 10 : An ultraviolet curable resin solution blended at 4: 1 can be used. Such an ultraviolet curable resin solution can be suitably sprayed by the spraying device 62 of the spray coating device 60 and can be suitably printed on the substrate 24 by the printing unit 72 of the raw fabric preparation device 70. .

FIG. 1 is a perspective view showing an embodiment of a release paper manufacturing apparatus and manufacturing method according to the present invention, and shows an apparatus and method for producing an original fabric and an apparatus and method for roughing an original fabric. is there. FIG. 2 is a perspective view showing an embodiment of a release paper manufacturing apparatus and manufacturing method according to the present invention, and shows an apparatus and method for forming a concavo-convex pattern on an original fabric. FIG. 3 is a cross-sectional view showing an apparatus and a method for spraying resin on the original fabric. FIG. 4 is a cross-sectional view showing the roughened raw material. FIG. 5 is a cross-sectional view showing an apparatus and method for forming an uneven pattern on an original fabric. FIG. 6 is a cross-sectional view showing an example of a release paper manufactured by the release paper manufacturing apparatus and manufacturing method shown in FIGS. 1 and 2. FIG. 7 is a view for explaining the operation of a sheet-like member produced using the release paper shown in FIG. 6 as a pattern paper.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Release paper 12 Uneven pattern 12a Uneven pattern convex part 12b Uneven pattern concave part 15 Resin 16 Small unevenness (micro uneven shape)
20 Raw fabric 20a Surface 22 Synthetic resin layer 22a Resin 24 Base material 40 Manufacturing device 50 Embossing device 52 Embossing type (embossing roll, embossing plate)
54 Uneven portion 54a Uneven portion convex portion 54b Uneven portion concave portion 56 Backup body (second backup body)
60 spray coating device 62 spraying device 62a outlet 64 cover 66 drying device (second drying device)
70 Original Fabric Making Device 71 Printing Unit 78 Drying Device (First Drying Device)

Claims (22)

A method for producing a release paper by forming an uneven pattern on a raw fabric,
The step of roughening the surface of the original fabric by spray coating the resin on the original fabric,
Forming the concavo-convex pattern on the roughened surface of the original fabric by embossing, and a method for producing a release paper. The method for producing a release paper according to claim 1, wherein the roughening step includes a step of spraying a resin on the original fabric and a step of drying the resin sprayed on the original fabric. . 3. The method for producing a release paper according to claim 1, wherein in the roughening step, the resin to be spray-coated is sprayed on the original fabric at a spraying distance of 20 cm or more. The original fabric has a base material and a synthetic resin layer laminated on the base material,
The method for producing a release paper according to any one of claims 1 to 3, wherein a surface on the synthetic resin layer side is roughened. Further comprising the step of producing the original fabric,
The step of producing the original fabric includes a step of coating a resin that forms the synthetic resin layer on one surface of the base material, and drying the resin coated on the base material to thereby form the base material. The method for producing a release paper according to claim 4, further comprising: forming the synthetic resin layer thereon. 6. The release paper manufacturing method according to claim 4, wherein the resin spray-coated on the original fabric is the same as the resin forming the synthetic resin layer. In the roughening step, the resin is adjusted so that the gloss value on the roughened surface of the original fabric is smaller than the gloss value on the surface of an emboss mold used in embossing. The method for producing a release paper according to any one of claims 1 to 6, wherein spray coating is performed. The said resin is spray-coated so that the glossiness on the roughened surface of the original fabric is 4 or more and 8 or less in the roughening step. A method for producing a release paper according to one item. In the roughening step, the average length Sm on the roughened surface of the original fabric is 30 μm or more and 80 μm or less, and the ten-point average roughness Rz on the roughened surface of the original fabric is 5 μm or more and 20 μm. The method for producing a release paper according to claim 8, wherein the resin is spray-coated so as to satisfy the following conditions. 10. The separation according to claim 1, wherein, in the roughening step, a region of the surface of the original fabric where the uneven pattern is to be formed is roughened. A method for manufacturing paper patterns. In the step of forming the concavo-convex pattern, the original fabric that is positioned in the concave portion of the concavo-convex pattern while maintaining the roughened surface of the original fabric that is positioned in the convex portion of the concavo-convex pattern The method for producing a release paper according to any one of claims 1 to 10, wherein the roughened surface is smoothed. A production apparatus for producing a release paper by forming an uneven pattern on a raw fabric,
Spray coating resin on the original fabric, and a spray coating device for roughening the surface of the original fabric;
An apparatus for producing release paper, comprising: an embossing device that is arranged on the downstream side of the spray coating device and forms the uneven pattern on the original fabric. The release coating paper according to claim 12, wherein the spray coating apparatus includes: a spraying device that sprays the resin onto the original fabric; and a drying device that dries the resin sprayed onto the original fabric. Manufacturing equipment. The spray coating apparatus has a spraying device that is arranged to face the original fabric and that sprays the resin on the original fabric,
14. The release paper manufacturing apparatus according to claim 12, wherein the spraying device is disposed such that a blow-out port for blowing out the resin of the spraying device is separated from the original fabric by 20 cm or more. . The apparatus further comprises an original fabric preparation device that is arranged on the upstream side of the spray coating apparatus and produces an original fabric having a base material and a synthetic resin layer laminated on the base material,
The raw fabric preparation apparatus includes: a coating apparatus that coats a resin that forms the synthetic resin layer on one surface of the base material; and a resin that is coated on the base material is dried on the base material. The release paper manufacturing apparatus according to claim 12, further comprising: a drying device that forms the synthetic resin layer. The original fabric has a base material and a synthetic resin layer laminated on the base material,
The spray coating device has a spraying device that is arranged to face the synthetic resin layer of the original fabric and sprays the resin on the synthetic resin layer,
16. The embossing device according to claim 12, wherein the embossing device has an embossing die that includes a concavo-convex portion corresponding to the concavo-convex pattern and that comes into contact with the synthetic resin layer. The release paper manufacturing apparatus as described. The original fabric has a base material and a synthetic resin layer laminated on the base material,
The release paper manufacturing apparatus according to any one of claims 12 to 16, wherein the spraying device sprays the same resin as the resin forming the synthetic resin layer onto the surface of the original fabric. The embossing device has an embossing mold including an uneven portion corresponding to the uneven pattern and including an uneven portion that comes into contact with the original fabric,
The spray coating apparatus roughens the surface of the original fabric so that the gloss value of the surface of the original fabric is smaller than the gloss value of the embossed uneven portion. The release paper manufacturing apparatus according to any one of claims 12 to 17, wherein the release paper manufacturing apparatus is used. 19. The spray coating apparatus according to claim 12, wherein the resin is spray-coated so that the glossiness of the roughened surface of the raw material is 4 or more and 8 or less. The release paper manufacturing apparatus according to the item. The spray coating apparatus has an average length Sm of 30 μm or more and 80 μm or less on the roughened surface of the original fabric, and a ten-point average roughness Rz of 5 μm or more and 20 μm or less on the roughened surface of the original fabric. The release paper manufacturing apparatus according to claim 19, wherein the resin is spray-coated so that The said spray coating apparatus roughens the area | region where the said uneven | corrugated pattern will be formed by the said embossing apparatus among the said surfaces of the said original fabric. The release paper manufacturing apparatus as described. The embossing device includes an embossing mold having a concavo-convex portion corresponding to the concavo-convex pattern, and a backup body that is disposed to face the embossing mold and presses the original fabric between the embossing mold. And
The convex portion of the concavo-convex portion of the embossed type presses the original fabric with the backup body to smooth the roughened surface of the original fabric. The release paper manufacturing apparatus according to claim 1.

Images