JP3325684B2 - Stamping die manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a concave / convex mold used for embossing for forming a grain pattern or the like as a concave / convex pattern. The present invention relates to a manufacturing method for manufacturing a mold by exposing light to a photosensitive resin through the synthetic linear plate.

[0002]

2. Description of the Related Art Conventional methods for manufacturing a stamping die for embossing are disclosed in Japanese Patent Application Laid-Open Nos. 4-140750 and 4-2.
No. 38032 is known. For example, in the former JP-A-4-140750, a mold of a transparent resin is cast from an object, a parallel light is transmitted through the mold of the transparent resin to obtain a film having a concentration corresponding to the surface irregularities, A method for producing an embossing plate based on this film is described.

[0003]

However, in the above-described conventional method for manufacturing an embossing plate, a real object serving as a manuscript is indispensable in order to mold an object, and it is difficult to obtain the real manuscript. There is a problem that there is. That is, a natural thing is usually adopted as a real manuscript, and it is essential that the natural thing is excellent in design. However, natural things excellent in design are rare and difficult to obtain. Also, it was more difficult to create a creative pattern while making use of the characteristics of natural objects. Further, in the embossing plate manufactured by the above-described method, since the depth of the concavo-convex pattern is finely and continuously changed corresponding to the concavo-convex depth of the object, the linear portions and the protruding portions (convex portions) of the concavo-convex pattern are provided. In addition, the contours of the depressions (recesses) and the like cannot be clearly recognized, and it is difficult to align (register) with the print image (printing pattern) when performing embossing. There was a problem that clear quality could not be obtained for both patterns. The present invention has been made in view of the above problems, and can be manufactured from a manuscript.
It is an object of the present invention to provide a method for manufacturing a stamping die that can easily perform registration during embossing.

[0004]

In order to achieve the above-mentioned object, a method for manufacturing a stamp according to the present invention comprises the steps of: providing an original with cyan (C), magenta (M), yellow (Y) and black (B) colors; A decomposed film producing step of producing a decomposed film and a black and white decomposed film, and a color separation film of each color of cyan (C), magenta (M), yellow (Y) or black (B) produced by the decomposed film producing step A color separation film having a large density difference is selected from the above, and a correction for enlarging the density difference is made to the selected color separation film to produce a corrected separation film having a clear pattern outline, and the corrected separation film and the black and white separation A synthetic linear printing plate manufacturing step of synthesizing a film and a synthetic linear printing plate, and exposing the photosensitive resin to the synthetic linear printing plate prepared in the synthetic linear printing plate manufacturing process, A developing process to after, and a push-type manufacturing process of manufacturing a press die having a concavo-convex pattern corresponding to a contrasting density of the original.

[0005] A method for producing an embossing plate according to the present invention is directed to a production method for producing an intermediate mold using the stamping die produced in the stamping die production step as a prototype, and using the intermediate mold to produce a silicone mold. It is possible to adopt a mode in which a plate making step is added, or a mode in which a flat screen is put on the synthetic line plate in the synthetic line plate forming step to add halftone dots to the synthetic line plate.

[0006] In this specification, the term "document" means
Natural objects such as wood, stone, Japanese paper, original art of paintings, art objects such as Buddha statues, real manuscripts that can be used as originals, color films such as photographic film and computer graphics output images, black and white films Such as a photo manuscript, a reflection manuscript capable of directly taking an image into a plate making camera for a printed matter, a painting, or the like.
However, although the original is included, the method of the present invention has a feature in that it is not necessary to directly cast a mold from an actual product in forming an embossing press die, and the image is taken by a plate-making camera or a scanner. It is enough to take in.

[0007]

According to the method for manufacturing a stamping die of the present invention, a synthetic linear printing plate is produced based on a four-color color separating film and a black-and-white separating film obtained from an original, and the photosensitive resin is passed through the synthetic linear printing plate. Is exposed and exposed to light to form a stamping die.
Therefore, there is no need for a real manuscript, and there is no trouble in obtaining the real manuscript. In addition, since the pressing mold uses a photosensitive resin having a uniform surface and hardness, the pressing mold is formed with an uneven pattern having an almost uniform height at the top, and the lines and contours of the uneven pattern of the pressing mold are formed. Can be clearly recognized,
Registration and the like during embossing can be easily performed.
Also, in the case of embossed products, since the uneven pattern is formed at a substantially uniform depth at the bottom, lines, grooves,
The outline becomes clear.

Further, according to the second aspect of the present invention, an intermediate mold is produced based on a pressing mold, and a silicone mold to be an embossing plate is obtained from the intermediate mold, so that a plate for commercial production can be easily prepared. Can be made. According to the third aspect of the present invention, fine irregularities can be imparted by covering the flat plate with the wire plate, so that the pattern or the background portion can be partially corrected, particularly, the resin surface of the stamping die at the time of molding. It is possible to prevent the occurrence of unnatural gloss on the resin surface of the embossed product caused by the transfer of the state, and to achieve both appropriate matting and appropriate gloss.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 4 show an embodiment of the present invention. FIG. 1 is a process diagram, FIG. 2 is a schematic cross-sectional view for explaining a manufacturing process of a synthetic linear plate, and FIG. 3 is a schematic diagram for explaining an embossing process. FIG. 4 is a cross-sectional view, and FIG. 4 is a schematic partial cross-sectional view of an embossed product.

As shown in FIG. 1, in this embodiment, first, in a film manufacturing process, cyan (C), magenta (M), yellow (Y) and black A color separation negative film of (B) is prepared, and a black-and-white separation negative film having a clear difference in shading is also prepared for preparing a synthetic linear plate described later. In this film production process, as is well known, a color photograph is color-separated by a color scanner or the like to produce a color separation negative film of each of the above colors, and a black-and-white separation negative film is produced by a color scanner or a black-and-white scanner directly from an original. Alternatively, it is prepared by printing using a photographic method.

In the printing step, a well-known offset printing using a separation positive film prepared from the color separation negative film of each color, that is, a pattern 21 (ink layer) is formed on a printing paper 20 such as coated paper or woodfree paper. Is formed (see FIG. 3). As described later, this printed printing paper 2
At 0, an uneven pattern corresponding to the picture is formed in the embossing step. It is needless to mention that the printing is not limited to the offset printing according to the picture or pattern, and various printing methods such as gravure, screen, letterpress printing and the like can be appropriately adopted. The substrate to be printed is not particularly limited as long as it is a normal printable substrate such as a resin, a foil, and a metal other than paper.

On the other hand, following the above-described film production step, a color separation negative film of four colors of cyan (C), magenta (M), yellow (Y) and black (B) is used in parallel with the printing step. Then, a modified decomposed positive film is prepared. Here, the corrected separation positive film is selected from the four color separation negative films having the largest difference in shade from among the four color separation negative films, and a correction is made so that the outline of the pattern becomes clear with respect to the selected color separation negative film. For example, a correction is made such that a low density portion is removed while leaving a range between a high density portion and a medium density portion of a halftone dot. As one example, it is produced by repeatedly performing a process such as producing a positive film by exposing through a spacer film or the like and increasing the exposure amount when producing a negative film from the positive film again.

In preparing the modified disassembled positive film, a plurality of disassembled negative films having a large difference in shading are selected, and the disassembled negative films are superimposed to produce a positive film. Can be made into a modified disassembled positive film,
It is also possible to repeat the reversal of such a positive film and a negative film several times to make the final negative film a corrected disassembled positive film.

Subsequently, the corrected decomposed positive film and the black-and-white decomposed negative film are registered by using register pins or the like, and the corrected decomposed positive film and the black-and-white decomposed negative film are synthesized to produce a composite linear plate. Here, when a satisfactory composite linear plate cannot be obtained, for example, when the gradation of the composite linear plate has a large variation or when the outline of the pattern is not clear, the correction of the modified decomposed positive film or the modified decomposed positive film is performed. The composition and registration of the black and white separation negative film and registration are repeated several times, and the composite linear printing plate is modified.

This composite linear plate is used to convert the high-density portion and the medium-density portion image of the corrected positive film into a high-density only image of a black-and-white original, for example, an image of a skeleton alone, in contrast to the actual unevenness of the original. It incorporates a slightly closer image, for example, it adds a slightly lower density part (medium density part) when compared to the high density part of a black and white negative, and adds contours, fine lines and grooves around the skeletal part. A corresponding image is provided. At the same time, the contours are more clearly formed in the high-density portion because the two concentrations overlap.

In order to prevent an unnatural luster of a pattern background or a pattern, or to perform a process such as partially frosting, when combining the above-mentioned modified decomposed positive film with a black-and-white decomposed negative plate, or After the combination, a predetermined flat screen (for example, 150 screen lines, 20%) is put on the combined linear plate. Then, as schematically shown in FIG. 2, a composite linear plate 1 with uniform halftone dots (a composite linear plate with a flat screen in FIG. 1) basically has a high density portion 1a and a low density portion 1b. It further has a portion (not shown in FIG. 2 and hereinafter referred to as an adjustment portion) formed at the top or bottom by the correction applied by the flat screen.

In the stamping process, a photosensitive resin whose chemical or physical properties change upon exposure to light, for example, Fuji Trelief WH manufactured by Fuji Photo Film Co., Ltd.
The stamping die 9 is manufactured using -F. In this stamping step, as shown in FIG. 2, the synthetic linear plate 1 is superimposed on and adhered to a photosensitive resin 3 bonded on a mold base 2 such as PET, and parallel light (arrows in the figure) is applied. Irradiate. Photosensitive resin 3
Is a state in which the pattern corresponding to the halftone dot (density) of the pattern of the synthetic linear printing plate 1 is exposed, a region corresponding to the low density portion 1b transmits a large amount of light, and a high density portion 1a transmits only a small amount of light. Exposure at Then, the exposed photosensitive resin 3 is developed and dried to obtain a pressing die 9. As shown in FIG.
After the processing, the photosensitive resin 3 of the stamping die 9 has a convex / concave pattern exposed at a large amount of light, a concave portion exposed at a small amount of light, and a convex / concave pattern having a substantially uniform height. Are formed in accordance with the light-transmitting characteristics (density) of the resin, and the unnatural luster on the resin surface is removed and natural luster is imparted by the adjustment portion (plane P, jagged surface in FIG. 2). It should be noted that by applying a flat screen when exposing the photosensitive resin in the pressing mold manufacturing step, it is possible to remove unnatural gloss and impart natural gloss in the same manner as described above.

Next, in the embossing step, a concavo-convex pattern corresponding to the printed picture 21 is formed on the printing paper 20 on which the picture has been printed in the printing step. In this embossing step, as shown in FIG. 3, a transparent resin sheet 22 made of a thermoplastic resin such as ethylene vinyl acetate is laminated on the printed surface of the pattern 21 of the printing paper 20, and a pressing die 9 is placed on the resin sheet 22. Is placed. Then, in a state where these are laminated, several cushion materials (not shown) are interposed vertically and mounted on a flat pressure press machine, and pressurized by a flat pressure press machine under predetermined temperature, pressure and time conditions. After performing temporary bonding, pressurization is again performed under predetermined conditions by a flat pressure press machine (for convenience, referred to as main pressurization). The cushion material described above has a thickness of 1 mm
It is constructed by stacking several pieces of chip cardboard or virgin pulp paper. In addition, although the printing paper was mentioned as an example for convenience of explanation, the material is not limited to paper, and resin, metal, etc. may be used.

The thickness of the transparent resin sheet 22 described above is appropriately selected according to the depth of the concavo-convex pattern to be formed. If the depth of the concavo-convex pattern to be formed is 200 μm or less, the thickness of the sheet 22 is About 60 μm is desirable. further,
The conditions for the temporary bonding and the final pressing are also arbitrarily determined according to the type and thickness of the resin of the thermoplastic resin sheet 22 to be used, but the following conditions are desirable for the sheet 22 described above.・ Temporary bonding temperature; 50 to 80 ° C, pressure; 10 to 30 kg / cm
² , time: about 10 to 20 minutes ・ Main pressurization temperature: 95 to 130 ° C, pressure: 15 to 35 kg / c
m ² , time; about 15 to 30 minutes

The final product 30 is completed by the embossing process described above. This product 30, as shown in FIG.
It has a concavo-convex pattern 31 corresponding to the picture 21 and has a matte surface 32 corresponding to the surface P of the press die 9. That is, in the product 30, since the depth of the bottom of the concave-convex pattern 31 is substantially constant, the lines, grooves, and contours of the pattern are clear, and registration in the embossing process is easy. Also,
In this embodiment, since the printing pattern 21 and the concavo-convex pattern of the press die 9 are manufactured from the same photographic film, a real original is unnecessary, and the acquisition of the original is not troublesome.
Further, the concave and convex pattern of the press die 9 exactly matches the pattern 21 by printing, so that registration and the like in the embossing step can be performed more easily. Although the matte surface 32 is formed on the bottom surface of the concave portion in FIG. 4, it goes without saying that it can be formed on the upper surface of the convex portion.

In the above-described embodiment, the embossing is performed by directly using the stamping die 9, but a stamping die for production is manufactured using the stamping die 9 as a prototype, and the embossing is performed using the stamping die for production. The production die can be produced as follows (production die production step). First, in the same manner as in the embossing step, a thermoplastic resin sheet is laminated and temporarily bonded on a mold base such as aluminum, and a pressing mold is overlapped and subjected to heat and pressure to produce an intermediate mold. Next, the surface of the intermediate mold is coated with a room temperature-curable silicone rubber to a predetermined thickness (for example, about 50 to 200 μm), and when the silicone rubber is semi-cured or cured, the silicone rubber is further smoothly coated and reinforced. Screen (eg, TNR-26 manufactured by NBC Industries, Ltd.), and when the silicone rubber is semi-cured or cured, the silicone rubber is coated again. Then, when these silicone rubbers are cured, they are separated from the pressing die 9 to obtain a production pressing die, and embossing is performed using the production pressing die.

FIG. 5 shows another embodiment of the present invention, and is a schematic sectional view for explaining embossing. As shown in the figure, in this embodiment, an unsaturated polyester resin, cobalt naphthenate, a peroxide and the like are mixed to prepare a raw material resin 51, and this raw material resin 51 is plywood, MDF (medium density fiberboard). Alternatively, the mold 9 or the production mold is placed on the resin 51 by pouring onto a substrate 50 such as a metal plate.
Then, the resin 51 is evenly stretched by pressing with a rubber roll 52 from above the pressing die 9 or the like to remove the air in the resin and remove the resin 5.
After the curing of 1, the press die 9 is released to obtain a product 55.

[0023]

As described above, according to the method of manufacturing a press die of the present invention, a press die can be manufactured based on a manuscript, and since there is no need for a real one, there is no need to bother with obtaining the manuscript. In addition, a synthetic linear plate is produced based on the color separation film, and a photosensitive die is exposed to the photosensitive resin through the synthetic linear plate to produce a stamping die. As a result, an uneven pattern having a uniform height is formed, the lines and contours of the embossed pattern of the press die can be clearly recognized, and the effect of easily registering the embossing can be obtained. Furthermore, since the embossed product also has an uneven pattern having a uniform depth, the lines, grooves, and contours of the uneven pattern become clear.

According to the second aspect of the present invention, in addition to the above-described effects, after an intermediate mold is produced based on a pressing mold, a silicone mold to be an embossed plate can be obtained from the intermediate mold. An effect is obtained that a plate for commercial production can be easily produced.

Further, according to the third aspect of the present invention, by applying a flat screen to the linear printing plate, it is possible to perform matting of the background, impart natural gloss, and the like, thereby preventing unnatural gloss. Alternatively, removal and moderate matting can be easily performed.

[Brief description of the drawings]

FIG. 1 is a process chart of a manufacturing method according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view schematically showing the production of a synthetic linear plate in the production method of the example.

FIG. 3 is a cross-sectional view schematically showing embossing in the manufacturing method of the embodiment.

FIG. 4 is a schematic cross-sectional view of a product manufactured by the manufacturing method of the embodiment.

FIG. 5 is a cross-sectional view schematically showing embossing in a manufacturing method according to another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Synthetic linear plate 1a High density part 1b Low density part 2 Type base 3 Photosensitive resin 9 Press type 20 Printing paper 21 Printing pattern 22 Transparent thermoplastic resin sheet 30 Product 31 Concavo-convex pattern 32 Matting surface 50 Base material 51 Raw material resin 52 Rubber roll 55 products P jagged surface

Continuation of the front page (72) Inventor Shunsuke Nishikawa 4-14-12 Koishikawa, Bunkyo-ku, Tokyo Kyodo Printing Co., Ltd. (56) References JP-A-5-92540 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) G03F 1/00-1/16 G03F ⁷ /20-7/24 G03F 9/00-9/02

Claims (3)

(57) [Claims] 1. A decomposition film producing step for producing a cyan (C), magenta (M), yellow (Y) and black (B) color separation film and a black and white separation film from a manuscript; Cyan (C), magenta (M), yellow (Y) or black (B) produced
A color separation film having a large difference in shade is selected from the color separation films of the respective colors, and a correction for enlarging the difference in density is made to the selected color separation film to produce a corrected separation film having a clear pattern outline, and the correction is performed. A synthetic linear printing plate manufacturing step of synthesizing the decomposed film and the black-and-white decomposing film to prepare a synthetic linear printing plate; and bonding the synthetic linear printing plate manufactured in the synthetic linear printing plate manufacturing process to a photosensitive resin plate to obtain a photosensitive linear plate. A method for manufacturing a press die, comprising: exposing the resin to light, exposing the resin, and developing the resin to produce a press die having an uneven pattern corresponding to the density of the document. 2. The press according to claim 1, further comprising a production plate production step of producing an intermediate mold using the press mold produced in the press mold production step as a prototype, and producing a silicone mold using the intermediate mold. Mold manufacturing method. 3. The method of manufacturing a stamping die according to claim 1, wherein the synthetic linear stencil is prepared by covering the synthetic linear stencil with a flat screen and adding halftone dots to the synthetic linear stencil.