JP2515501B2 - Embossing roll manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing an embossing roll for embossing a sheet such as a synthetic resin film, paper or artificial leather.

2. Description of the Related Art Conventionally, embossing rolls have been well manufactured by directly engraving hard rolls such as metal rolls.

Also known is a method for producing a sheet having an embossed pattern by casting a resin such as polyvinyl chloride on a long embossed release paper.

Problems to be Solved by the Invention However, it is extremely costly to provide an emboss by directly engraving on a metal roll. Therefore, even if it is suitable for the production of mass-produced products, the purpose is to obtain a small amount of a variety of embossed rolls. Is not appropriate.

On the other hand, the method of manufacturing a sheet having an embossed pattern by casting a resin such as polyvinyl chloride on a long release paper that has been embossed is a small amount for those who purchase and use this release paper. Although it is possible to cope with the type of product, the long release paper itself that has been embossed must be manufactured using metal embossing rolls. Further, since the release paper is a consumable item, it is not always advantageous for the purchaser of the release paper, and there is a restriction that it can be applied only to the casting type resin.

Therefore, the present inventor wound a hard resin roll with a planar resin mask having through holes corresponding to the embossed pattern,
I thought about manufacturing an embossing roll by sandblasting through this resin mask, but when I wrapped a hard resin roll with a planar resin mask, I faced the problem that it was extremely difficult to accurately match the seams. .

In view of such a situation, the present invention aims to provide a method for manufacturing an embossing roll by a method completely different from the above-mentioned conventional method.

Means for Solving the Problems In the method for manufacturing an embossing roll of the present invention, a photosensitive resin liquid is supplied into the inside of a cylinder having actinic ray transparency, and the cylinder is rotated at a high speed to cause photosensitivity by centrifugal force. The resin liquid is evenly adhered to the inner surface of the cylinder to form the photosensitive resin layer, and the image carrier for forming the embossed pattern arranged on the outer surface of the cylinder or the embossed pattern previously attached to the inner surface of the cylinder before supplying the photosensitive resin liquid. A step (A) of exposing the photosensitive resin layer by irradiating an actinic ray from the outside of the cylinder through the image carrier for forming, and a seamless cylindrical resin molded product obtained in the previous step (A). A step (B) of washing and removing the unexposed resin to form a resin mask of a cylindrical body having a through hole or a penetrable hole corresponding to the embossed pattern; and the cylindrical shape obtained in the previous step (B). External fitting of resin mask to hard roll It is characterized in that it comprises a step (C) of performing blasting or enching treatment in the state.

 The present invention will be described in detail below.

As the photosensitive resin liquid in the present invention, the following types are used.

(A) Photopolymerization composition system consisting of photopolymerizable monomer and polymer Examples of the system belonging to this system include, for example, a type in which a monofunctional monomer is photopolymerized in a polymer matrix, and a polyfunctional monomer is a polymer matrix. Photopolymerization type in or a type in which a monofunctional monomer is added thereto, a type in which a monofunctional monomer is photopolymerized in a prepolymer,
Examples thereof include a type in which a polyfunctional monomer and a monofunctional monomer are photopolymerized in a prepolymer, and a type including a prepolymer and a polymer.

Examples of the photopolymerizable monomer include acrylic acid esters of polyhydric alcohols, urethane type acrylic acid esters, unsaturated esters of polyhydric carboxylic acids, unsaturated acid amides, acetylenically unsaturated group-containing monomers, glycidyl group-containing monomers and the like. As the polymer, epoxy resin, polyester, polyurethane, polyether, polyamide,
Examples are various polymers or prepolymers including polyacrylic acid or maleic acid copolymers, silicone resins, cellulosic resins, and synthetic rubber polymers.

(B) System consisting of photosensitive compound and polymer As a system belonging to this system, those using dichromate as a photosensitive compound, those using an aromatic diazo compound, those using an aromatic azide compound, organic Examples thereof include those using a halogen compound and those resulting from crosslinking an unsaturated polymer with a photopolymerization initiator.

(C) System composed of a polymer having a photosensitive group As a compound belonging to this system, a polymer having a cinnamoyl group, a polymer having a diazo group, a polymer having an azide group and the like can be mentioned.

Step (A) In the first step of the present invention, a photosensitive resin liquid is supplied to the inside of a cylindrical body having actinic ray transparency, the cylindrical body is rotated at a high speed, and the photosensitive resin liquid is centrifugally applied to the inner surface of the cylindrical body. To form a photosensitive resin layer evenly on the inner surface of the cylinder, and the image carrier for embossing pattern formation placed on the outer surface of the cylinder or the image carrier for forming embossing pattern previously attached to the inner surface of the cylinder before supplying the photosensitive resin liquid. The photosensitive resin layer is exposed by irradiating an actinic ray from the outside of the cylindrical body (A).

That is, a cylinder having actinic ray transparency is arranged so that its center line is in a substantially horizontal direction, the photosensitive resin liquid is poured into the cylinder by an appropriate supply tool while rotating the cylinder at a low speed, and then Rotate the cylinder at high speed. Due to this high speed rotation, the photosensitive resin liquid adhering to the inner surface of the cylinder is diffused to the inner surface of the cylinder by a centrifugal force, and a photosensitive resin layer having a uniform film thickness is formed without containing bubbles. If the system is moved to a depressurized condition while the cylinder is rotating, the possibility of bubbles entering the photosensitive resin layer to be formed is further reduced.

If the cylindrical body has a slight taper, the viscosity of the photosensitive resin liquid and the rotation speed of the cylindrical body are controlled so that the photosensitive resin layer or the film thickness having a slight taper instead of the right cylinder shape can be obtained. Since it is possible to obtain a photosensitive resin layer that gradually increases in thickness from one end to the other end, it is possible to easily mount the photosensitive resin layer on a hard roll in a subsequent step.

An image carrier for forming an embossed pattern is previously attached to the inner surface of the cylinder before supplying the photosensitive resin liquid. A coating layer of silicone, fluororesin, or the like can be formed on this carrier in order to facilitate separation from the photosensitive resin layer.

However, it is possible in some cases to dispose the embossed pattern forming image carrier on the outer surface of the cylinder.

When a uniform photosensitive resin layer is formed on the inner surface of the cylinder, the photosensitive resin layer is exposed by irradiating an actinic ray from the outside of the cylinder through the embossed pattern forming image carrier. This exposure is performed until the resin is cured to the opposite surface through the photosensitive resin layer. In some cases, the actinic ray may be irradiated from the inside of the cylinder for a short time.

Actinic rays include ultraviolet rays, X-rays, electron beams, etc., and ultraviolet rays are particularly important. When the actinic ray is an ultraviolet ray, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a carbon arc lamp, a xenon lamp, a metal halide lamp, a chemical lamp, a black light and the like are used as a light source.

As the material of the cylindrical body having an actinic ray transmitting property, in addition to various inorganic glasses, organic glasses made of polymethylmethacrylate, polystyrene, polyolefin, polyvinyl chloride or the like are used.

Step (B) In the next step of the present invention, the seamless cylindrical resin molded product obtained in all the steps (A) is washed to remove the unexposed resin to allow penetration or penetration corresponding to the embossed pattern. Step (B) of forming a cylindrical resin mask having various holes.

As the cleaning liquid, that is, the washout liquid, water, alkaline water, acidic water, water containing a surfactant, an organic solvent or the like is used depending on the type of the photosensitive resin liquid used.

The washing is usually performed after peeling the tubular resin molded product from the tubular body, but it can also be performed while it is still attached to the inner surface of the tubular body. Alternatively, the tubular resin molded product may be peeled from the tubular body, fitted onto a hard roll, and washed in this state.

After washing, it is dried and, if necessary, post-exposed. The post-exposure is for complete curing.

Step (C) The final step of the present invention comprises a step (C) of performing blasting or etching treatment with the tubular resin mask obtained in the previous step (B) fitted onto a hard roll.

A metal roll is often used as the hard roll, but a roll made of a hard resin such as hard plastics or fiber reinforced plastics, or a roll made of glass may also be used.

The sandblasting method is adopted as the blasting process. In the case of the blast treatment, the portion corresponding to the unexposed portion of the resin mask need not be a through hole but may be thin enough to be easily punched by sandblasting. As the etching treatment, a method using a corrosive liquid such as a strong acid or hydrogen fluoride or a corrosive gas is adopted depending on the material of the hard roll.

The emboss depth of the hard roll by blasting or etching treatment can be arbitrarily adjusted by changing the treatment time and the treatment conditions.

Use The embossing roll obtained as described above is preferably used for the purpose of embossing a sheet of synthetic resin film, paper, artificial leather, or the like.

Action The photosensitive resin liquid supplied to the inside of the cylinder is diffused to the inner surface of the cylinder by the centrifugal force when the cylinder is rotated at a high speed, and a layer having a uniform film thickness containing no bubbles is formed.

Then, when the photosensitive resin layer is exposed by irradiating an active ray from the outside of the cylinder through the embossed pattern forming image carrier while rotating the cylinder, only the portion corresponding to the embossed pattern is cured.

Next, the exposed cylindrical resin molded product after the exposure is washed to remove the unexposed resin and form a cylindrical resin mask having a penetrating or penetrating hole corresponding to the embossed pattern.

The target embossing roll can be manufactured by blasting or etching the cylindrical resin mask thus obtained on the hard roll.

Examples Next, examples will be given to further explain the method of the present invention.

Example 1 FIG. 1 is a partially cutaway front view showing an example of an apparatus used for carrying out the step (A) of the present invention, FIG. 2 is a left side view thereof, and FIG. FIG.

(1) is a cylindrical body made of glass or transparent resin,
It is arranged so that its center line is horizontal, and its side surface on the base end side is closed by a side plate (2). The tubular body (1) is configured to be rotatable at a low speed and a high speed around a rotation shaft (3) attached to the outside of the side plate (2). (F) is a negative or positive film as an image carrier for forming an embossed pattern, which is provided in close contact with the inner periphery of the cylindrical body (1).

(4) is a weir provided inside the free end side of the tubular body (1).
Although illustration is omitted, a lid having a central opening may be detachably provided instead of or together with the weir (4).

Reference numeral (5) is a box body that covers the entire tubular body (1), and a door (6) is provided on the free end side of the tubular body (1), and a window (7) made of a glass plate is provided on the door (6). ) Is attached. (8) is a handle for opening and closing the door (6), and (9) is a hinge.

(10) is a chemical lamp as an example of an actinic ray irradiation source provided in large numbers inside the box (5).

In FIGS. 1 and 2, (11) is a base, (12) is a motor for rotating the rotary shaft (3), (13) is a pulley attached to the drive shaft of the motor (12), and (14). Is a pulley attached to the rotary shaft (3), and (15) is a belt connecting these pulleys (13) and (14). (16) is an operation panel, (17) is a switch, (18) is a vacuum gauge,
(19) is a speed tachometer, and (20) is temperature control. (21) is a temperature sensor provided in the cylindrical body (3).

Reference numeral (22) indicated by a one-dot chain line is a long "shaped" supply tool for supplying the photosensitive resin liquid to the inside of the cylindrical body (1).

Using the above apparatus, a resin mask for manufacturing an embossing roll was manufactured as follows.

Open the door (6) of the box (5) to open the photosensitive resin liquid (L)
Insert the supply tool (22) with the insert into the inner part of the cylinder (1) as shown by the alternate long and short dash line in FIG. 1, and operate the motor (12) to rotate the cylinder (1) at a low speed of 100 rpm. While rotating, gently invert the supply tool (22) to pour the photosensitive resin liquid (L), then pull out the supply tool (22), and then remove the cylindrical body (1).
The photosensitive resin liquid (A) was rotated at a high speed of 1,000 rpm to uniformly adhere to the inner surface of the cylindrical body (1) by centrifugal force. While continuing the high speed rotation of the cylinder (1) in this state, the vacuum gauge (17) is operated as necessary to place the inside of the box (5) and the cylinder (1) under a decompressed condition, and then the chemical Exposure was performed by irradiation of a lamp (10).

After the exposure was completed, a seamless tubular resin molded product was peeled from the tubular body (1) and pulled out, and a washout solution was sprayed onto the outer peripheral surface to wash away the unexposed portion, and then water was sprayed to rinse it. After drying, the molded product after washing with water was set in a suitable transparent cylinder, and post-exposure was performed by irradiating ultraviolet rays from inside and outside the transparent cylinder to obtain a cylindrical resin mask.

Next, when the resin mask was externally fitted to a hard roll made of metal, and sandblasting was performed through the mask,
Only the through-hole portion of the mask was ground to form a recess.
After the sandblast treatment was completed, the mask was cut and removed. As a result, the desired embossing roll was obtained.

Example 2 FIG. 4 is a partially cutaway front view showing another example of the apparatus used for carrying out the step (A) of the present invention, and FIG. 5 is a left side view thereof.

(1) is a cylindrical body made of glass or transparent resin,
The center lines are arranged so as to be horizontal, and are supported by the support rolls (23) ... at the upper one place and the lower two places near both ends of the outer periphery thereof, respectively.
(F) is a negative or positive film as an image carrier for forming an embossed pattern, which is provided in close contact with the inner periphery of the cylindrical body (1). The driven gear (2
4) is provided. It should be noted that both ends of the inner circumference of the tubular body (1) are formed in different steps so as to form a weir (4).

A drive gear (25) is attached to the box body (5) so as to rotate together with the drive shaft (26) below the base end side extending portion of the cylinder body (1). The driven gear (24) meshes with the drive gear (25).

In the figures, the meanings of other symbols are the same as those in FIGS.

Using the above apparatus, a resin mask and an embossing roll were manufactured in the same manner as in Example 1.

The embossed pattern forming image carrier (F) may be arranged on the outer surface of the cylindrical body (1). That is, it is provided so as to be wound around the outer periphery of the tubular body (1), or to contact the tubular body (1) from the outside of the tubular body (1) and run at the same rotational speed of the tubular body (1). You can also do it. However, in this case, the ultraviolet rays passing through the carrier (F) tend to be scattered while passing through the inside of the cylindrical body (1) to make the image unclear. Therefore, it is possible to irradiate the ultraviolet rays through the slit holes. desirable.

EFFECTS OF THE INVENTION According to the method of the present invention, the photosensitive resin liquid is supplied to the inside of the cylindrical body, and the cylindrical body is rotated at a high speed to uniformly attach the photosensitive resin liquid to the inner surface of the cylindrical body by centrifugal force. Since the exposure is carried out through the image carrier for forming an embossed pattern in the above, only a portion corresponding to the embossed pattern is cured to obtain a completely homogeneous, seamless cylindrical resin molded product in the circumferential direction. .

Then, this resin molded product was washed to form a resin mask by removing the unexposed portion, and the hard roll surface was blasted or etched through the resin mask, so a seamless embossed pattern was formed on the roll surface. It can be formed efficiently. Moreover, at this time, the emboss depth can be arbitrarily set by controlling the blasting or etching processing conditions.

As described above, according to the present invention, the embossing roll can be manufactured much more easily than in the past, so that the present invention greatly contributes to this industry.

[Brief description of drawings]

FIG. 1 is a partially cutaway front view showing an example of an apparatus used for carrying out the step (A) of the present invention, FIG. 2 is a left side view of the same, and FIG. 3 is a side view of an essential part. Is. FIG. 4 is a partially cutaway front view showing another example of the apparatus used for carrying out the step (A) of the present invention, and FIG. 5 is a left side view thereof. (1) …… Cylinder, (2) …… Side plate, (3) …… Rotary axis,
(4) ... weir, (5) ... box, (6) ... door, (7)
…… Window, (8) …… Handle, (9) …… Hinge, (10),
(10 ′) …… Actinic ray irradiation source, (11) …… Base, (12)
...... Motor, (13), (14) …… Pulley, (15)…
… Belt, (16) …… Control panel, (17) …… Switch, (18) …… Vacuum gauge, (19) …… Speed tachometer, (20) …… Temperature control, (21) …… Temperature sensor , (22) …… Supplier, (23) …… Support roll, (2
4) …… Drive gear, (25) …… Drive gear, (26) …… Drive shaft, (L) …… Photosensitive resin liquid, (F) …… Image carrier for embossed pattern formation

Claims (1)

(57) [Claims] 1. A photosensitive resin liquid is supplied to the inside of a cylinder having an actinic ray transmitting property, the cylinder is rotated at a high speed, and the photosensitive resin liquid is uniformly attached to the inner surface of the cylinder by a centrifugal force to be exposed. Of the actinic ray from the outside of the cylinder through the image carrier for forming an embossed pattern formed on the outer surface of the cylinder or the image carrier for forming an embossed pattern previously attached to the inner surface of the cylinder before the photosensitive resin liquid is supplied while forming the resin layer. Step (A) in which the photosensitive resin layer is exposed by irradiating with, the seamless cylindrical resin molded product obtained in the previous step (A) is washed, and the unexposed resin is removed to form an embossed pattern. Step (B) of forming a cylindrical resin mask having a corresponding penetrating or penetrable hole, and blasting with the cylindrical resin mask obtained in the previous step (B) fitted onto a hard roll. Etching process (C Preparation of embossing rolls, characterized in that it consists of.