JP2017065220A - Uneven shape forming method and uneven shape forming device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an uneven shape forming method and an uneven shape forming device capable of forming an uneven shape-formed body having the uneven shape formed on a surface with high quality, at increased speed and with high productivity, while suppressing occurrence of a bubble defect on a film surface due to air entrainment.SOLUTION: In an uneven shape forming method, a heating mechanism heating a roll plate 5 and a backup roll 2 at a fixed temperature is provided, a thermoplastic film 1 is delivered from the backup roll 2 to a pressure roll 4 directly, and then the thermoplastic film 1 is pressed to the roll plate 5. The diameter of the pressure roll 4 is controlled to the diameter of the backup roll 2 or less, and the diameter of an intermediate roll 3 is controlled to less than that of the backup roll 2.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an uneven shape forming method and an uneven shape suitable for forming a film-like object such as an embossed film having a special optical effect with a surface having an uneven shape and high quality without defects and with high productivity. The present invention relates to a shape forming apparatus.

  In recent years, as an application for optical devices such as displays and illumination, various types such as an embossed film having an antireflection effect, a flat lens such as a lenticular lens and a fly-eye lens, a light diffusion film, a brightness enhancement film, an optical waveguide, and a prism sheet Film is being used.

  As such a film, a film having a regular uneven shape formed on the surface is known, and various methods are known as a method for forming a regular uneven shape.

  For example, a resin is applied to the surface of a plate cylinder having a regular irregular shape formed on the surface, a continuously running film is sandwiched between the plate cylinder and an impression cylinder, and the resin of the plate cylinder is in contact with the film The contents of irradiating the resin with ionizing radiation and curing it, and then winding the film on a peeling roll and peeling it from the plate cylinder is disclosed (Patent Document 1).

  In addition, a resin is applied in advance to the surface of a continuously running film, and this film is sandwiched between a plate cylinder and an impression cylinder on which a regular uneven shape is formed, and the uneven shape of the plate cylinder is transferred to the resin. In such a state, the resin is irradiated with ionizing radiation and cured, and then the film is wound around a peeling roll and peeled off from the plate cylinder (Patent Document 2).

  In the above process, if the conveyance speed is increased, air is entrained between the cured resin film on the film surface and the plate cylinder, and defects due to bubbles are generated on the film surface. Can not.

  Further, in the method of Patent Document 1, a staying part that is spread in the width direction while the resin stays in the plate cylinder is formed, but there is a concern that film formation may become unstable, and as the speed increases, Setting conditions becomes difficult.

JP-A-11-300768 JP 2001-62853 A

  The present invention has been made in view of such circumstances, and provides a concavo-convex shape forming method and a concavo-convex shape forming apparatus capable of forming a concavo-convex shape formed body having a concavo-convex shape on the surface with high productivity and high quality. The purpose is to do.

The uneven shape forming method for solving the above problem continuously conveys the thermoplastic film unwound from the unwinding device,
A roll plate for forming an uneven shape;
A pressure roll for pressing the thermoplastic film against the roll plate;
An intermediate roll in contact with the pressure roll;
A backup roll in contact with the intermediate roll that presses the pressure roll against the roll plate via the intermediate roll;
A backup roll that contacts the intermediate roll, presses the pressure roll against the roll plate via the intermediate roll, and preheats the thermoplastic film;
At least a heating mechanism that heats any one of the roll plate, the pressure roll, the intermediate roll, and the backup roll to a constant temperature,
The diameter of the pressure roll is equal to or less than the diameter of the backup roll,
The diameter of the intermediate roll is set to be smaller than the diameter of the backup roll, and the thermoplastic film is directly transferred from the backup roll to the pressure roll, and then the thermoplastic film is pressed against the roll plate.

  The intermediate roll is a single roll having a diameter less than the geometric average of the diameter of the backup roll and the pressure roll, and the rotation axes of the backup roll, the intermediate roll, and the pressure roll are on the same plane. An uneven shape forming method characterized in that the thermoplastic film is pressed onto a roll plate.

  Further, in the state where the pressure roll is not pressed against the roll plate, the back-up roll, the pressure roll, or the back-and-forth roll and the pressure roll are preheated, and then the concavo-convex shape forming method for pressing the thermoplastic film against the roll plate. .

  In addition, the conveyor belt is wound around the two rolls of the backup roll and the pressure roll, the thermoplastic film is conveyed by the conveyor belt, and then the thermoplastic film is pressed against the roll plate via the conveyor belt. This is a shape forming method.

  Moreover, it is an uneven | corrugated shape formation method which peels a thermoplastic film and a roll plate, after irradiating an ultraviolet-ray with the thermoplastic film pressed on said roll plate in the state closely_contact | adhered to the roll plate.

  In addition, with respect to the thermoplastic film pressed against the roll plate, an uneven shape forming method of peeling the thermoplastic film and the roll plate while pressing a cooling release roll whose surface temperature is lower than the surface temperature of the roll plate against the roll plate. is there.

Moreover, the uneven | corrugated shape forming apparatus for solving said subject is a roll plate for forming uneven | corrugated shape,
A pressure roll that presses the thermoplastic film against the roll plate;
An intermediate roll in contact with the pressure roll;
A backup roll in contact with the intermediate roll, pressing the pressure roll against the roll plate via the intermediate roll, and preheating the thermoplastic film;
And at least a heating mechanism that heats the roll plate, pressure roll, intermediate roll, backup roll to a certain temperature,
The diameter of the pressure roll is less than the diameter of the backup roll,
The diameter of the intermediate roll is less than the diameter of the backup roll,
It is the uneven | corrugated shape formation apparatus characterized by having made it.

  The intermediate roll is a single roll having a diameter less than the geometric average of the diameter of the backup roll and the pressure roll, and the rotation axes of the backup roll, the intermediate roll, and the pressure roll are on the same plane. It is an uneven | corrugated shape formation apparatus on the top.

  Further, in the state where the above-mentioned pressure roll is not pressed against the roll plate, it is an uneven shape forming apparatus having a heating mechanism for preheating at least either the backup roll or the pressure roll.

  In addition, a transport belt is wound around the two rolls of the backup roll and the pressure roll, and a mechanism that the thermoplastic film is transported on the transport belt and then pressed against the roll plate via the transport belt. It is the uneven | corrugated shape formation apparatus which has.

  Also, an ultraviolet irradiation device for irradiating the thermoplastic film pressed against the roll plate with ultraviolet rays in close contact with the roll plate, and a mechanism for peeling the thermoplastic film and the roll plate after irradiating with ultraviolet rays. It is the uneven | corrugated shape formation apparatus which has.

  Moreover, with respect to the thermoplastic film pressed against the roll plate, the unevenness having a mechanism for peeling the thermoplastic film and the roll plate while pressing a cooling release roll whose surface temperature is lower than the surface temperature of the roll plate against the roll plate. A shape forming apparatus.

  According to the present invention, a roll plate for forming a concavo-convex shape on the surface of a continuously conveyed film, a pressure roll for pressing the film against the roll plate, and a backup for indirectly pressing the pressure roll against the roll plate Using a roll, a heating mechanism that heats at least one intermediate roll and a roll plate to a certain temperature, in contact with both the pressure roll and the backup roll, and transmitting the pressing force of the backup roll to the pressure roll The diameter of the pressure roll is equal to or less than the diameter of the backup roll, the diameter of the intermediate roll is less than the diameter of the backup roll, and the film is transferred to the pressure roll directly from the backup roll, and then pressed against the roll plate. By forming the shape, the preheating effect of the film is high even when the diameter of the pressure roll is reduced, and the pressure is high. It is possible to apply a uniform.

  The backup roll of the present invention has a function of uniformly applying a high pressure and a function of preheating the film. In addition, in the forming method of the present invention, the holding angle can be increased without bringing the roll into contact with the concavo-convex shape forming surface of the preheated film after reducing the diameter of the pressure roll. Problems caused by the entrapment of bubbles are suppressed.

  Further, one intermediate roll having a diameter less than the geometric average of the diameter of the backup roll and the pressure roll is arranged so that the rotation axes of the backup roll, the intermediate roll and the pressure roll are on the same plane. Thus, a method for forming a concavo-convex shape with high pressure roll uniformity can also be used.

  If the diameter of the intermediate roll is less than the geometric average of the diameter of the backup roll and the pressure roll, when the film is conveyed from the backup roll to the pressure roll, it may come into contact with the intermediate roll rotating in the opposite direction. Therefore, problems such as the occurrence of scratches due to contact can be avoided.

  Furthermore, by providing a mechanism for heating the backup roll and the pressure roll, and forming the concavo-convex shape with these rolls preheated, the concavo-convex shape can be stably formed immediately after operation. It can also be a forming method.

  The formability of the concavo-convex shape is affected by the temperature of the pressure roll, and generally the formability decreases when the temperature is low. By preheating the pressure roll, it is possible to give the pressure roll a temperature necessary for the formation of the uneven shape, and thus it is possible to stably form the uneven shape immediately after operation.

  Furthermore, it can also be set as the uneven | corrugated shaped formation method with a higher preheating effect of a film by winding a conveyance belt around a backup roll and a pressure roll, and conveying a film with this conveyance belt.

  By transporting the film with a transport belt heated by preheating or the heat of the roll plate, sufficient heat can be applied to the film, which can be expected to improve the formability of the concavo-convex shape.

  Furthermore, the film pressed against the roll plate is irradiated with ultraviolet rays in a state of being in close contact with the roll plate, and then the film and the roll plate are peeled off, whereby the film having a good concavo-convex shape and high heat resistance is obtained. It can also be set as the uneven | corrugated shaped formation method which can form.

  Furthermore, for the film pressed against the roll plate, the film and the roll plate are peeled while pressing the cooling release roll whose surface temperature is lower than the surface temperature of the roll plate against the roll plate. And it can also be set as the uneven | corrugated shape formation method with the favorable peelability from a roll plate.

  Moreover, according to the uneven | corrugated shape formation apparatus of this invention, the uneven | corrugated shape formation apparatus which implement | achieves said uneven | corrugated shape formation method can be provided.

It is the conceptual diagram which showed the structure of the uneven | corrugated shape forming apparatus of this invention. It is the conceptual diagram which showed the pressurization mechanism of the uneven | corrugated shape forming apparatus of this invention. It is the conceptual diagram which showed the structure in the preheating state of the uneven | corrugated shape forming apparatus which has the preheating mechanism of this invention. It is the conceptual diagram which showed the other structure in the uneven | corrugated shape forming apparatus of this invention. It is the conceptual diagram which showed the structure of the uneven | corrugated shape forming apparatus which has the conveyance belt of this invention. It is the conceptual diagram which showed the structure of the uneven | corrugated shape formation apparatus which has an ultraviolet irradiation means of this invention. It is the conceptual diagram which showed the structure of the uneven | corrugated shape forming apparatus which has the cooling peeling roll of this invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. FIG. 1 shows a configuration of a concavo-convex shape forming apparatus to which the present invention is applied, and includes a backup roll 2, an intermediate roll 3, a pressure roll 4, a roll plate 5, and a cooling roll 6. In addition, this embodiment is an apparatus which can be formed by a roll-to-roll, and may be configured to combine a feeding device for feeding the thermoplastic film 1 continuously conveyed, a winding device for winding, and the like. it can.

  The backup roll 2 is a roll for applying pressure evenly in the width direction of the pressure roll 4. However, in the present invention, the backup roll 2 is not in direct contact with the pressure roll 4, but is pressed through the intermediate roll 3. It is a mechanism to transmit.

  FIG. 2 schematically shows how the force is transmitted by the pressure mechanism of the present invention. The force applied to the backup roll 2 is transmitted to the roll plate 5 through the intermediate roll 3 and the pressure roll 4. Given.

In the present invention, the reason why the intermediate roll 3 is provided between the backup roll 2 and the pressure roll 4 is that the backup roll 2 also has a function as a transport roll for the continuous thermoplastic film 1. By providing, the rotation direction of the backup roll 2 and the pressure roll 4 can be made the same direction with respect to the thermoplastic film 1 to be conveyed.

  The diameter of the backup roll 2 needs to be larger than the diameter of the pressure roll 4. The length (width) of the contact portion between the backup roll 2 and the intermediate roll 3 is preferably equal to or greater than the length of the contact portion between the pressure roll 4 and the intermediate roll 3. Thereby, it can press equally with respect to the length direction of the pressure roll 4, ie, the width direction of the thermoplastic film 1 conveyed continuously.

  Furthermore, the backup roll 2 also has a function as a heating roll that heats the thermoplastic film 1 when the thermoplastic film 1 is conveyed. Since the backup roll 2 receives the heat of the heated roll plate 5 via the pressure roll and the intermediate roll, the temperature becomes high during operation, and thus the thermoplastic film 1 can be heated.

  The white arrow in FIG. 1 indicates the direction in which heat is transferred during operation when the roll plate 5 has a heating mechanism. The heat of the heated roll plate 5 is caused by the contact rotation during operation and the pressure roll 4. , Intermediate roll 3 and backup roll 2 in this order.

  Further, in this method, the temperature of the backup roll 2 immediately after the start of operation is low, but it is also possible to provide a heating mechanism in the backup roll 2 itself and apply sufficient heat immediately after the start of operation.

  Further, any one of the backup roll 2, the intermediate roll 3, and the pressure roll 4 has a heating mechanism, and a mechanism that rotates these rolls in contact with the pressure roll 4 not pressed against the roll plate 5. By providing, sufficient heat can be applied immediately after operation.

  FIG. 3 schematically shows how heat is transferred when a backup roll 2 is provided with a heating mechanism and a preheating operation is performed. In a state where the thermoplastic film 1 is not passed before operation, By heating the backup roll 2 while rotating the backup roll 2, the intermediate roll 3, and the pressure roll 4 in contact with each other, the heat of the backup roll 2 is transmitted in the order of the intermediate roll 3 and the pressure roll 4.

  By providing the backup roll 2 with a heating mechanism, the backup roll 2 can be a roll having a diameter larger than that of the intermediate roll 3 and the pressure roll 4, so that the heat capacity is increased and a stable preheating effect can be provided. Is a point.

  Furthermore, the backup roll 2 is a roll that preheats the thermoplastic film 1 during operation. By directly heating the roll, the thermoplastic film 1 can be stably given a high preheating effect.

  By preheating the thermoplastic film 1 with the backup roll 2, it is possible to improve the molding stability of the concavo-convex shape on the thermoplastic film 1, but in addition, rapid heating by the pressure roll 4 and the roll plate 5 It can also be expected to suppress the generation of thermal wrinkles.

  In order to give a sufficient preheating effect to the thermoplastic film 1, the holding angle of the thermoplastic film 1 in the backup roll 2 is preferably 90 ° or more, and more preferably 120 ° or more.

On the other hand, by providing the intermediate roll 3 with a heating mechanism, since the intermediate roll 3 is in contact with both the backup roll 2 and the pressure roll 4, a preheating effect can be equally applied to both rolls.

  Moreover, as a merit of providing a heating mechanism in the pressure roll 4, the temperature at the time of forming the uneven | corrugated shape by pressing the thermoplastic film 1 against the roll plate 5 can be mentioned.

  When a heating mechanism for performing a preheating operation is provided, the surface temperature is preferably set so that the temperature difference is within 100 ° C. with the surface temperature of the roll plate 5 being the upper limit, and the temperature difference is within 50 ° C. It is more preferable to set so. If this temperature difference is within 100 ° C., it is possible to prevent the occurrence of problems due to the temperature difference immediately after operation. It is preferable because moldability can be obtained.

  Any material can be used for the backup roll 2 as long as it can transmit pressure uniformly to the pressure roll 4, and a general metal roll, resin roll, rubber roll, or the like can be used. When performing, it is preferable to use a metal roll having sufficient strength.

  Further, when the backup roll 2 has a heat and preheating mechanism that is received during operation, the backup roll 2 is pressurized under the influence of the heat, and therefore needs to be made of a material that can sufficiently withstand the environment.

  The backup roll 2 can be provided with a drive mechanism as required. For example, it is possible to adopt a configuration in which the drive is performed during the operation and the drive is performed directly during the preheating. This is because it is necessary to forcibly rotate without contacting the roll plate 5 during the preheating. On the other hand, it is effective when it is necessary to adjust the rotational speed of the backup roll 2 in accordance with the rotational speed of the roll plate 5 during operation.

  The intermediate roll 3 is a roll for transmitting the pressure of the backup roll 2 to the pressure roll 4, and is therefore a roll in contact with these two rolls. Two or more intermediate rolls 3 can be provided, and FIG. 4 is a conceptual diagram showing the configuration of the concavo-convex shape forming apparatus of the present invention when there are two intermediate rolls 3.

  Since the intermediate roll 3 is in direct contact with the backup roll 2 and the pressure roll 4, the rotation direction is opposite to the conveyance direction of the thermoplastic film 1. For this reason, it is necessary to install the intermediate roll 3 so as not to contact the thermoplastic film 1.

  When the number of intermediate rolls 3 is one, the pressures are made uniform when the rotation axes of the backup roll 2, the intermediate roll 3, and the pressure roll 4 are on the same plane, that is, when these three rolls are arranged in a straight line. At this time, if the diameter of the intermediate roll 3 is less than the geometric average of the diameters of the backup roll 2 and the pressure roll 4, the thermoplastic film 1 is conveyed without contacting the intermediate roll 3. Is done.

  The intermediate roll 3 can be made of the same material as the backup roll 2. It is also possible to provide a heating mechanism and a driving mechanism. The reason for providing these is the same as the reason for providing these for the backup roll 2.

  The pressure roll 4 is a roll for forming the inverted shape of the uneven shape provided on the roll plate 5 on the thermoplastic film 1 by pressing the thermoplastic film 1 against the roll plate 5. In the present invention, the pressure roll 4 is configured to receive the force from the backup roll 2 via the intermediate roll 3.

  When the thermoplastic film 1 is pressed against the roll plate 5 by the pressure roll 4, air is trapped between the thermoplastic film 1 and the roll plate 5 depending on the concavo-convex shape provided on the roll plate 5, resulting in molding defects. There are things to do.

  At this time, air can easily escape by reducing the diameter of the pressure roll 4, and the occurrence of molding defects can be suppressed. Although it is necessary to design the diameter of the pressure roll 4 according to the uneven | corrugated shape to form, 200 mm or less is preferable and 100 mm or less is more preferable.

  If the diameter of the pressure roll 4 is 200 mm or less, the contact area of the pressurizing portion that is pressed linearly becomes small, and thus the entrapment of bubbles in the fine structure where the structural height is 10 μm or less. If it is 100 mm or less, even if it is a concavo-convex shape exceeding the structural height of 10 μm, it is preferable because it is possible to suppress the entrapment of bubbles.

  The material of the pressure roll 4 may be any material as long as the thermoplastic film 1 can be uniformly pressed against the roll plate 5, and a general metal roll, resin roll, rubber roll, etc. can be used. It is necessary to select appropriately according to conditions such as size and aspect ratio.

  For example, when a material having a relatively high moldability is used for the thermoplastic film 1 and a shape having a concavo-convex shape exceeding 10 μm is generated, a rubber roll is used to form the shape without unevenness. preferable.

  Moreover, since the pressure roll 4 is pressurized in the state which received the heat | fever of the roll plate 5, it needs to be the material which can fully endure the environment. Examples of the rubber roll having high heat resistance include silicone rubber and fluorine rubber.

  Further, the pressure roll 4 can be provided with a heating mechanism and a driving mechanism. The reason for providing these is the same as the reason for providing these for the backup roll 2.

  The roll plate 5 is a roll having a concavo-convex shape on its surface, and has a shape in which the concavo-convex shape is reversed with the shape formed on the thermoplastic film 1. Or you may wind and use a flat mold.

  The uneven shape of the roll plate 5 can be created using methods such as cutting, corrosion, engraving, laser processing, and electron beam processing. In the case of using a cylindrical or flat mold, it is also possible to duplicate and use an original plate prepared by these methods by a method such as transfer or electroforming.

  As the material of the concavo-convex shape of the roll plate 5, various metals, resins, glass and the like can be used. Examples of the metal include iron, chromium, nickel, copper, aluminum, and alloys thereof, and the outermost surface of the concavo-convex shape may be plated with a thickness of about several μm. When resin or glass is used for the concavo-convex shape, a cylindrical or flat mold is mainly used for these.

  As the concavo-convex shape formed on the thermoplastic film 1, a lenticular lens, a prism lens, a microlens array, a Fresnel lens, a diffraction grating having a finer structure, a non-reflective structure, or the like is used. The shape is that in which this inverted shape is formed.

The depth of the uneven structure can be about 0.01 μm to 50 μm, and the pitch of the uneven structure can be about 0.01 μm to 100 μm.

  The pitch mentioned here means the interval between the structures of a single structure such as a lenticular lens, a prism lens, a microlens array, and a finer structure, like a Fresnel lens. In a structure constituted by a plurality of grooves, it means the interval between the grooves.

  Further, the width of the roll plate 5 is generally 0.1 or more and 1.5 m or less, and accordingly, the width of the thermoplastic film 1 is generally 0.1 or more and 1.5 m or less. The If the width of the roll plate 5 is 0.1 or more, the thermoplastic film 1 can be conveyed relatively stably even if it is affected by heat during molding. This is preferable because there is little distortion and the load applied to the entire roll can be suppressed.

  The roll plate 5 preferably has a drive mechanism. By transporting the thermoplastic film 1 based on the rotation speed of the roll plate 5, it is possible to form an uneven shape with high dimensional stability.

  Furthermore, the roll plate 5 preferably has a heating mechanism. This is to improve the formation rate of the concavo-convex shape by softening the surface of the thermoplastic film 1 when forming the concavo-convex shape on the thermoplastic film 1.

  As the heating mechanism, means such as hot water, heat medium oil, induction heating, infrared heater, etc. can be used, among which hot water and heat medium oil are heated from inside the roll plate, infrared heater is heated from the outside can do. With respect to induction heating, both internal heating and external heating can be employed.

  The heating temperature of the roll plate 5 is not particularly limited, but the surface of the thermoplastic film 1 needs to be within a temperature range in which the surface of the thermoplastic film 1 is softened and the thermoplastic film 1 itself is not broken or undergoes a large dimensional change. Therefore, when PET is used as the base material of the thermoplastic film 1, for example, the upper limit of the heating temperature is about 150 to 200 ° C. If the heating temperature is 150 ° C. or higher, sufficient moldability can be obtained even when a resin such as polypropylene or acrylic is provided on the PET substrate as the concavo-convex shape forming layer. This is preferable because no breakage occurs.

  Here, the thermoplastic film 1 used for uneven | corrugated shape formation of this invention is demonstrated. The thermoplastic film 1 that forms an uneven shape according to the present invention may be composed of a single layer or may be composed of a plurality of layers.

  Moreover, each layer does not need to be a single material, and may be composed of a plurality of resins and inorganic particles. Further, when the thermoplastic film 1 is composed of a plurality of layers, it is composed of only a metal or a metal oxide. Layers may be included.

  When the thermoplastic film 1 is composed of a plurality of layers, for example, on a base material such as PET, a material that is more easily thermally deformed than the base material can be laminated, and this layer can be used as an uneven shape forming layer. While ensuring the strength of the entire thermoplastic film 1, it is possible to improve the formability of the concavo-convex shape.

FIG. 5 is a conceptual diagram showing the configuration of the concavo-convex shape forming apparatus of the present invention when the conveyor belt 7 is wound around the backup roll 2 and the pressure roll 4. When the transport belt 7 is used, the thermoplastic film 1 is pressed against the roll plate 5 through the transport belt 7 instead of the pressure roll 4 itself.

  Further, as shown in FIG. 5, the thermoplastic film 1 is transported by the transport belt 7 until it is held by the pressure roll 4 from the backup roll 2 and pressed against the roll plate 5, and the transport belt 7 has a heating mechanism. In the case of having the heat received from the roll and the preheating mechanism, the thermoplastic film 1 is heated while being conveyed by the conveying belt 7 because it is heated by the heat. Due to the preheating effect of the thermoplastic film 1, the formability of the concavo-convex shape on the thermoplastic film 1 can be improved.

  Various materials such as metal and rubber can be used as the material of the conveyor belt 7. The conveyor belt 7 has a role of directly pressing the thermoplastic film 1 against the roll plate 5, and its smoothness and hardness affect the moldability. Therefore, it is necessary to appropriately select the conveyor belt 7 according to the shape to be formed.

  Further, since the tension of the wound conveyor belt 7 is affected by heat, a separate tension adjusting mechanism may be provided.

  FIG. 6 shows the configuration of an uneven shape forming apparatus having ultraviolet irradiation means. In this apparatus configuration, the thermoplastic film 1 pressed against the roll plate 5 by the pressure roll 4 and the thermoplastic film 1 After the roll plate 5 is kept in close contact with the ultraviolet lamp 8, the thermoplastic film 1 is peeled off from the roll plate 5 using a peeling roll 9.

  As the thermoplastic film 1 used in the uneven shape forming apparatus having this configuration, a film including a layer having a resin curable by ultraviolet rays is used.

  The layer having a resin that is cured by ultraviolet rays may be in a liquid state before being cured, but volatile components such as a solvent need to be removed at the time of forming the uneven shape. For this reason, it is also possible to provide a coating device and a drying device between the device of the present invention and the feeding device.

  As the coating device and drying device, general coating methods such as gravure, reverse gravure, kiss reverse, die, lip, comma, and the accompanying drying device are used, but in the case of solventless coating, the drying device Can be omitted.

  By curing the resin cured by ultraviolet rays with the ultraviolet lamp 8, the uneven shape formed on the thermoplastic film 1 is deformed after peeling, or a part of the material constituting the uneven shape is taken up by the roll plate 5. This can be prevented.

  As the ultraviolet lamp 8, a discharge lamp such as a mercury lamp or a metal halide lamp, an LED lamp having a light emission wavelength in the ultraviolet region, or the like can be used. However, it is necessary to appropriately select a lamp that matches the curing characteristics of the thermoplastic film 1. is there.

  As shown in FIG. 6, when the ultraviolet lamp 8 is installed outside the roll plate 5, it is necessary to use a material that transmits ultraviolet rays having a wavelength contributing to curing for the layer constituting the thermoplastic film 1. Is made of a material that transmits ultraviolet rays such as a glass mold, for example, it is also possible to install the ultraviolet lamp 8 inside the roll plate 5.

  The peeling roll 9 is for stably peeling the thermoplastic film 1 from the roll plate 5. When the thermoplastic film 1 is peeled from the roll plate 5, an uneven shape is formed on the surface of the thermoplastic film 1, and the force necessary to peel the thermoplastic film 1 from the roll plate 5 is the uneven shape. Affected by.

  When the uneven shape is not a uniform pattern, the force required for peeling differs locally, so that peeling is stable when the thermoplastic film 1 is peeled from the roll plate 5 without using the peeling roll 9. Otherwise, so-called zipping may occur.

  As a material of the peeling roll 9, a general metal roll, a resin roll, a rubber roll, or the like can be used. However, since the peeling roll 9 is affected by the heat of the roll plate 5, it is a material that can sufficiently withstand the environment. There is a need.

  In addition, as with the backup roll 2, a heating mechanism can also be provided for the peeling roll 9. Although the temperature of the peeling roll 9 does not affect the moldability of the concavo-convex shape of the thermoplastic film 1, by heating the peeling roll 9, even a deep concavo-convex shape having a heavy peeling can be lightened, Cracks can be reduced.

  FIG. 7 shows a configuration of a concavo-convex shape forming apparatus having a cooling peeling roll 10, and after the concavo-convex shape is formed by being pressed against the roll plate 5 by the pressure roll 4 depending on the material of the thermoplastic film 1. If peeling is performed while the temperature is high, the formed uneven shape may be deformed after peeling, or a part of the material constituting the uneven shape may be taken on the roll plate 5.

  In order to prevent this, after the thermoplastic film 1 pressed against the roll plate 5 by the pressure roll 4 is not peeled off by the pressure roll 4, it is conveyed while the thermoplastic film 1 and the roll plate 5 remain in close contact with each other. The structure which peels the thermoplastic film 1 from the roll plate 5 using the cooling peeling roll 10 can be used.

  The cooling peeling roll 10 is a roll having a cooling mechanism. The cooling mechanism includes water cooling and air cooling from the inside, air cooling from the outside, and cooling from the outside by rotating the other rolls cooled by these means. These means can be used alone or in combination.

  The surface temperature of the cooling peeling roll 10 is set to be lower than the surface temperature of the roll plate 5, but if the temperature difference is made too large, the peeling becomes heavy depending on the uneven shape, or there are defects such as wrinkles and cracks. May occur.

  Moreover, since the cooling peeling roll 10 always receives the heat of the roll plate 5 during operation, if the temperature difference is too large, the energy required for cooling the cooling peeling roll 10 and the roll plate 5 are taken away by the cooling peeling roll 10. The energy required to make up for heat will increase. On the other hand, if the temperature difference is too small, the formed uneven shape is broken, so the temperature difference between the cooling peeling roll 10 and the roll plate 5 is set to be about 10 to 50 ° C.

  The purpose of the cooling peeling roll 10 is to keep the temperature difference from the surface of the roll plate 5 constant, and therefore a heating mechanism may be provided in addition to the cooling mechanism. Thus, heating is performed so that the temperature of the cooling peeling roll 10 does not become too low before operation, but during operation, cooling is performed so as to suppress a temperature rise due to heat received from the roll plate 5. It becomes possible. The temperature adjustment mechanism using warm water or heat medium oil can be used as a mechanism having both cooling and heating functions.

  Moreover, the cooling peeling roll 10 can be used in place of the peeling roll 9 of the uneven shape forming apparatus having ultraviolet irradiation means.

  As a material of the cooling peeling roll 10, a general metal roll, a resin roll, a rubber roll, etc. can be suitably selected and used according to a cooling means. Since the metal roll has high thermal conductivity, the temperature control responsiveness when the temperature is adjusted from the inside of the roll with warm water or heat medium oil is high. On the other hand, since a resin roll and a rubber roll have low thermal conductivity, there is a merit that the temperature hardly changes even if the surrounding environment changes rapidly. For this reason, the temperature control mechanism for cooling and heating the resin roll and the rubber roll is preferably based on contact from the outside.

  Moreover, since the peeling roll 9 and the cooling peeling roll 10 have a mechanism that presses against the roll plate 5 via the thermoplastic film 1, when the roll has a high hardness, the thermoplastic film 1 and the roll depending on the concavo-convex shape to be formed. The plate 5 may be damaged. In such a case, it is preferable to use a rubber roll as the roll material.

DESCRIPTION OF SYMBOLS 1 ... Thermoplastic film 2 ... Backup roll 3 ... Intermediate roll 4 ... Pressure roll 5 ... Roll plate 6 ... Cooling roll 7 ... Conveying belt 8 ... Ultraviolet lamp 9 ... Peeling roll 10 ... Cooling peeling roll

Claims (12)

A roll plate for forming an uneven shape;
A pressure roll that presses the thermoplastic film against the roll plate;
An intermediate roll in contact with the pressure roll;
A backup roll that contacts the intermediate roll, presses the pressure roll against the roll plate via the intermediate roll, and preheats the thermoplastic film;
At least a heating mechanism for heating to any one of the roll plate, the pressure roll, the intermediate roll, and the backup roll,
An uneven shape forming method for providing an uneven shape to the thermoplastic film,
The diameter of the pressure roll is equal to or less than the diameter of the backup roll,
The intermediate roll has a diameter less than the diameter of the backup roll, the thermoplastic film is directly transferred from the backup roll to the pressure roll, and then the thermoplastic film is pressed against a roll plate. .   The intermediate roll is one roll having a diameter less than the geometric mean of the diameter of the backup roll and the pressure roll, and the rotation axis of the backup roll, the intermediate roll, and the pressure roll is The method for forming a concavo-convex shape according to claim 1, wherein the thermoplastic film is placed on the same plane and the thermoplastic film is pressed against a roll plate.   In a state where the pressure roll is not pressed against the roll plate, the thermoplastic film is pressed against the roll plate after preheating the backup roll, the pressure roll, or the backup roll and the pressure roll. The uneven | corrugated shape formation method of Claim 1 or Claim 2 characterized by the above-mentioned.   A conveyor belt is wound around the two rolls of the backup roll and the pressure roll, the thermoplastic film is conveyed by the conveyor belt, and then the thermoplastic film is pressed against the roll plate via the conveyor belt. The uneven | corrugated shape formation method as described in any one of Claims 1-3 characterized by these.   The thermoplastic film and the roll plate are peeled off after irradiating the thermoplastic film pressed against the roll plate with ultraviolet rays in close contact with the roll plate. The uneven | corrugated shaped formation method as described in any one of Claims.   The thermoplastic film and the roll plate are peeled from the thermoplastic film pressed against the roll plate while pressing a cooling release roll having a surface temperature lower than the surface temperature of the roll plate against the roll plate. The concavo-convex shape forming method according to any one of claims 1 to 5. A roll plate for forming an uneven shape;
A pressure roll that presses the thermoplastic film against the roll plate;
An intermediate roll in contact with the pressure roll;
A backup roll that contacts the intermediate roll, presses the pressure roll against the roll plate via the intermediate roll, and preheats the thermoplastic film;
And at least a heating mechanism for heating the roll plate, the pressure roll, the intermediate roll, and the backup roll to a certain temperature,
The diameter of the pressure roll is equal to or less than the diameter of the backup roll,
An uneven shape forming apparatus, wherein a diameter of the intermediate roll is less than a diameter of the backup roll.   The intermediate roll is one roll having a diameter less than the geometric mean of the diameter of the backup roll and the pressure roll, and the rotation axis of the backup roll, the intermediate roll, and the pressure roll is 8. The uneven shape forming apparatus according to claim 7, wherein the uneven shape forming apparatus is on the same plane.   9. A heating mechanism for preheating at least one of the backup roll and the pressure roll in a state where the pressure roll is not pressed against the roll plate. The uneven | corrugated shape formation apparatus as described in any one of.   A transport belt is wound around the two rolls of the backup roll and the pressure roll, and after the film is transported on the transport belt, the mechanism is pressed against the roll plate via the transport belt. The uneven | corrugated shape formation apparatus as described in any one of Claims 7-9 characterized by the above-mentioned.   The film pressed against the roll plate has an ultraviolet irradiation device that irradiates ultraviolet rays in close contact with the roll plate, and a mechanism for peeling the film and the roll plate after irradiating ultraviolet rays. The uneven | corrugated shape formation apparatus of Claims 7-10 characterized by the above-mentioned.   The film pressed against the roll plate has a mechanism for peeling the film and the roll plate while pressing a cooling release roll having a surface temperature lower than the surface temperature of the roll plate against the roll plate. The concavo-convex shape forming apparatus according to claim 7.

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