JP3248585B2 - Apparatus for manufacturing a film having an uneven surface - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for producing a film having an uneven surface.

[0002]

2. Description of the Related Art Hitherto, a film having an uneven surface has been used for an embossing film, a decorative film and the like. As a method for producing this film, a method of producing an uneven surface by embossing and printing on a film substrate, and in particular, embossing and printing an ultraviolet curable resin on the film substrate, and then irradiating ultraviolet light to cure the irregular surface. Is known. As a manufacturing apparatus used in the above manufacturing method, a printing apparatus such as a normal screen printing or a gravure printing has been used.

[0003]

However, when an attempt is made to produce a film having surface irregularities by using the above-mentioned conventional production apparatus, for example, in such a case, the liquid ink transferred from the plate onto the film substrate flows. However, it is difficult to form a sharp and fine embossed shape by printing, and since the ink for embossing printing is generally made of a thermoplastic resin, there is a problem that only an uneven surface having poor releasability and surface physical properties can be obtained. In addition, in the above case, the resin formed by the emboss printing flows before the irradiation of the ultraviolet rays, and the uneven shape is broken, and it is impossible to give a sharp and fine uneven shape. The present invention has been made in order to solve the above-mentioned disadvantages of the prior art, and it is possible to easily and reliably apply a sharp and fine uneven shape to a film substrate, and it is excellent in mold release properties, surface physical properties, and the like. An object of the present invention is to provide a manufacturing apparatus capable of manufacturing a film having an uneven surface.

[0004]

According to the present invention, there are provided (1) a concave and convex pattern;
Roll intaglio, and apply curable resin to the roll intaglio
Coating equipment for processing, roll intaglio and film substrate
The press roll to be in close contact with the roll
And a curing device for curing the cured resin.
A temperature control device for cooling and / or heating the plate is provided
When a curable resin coating device is installed in the middle of the nozzle,
The unevenness table characterized by being a nozzle coating device provided with
Production equipment for film with surface, (2) Curing equipment is ionized
It has an uneven surface as described in (1) above, which is a radiation irradiation device.
(3) The curing device is a dielectric heating device
Production of a film having an uneven surface according to the above (1)
(4) Roll intaglio, coating device, press roll, and hard
(1), (2) or (3) above comprising a plurality of
Production equipment for film with uneven surface
Cures the curable resin that has been peeled off from the intaglio
(1) with a curing device for, (2), (3) The
Is an apparatus for producing a film having an uneven surface according to (4),
Is the gist.

[0005]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an embodiment of the present invention, wherein 1 is a roll intaglio having desired concavities and convexities, 2 is a concave portion of the roll intaglio 1, 3 is a curable resin, 4 is a film substrate, 5 Denotes a pressing roll that abuts against the roll intaglio and presses the roll intaglio 1, and 6 denotes a feed roll. In the figure, 7 is a curable resin 3
Is a coating device for coating the curable resin 3 on the roll intaglio 1.

In the apparatus of the present invention, although not particularly shown, the roll intaglio 1 is provided with a driving device and is formed so as to rotate. The press roll 5 and the feed roll 6 are rotatable to feed the film substrate. These may be of a type in which they roll together with the roll intaglio 1, but can also be driven by a driving device. The apparatus of the present invention may further include a film supply device for feeding the film substrate 4 and a winding device for winding the film on which the uneven pattern is formed.

The above-mentioned roll intaglio 1 used in the present invention
Any method may be used as long as the desired recess 2 is provided with a predetermined recess 2 by a method such as electronic engraving, etching, milling, and electroforming. Further, as the material of the roll intaglio 1, a metal such as copper chrome, a synthetic resin such as NBR, epoxy, ebonite, etc., and a ceramic such as glass can be used. The size of the roll intaglio 1 is not particularly limited, and can be appropriately provided according to the size of the film having the uneven surface to be manufactured.

The size, shape, pattern, etc. of the recess 2 are not particularly limited, but the size is usually 10 to 100 μm.
m and preferably about 30 μm. And the depth
About 0.1 to 100 μm is preferable. Further, the pattern of the concave portion 2 may be a copy of a known uneven shape of a natural product such as wood grain, stone grain, cloth grain, etc., a character symbol, a line, various abstract patterns, various matte surfaces, specular gloss, and the like. Examples of the line pattern include, for example, a group of concavo-convex or grooves forming parallel straight lines or curves and a closed boundary line surrounding the group, in which directions of parallel straight lines or groups of straight lines in adjacent patterns are different. A pattern such as an aggregate of those having a straight line or a group of curves in a closed region is exemplified.

FIG. 3 shows an example of a temperature control device for a roll intaglio, and is a cross-sectional view of the roll intaglio 1 in the rotation axis direction. FIG.
5 is a cross-sectional view showing another example of a roll intaglio temperature control device, and FIG. 6 is a surface portion (A portion) of the roll intaglio in FIG.
FIG. In the manufacturing apparatus of the present invention,
The temperature control device for cooling and / or heating the roll intaglio
Have . As shown in FIGS. 3 to 5, the temperature control device for the roll intaglio circulates a heat medium such as water or Freon for controlling the temperature of the roll intaglio 1 inside the roll intaglio 1, and cools or inflates the roll intaglio 1 by heat conduction. Can be heated. The temperature of the heat medium can be arbitrarily adjusted by a heat medium heating device or a cooling device provided outside the roll intaglio 1 (not shown). In order to control the temperature of the roll intaglio, the shape of the roll intaglio is adjusted by providing a pipe 22 for passing a heat medium through the roll intaglio 1 as shown in FIG. The temperature can be controlled by using a heat medium from the inside of the roll intaglio by passing in the direction opposite to the direction of the arrow or the arrow.
Alternatively, as shown in FIG. 4, it is also possible to simply form a heat medium from both ends of the roll intaglio 1 so as to allow the heat medium to pass therethrough, and to pass the heat-regulated heat medium from one end to the other end of the roll intaglio. As shown in FIG. 5, a jacket 23 is provided inside the roll intaglio 1 as a shape of the roll intaglio for controlling the temperature.
It is also possible to form the inside of the roll intaglio into a hollow shape and allow the heat medium to pass through only the inside of the jacket 23.

In the apparatus of the present invention, as shown in FIG.
To form a double structure in which an etchable material such as a copper plate 25 is adhered to the surface side (the outer side of the roll intaglio C) of the core material, and after forming the concavo-convex pattern 8 on the copper plate 25, the release layer 26 is formed on the surface. Can be formed. The release layer 26 is provided to improve the abrasion resistance and releasability of the roll intaglio, and is made of metal such as chrome or the like, silicon resin, fluorine resin, or the like.

The temperature of the roll intaglio 1 can be appropriately determined by a temperature control device. For example, the roll intaglio is cooled when a heat-sensitive substrate film is used or when a paint having a slow curing speed is used. Thereby, the deterioration of the film substrate due to heat can be avoided.

Further, by heating the roll intaglio,
The viscosity of the paint is reduced, and the paint is easily filled completely in the roll intaglio, and the reproducibility of the uneven shape is improved. It is particularly effective in the case where the paint is filled into the concave portion of the roll intaglio in a state where the viscosity of the paint is high, such as when a solventless paint or a solvent is volatilized through a drying step. Furthermore, since the heating of the roll intaglio can anneal while curing the base film, it can release the residual stress at the time of curing, and the curl and distortion after the formation of the film having the uneven surface are less likely to occur. . In addition, when using a paint to which a matting agent, an antifogging agent, a conductive agent, an abrasive, a release agent, etc. is added, by heating and curing the roll intaglio, the temperature of the film substrate side and the roll intaglio side can be increased. Using the heat convection inside the coating film due to the difference, the concentration of the additive can be changed in the thickness direction of the coating film (the larger the temperature difference, the higher the additive concentration on the film substrate side).

The pressing roll 5 only needs to be able to press the film substrate, but it is usually about 140 mm in diameter, and can be made of silicon rubber, NBR, EPT or the like.

The curing device 7 can be selected according to the type of resin forming the surface irregularities. For example, when an ionizing radiation curable resin is used as the resin, an ionizing radiation irradiating device can be used. When a thermosetting resin is used as the resin, a dielectric heating device can be used.

As the above-mentioned ionizing radiation irradiating apparatus, in the case of ultraviolet rays, for example, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light lamp, a metal halide lamp or the like; Examples of the device include an irradiation source such as a bandeograph type, a resonance transformer type, an insulating core transformer type, or various electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type. Known devices can be used as the dielectric heating device, and examples thereof include a roller electrode type and a parallel plate electrode type.

The coating device 10 for coating the curable resin on the roll intaglio is a nozzle coating device (the method shown in FIG. 1) .
Can be. In the nozzle coating device, the nozzle has a fixed width in the rotation direction of the roll intaglio 1 and a direction perpendicular to the rotation direction (width direction).
And a discharge device for pressurizing and discharging the curable resin. 7 and 8 show an example of a nozzle coating apparatus, in which (a) is a longitudinal sectional view as viewed from the side of the roll intaglio, and (b) is b in (a).
FIG. 4 is a vertical sectional view (width direction) of a line b. Nozzle coating equipment
In order to reduce the unevenness of the discharge amount and the change with time, a cavity or a groove 12 (shaded portion) is provided in the middle of the nozzle as shown . It is preferable that the groove is formed in a hanger shape as shown in FIG. 7 because the discharge unevenness is reduced before the resin entering from the resin supply port 14 reaches the slit 15 at the nozzle tip. Also, as shown in FIG.
A linear groove 13 may be provided on the slit 15 side of the hanger-shaped groove 12, and the groove 12 on the hanger and the linear groove 13 may be combined, so that the discharge unevenness can be further reduced.

In the present invention, a solvent drying device 11 for volatilizing the solvent of the resin may be provided. The drying device 11 can use warm air, an infrared heater, or the like. By providing the solvent drying device 11, a solvent-type resin can be used, so that the range of choice of the resin to be used is widened and the coating property is easily adjusted.

Next, a method for producing a film having an uneven surface using the apparatus of the present invention will be described. First, a curable resin 3 is filled into a concave portion 2 of a roll intaglio 1 by a coating apparatus 10, and a resin 3 in which a film substrate 4 is filled in the roll intaglio 1.
Contact so that it also touches. Here, as a method of filling the concave portion with the curable resin, a predetermined amount of the curable resin 3 is previously applied to the surface of the roll intaglio 1 as shown in FIG.
When the base film 4 is supplied to the roll intaglio 1, the curable resin 3 applied to the base material is distributed and filled into the concave portions 2 by pressing the pressing roll 5 from the back surface of the base material.

In this case, a solvent type curable resin can be used, and the resin 3 applied to the film substrate 4 is a drying apparatus 1 for controlling the fluidity to some extent.
The solvent and the like used for dilution by 1 are dried and removed, and the curable resin obtained by drying the solvent is semi-cured by the curing device 7a. When using a non-solvent type curable resin, the drying device 11 is unnecessary.

Next, while the film substrate 4 is in contact with the roll intaglio 1 (specifically, when the film substrate 4 is located between the pressing roll 5 and the feed roll 6 in the drawing), the film is cured by the curing device 7. The conductive resin 3 is cured. Generally, when, for example, an ionizing radiation irradiating device is used as a curing device, ionizing radiation is irradiated from the film substrate 4 side as shown in the figure, but the roll intaglio 1 is formed of an ionizing radiation transmitting material such as quartz or glass. Irradiation can also be performed from the inside of the intaglio 1 (specifically, by an irradiation device installed inside the roll hollow). Irradiation may be performed from the film substrate side, the intaglio inner side, and both sides. Even when a dielectric heating device is used as the curing device 7, curing can be performed in the same manner as described above.

The curing device 7 causes the concave portion 2 of the roll intaglio 1
The curable resin 3a inside is brought into close contact with the film substrate 4. The degree of curing at this time should be at least such that the fluidity of the resin 3 is lost and the adhesiveness to the film substrate is generated. After passing through the curing device 7, the film substrate 4 is peeled from the intaglio 1. As a result, the cured curable resin 3a is integrated with the film substrate, and is separated from the recess 2 to obtain the film 9 having the uneven surface.

In the present invention, as shown in FIG. 1, a curing device 7b may be further provided to the desorbed curable resin to completely cure the curable resin. Further, the roll intaglio 1, the pressing roll 5, and the curing device 7 may be combined into a single line. For example, this combination makes it possible to efficiently perform raised color printing, surface raised printing, registered multicolor raised printing, and the like.

FIG. 2 shows an example of a film having surface irregularities manufactured by the apparatus of the present invention. In the present invention, the roll intaglio 1
Providing a device for adjusting the gap and pressure between the pressure roller 5 and the pressing roll 5 can control the thickness of the resin film 8b on the uneven surface composed of the resin film 8b serving as the convex portion 8a and the concave bottom surface. Preferred. Of course, the resin other than filling the concave portions may be removed with a doctor blade or the like to form a pattern of only the convex portions 8a.

The film substrate 4 used in the present invention includes polyester such as polyethylene terephthalate, polyamide such as nylon, acrylic resin such as polyvinyl chloride and polymethyl methacrylate, polycarbonate, polystyrene, polyacrylate, and fluororesin. , Polypropylene, cellulose triacetate, plastic film composed of cellophane, etc., or copper, iron, metal foil such as aluminum, paper and the like, and these may be used alone or as a base material appropriately laminated. Is also good. However, substrate 4
When irradiating with ionizing radiation from the side, the substrate 4 needs to be ionizing radiation permeable. In addition, as the base material 4, a structure in which another layer is laminated according to the intended use may be used. For example, a material in which a printed layer or the like is laminated may be used (in this case, the printed layer has The material may be formed on the surface opposite to the pattern 8 or on the same surface, but the material of the printing layer is selected or irradiated so as not to prevent the ionizing radiation from reaching the curable resin 3. It is necessary to select the direction). The thickness of the substrate 4 is appropriately selected depending on the application, but is generally 10 to 100 μm, preferably 25 to 50 μm.
m.

As the curable resin 4, a known ionizing radiation curable resin or a thermosetting resin can be used. Examples of the ionizing radiation-curable resin include a composition in which a prepolymer, an oligomer and / or a monomer having a polymerizable unsaturated bond or an epoxy group in a molecule, such as urethane acrylate or polyester acrylate, is appropriately mixed.

The thermosetting resin includes a phenol resin, a urea resin, a diallyl phthalate resin, a melamine resin, a guanamine resin, an unsaturated polyester resin,
Examples include a polyurethane resin, an epoxy resin, an amino alkyd resin, a melamine / urea co-condensation resin, a silicon resin, and a polysiloxane resin.

The film having an uneven surface manufactured by using the manufacturing apparatus of the present invention can be used for various applications such as a decorative film, a shaping film, and a transfer film.

Next, the present invention will be described in more detail with reference to specific examples. Example 1 A film having an uneven surface was manufactured based on the following conditions and materials using a manufacturing apparatus shown in FIG. 1 using an easily adhesive polyester film (HP-7, manufactured by Teijin) having a thickness of 28 μm as a film substrate. did. The resulting film having an uneven surface is excellent in heat resistance, solvent resistance, stain resistance and the like,
When used for applications such as decorative films and shaped films,
It was good.・ Ultraviolet curable resin: manufactured by Dainichi Seika, Seika Beam EX-880
926B (viscosity: 750 cps). Roll intaglio: An indentation having a plate depth of 15 μm formed by a direct etching method on a cylinder whose surface layer is made of copper, and equipped with a cooling device shown in FIG.・ Ultraviolet irradiation equipment: Ozone high pressure mercury lamp, output: 120 W
/cm .

[0029]

The manufacturing apparatus of the present invention comprises a roll intaglio having an uneven pattern, a coating apparatus for applying a curable resin to the roll intaglio, a pressing roll for bringing the roll intaglio into close contact with the film substrate, By providing a curing device for curing the curable resin held in the concave portion of the roll intaglio, the curable resin is held in the concave portion of the roll intaglio, and the resin becomes inefficient as compared with a conventional printing device. There is an effect that sharp unevenness corresponding to the shape of the concave portion can be easily and reliably applied to the film surface without flowing easily. Further coating
By using a nozzle coating device as the device, there is no danger that air will be entrained when applying the curable resin to the roll intaglio, and the curable resin can be uniformly and evenly applied in the recess. In addition, the uneven pattern can be more reliably formed in a stable shape. Furthermore, the production equipment of the present invention is cooled to roll intaglio
And / or a temperature control device for heating is provided
Therefore, the following effects are obtained. For example, if the temperature controller is
In some cases, avoid the effects of heat on the film substrate
Can be. If the temperature control device is a heating device, the uneven shape
Processed film can improve the reproducibility of
Less curl and distortion, and more beautiful fill
Is obtained. When using paints that use additives
In addition, it is necessary to arbitrarily change the concentration of the additive in the thickness direction of the coating film.
Can be. Further, the device of the present invention has a hollow or
Is equipped with a nozzle coating device with grooves, so that the discharge amount and
Stable coating is possible with little unevenness. In the above-described apparatus, when an ionizing radiation irradiating apparatus is used as a curing apparatus, an ionizing radiation-curable resin can be used, so that the resin can be cured in an extremely short time and workability is improved. Further, by using a dielectric heating device as the curing device, a thermosetting resin such as a phenol resin, a polyamide resin, and a melamine resin can be used. In addition, if a configuration having a plurality of sets of a roll intaglio, a coating device, a pressing roll, and a curing device is used, for example, an embossed color printing such as forming a concavo-convex pattern with a large number of colors, it becomes an apparatus most suitable for applications such as surface embossed printing, The use range of the present apparatus is further expanded, and, for example, when the above-described combination is provided on the same line, workability is further improved. In addition, by providing a curing device for curing the curable resin integrated from the intaglio roll, the resin can be peeled from the concave portion in a state where the resin is not completely cured. Peeling can be easily performed. Further, by completely curing the resin, the physical properties of the uneven surface due to the cured resin can be further improved.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an embodiment of the device of the present invention.

FIG. 2 is a longitudinal sectional view of a film having surface irregularities manufactured by using the manufacturing apparatus of the present invention.

FIG. 3 is a cross-sectional view of the roll intaglio in the rotation axis direction, showing an example of a temperature control device for the roll intaglio.

FIG. 4 is a cross-sectional view of a roll intaglio in a rotation axis direction, showing another example of a temperature control device for the roll intaglio.

FIG. 5 is a cross-sectional view of a roll intaglio in a rotation axis direction showing another example of a roll intaglio temperature control device.

FIG. 6 is a partially enlarged view showing a surface portion of a roll intaglio cross section.

FIGS. 7A and 7B show an example of a coating apparatus, wherein FIG. 7A is a vertical cross-sectional view when viewed from a roll intaglio side surface direction, and FIG. 7B is a vertical cross-sectional view (width direction) along line bb in FIG. .

8A and 8B show an example of a coating apparatus, in which FIG. 8A is a longitudinal sectional view when viewed from the side of the roll intaglio, and FIG. 8B is a longitudinal sectional view (width direction) along the line bb in FIG. is there.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 roll intaglio 2 concave portion 3 curable resin 4 film base material 5 pressing roll 6 feed roll 7 curing device 9 film having uneven surface 10 coating device

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Yasuo Nakai 1-1-1, Ichigaya-Kaga-cho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. (72) Inventor Masashi Toyoizumi 1-chome, Ichigaya-cho, Shinjuku-ku, Tokyo No. 1 Inside Dai Nippon Printing Co., Ltd. (72) Inventor Yoshiyuki Yamashita 1-1-1, Ichigaya Kagacho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. (56) References JP-A-51-558 (JP, A) JP-A-62-262762 (JP, A) JP-A-2-139060 (JP, A) JP-A-52-119649 (JP, A) JP-A-57-21966 (JP, A) 69677 (JP, U) JP 62-18222 (JP, B2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B05C 1/08 B05C 9/12-9/14

Claims (5)

(57) [Claims] 1. A roll intaglio having an embossed pattern, a coating device for applying a curable resin to the roll intaglio, a pressing roll for bringing the roll intaglio into close contact with a film substrate, and a roll intaglio held in a recess of the roll intaglio. And a curing device for curing the curable resin, for cooling and / or heating the roll intaglio
Temperature controller is provided, the coating apparatus of the curable resin nozzles
An apparatus for producing a film having an uneven surface, characterized in that the apparatus is a nozzle coating apparatus provided with a cavity or groove in the middle of the step . 2. The apparatus according to claim 1, wherein the curing device is an ionizing radiation irradiating device. 3. The curing device according to claim 1, wherein the curing device is a dielectric heating device.
An apparatus for producing a film having an uneven surface according to the above. 4. The apparatus for producing a film having an uneven surface according to claim 1, comprising a plurality of sets of a roll intaglio, a coating device, a pressing roll, and a curing device. 5. The apparatus according to claim 1, further comprising a curing device for curing the curable resin integrated from the roll intaglio.
An apparatus for producing a film having an uneven surface according to 2, 3, or 4.