JP4329122B2 - Method and apparatus for manufacturing uneven sheet - Google Patents

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for a concavo-convex sheet, and in particular, a sheet-like material such as an embossed sheet having an antireflection effect having a regular fine concavo-convex pattern formed on the surface, with high quality without defects. The present invention relates to a method and apparatus for manufacturing a concavo-convex sheet suitable for manufacturing.

  In recent years, an embossed sheet having an antireflection effect has been adopted for use in electronic displays such as liquid crystals. In addition, flat lenses such as lenticular lenses and fly-eye lenses, embossed sheets such as light diffusion sheets, brightness enhancement sheets, and optical waveguide sheets are used. As such an embossed sheet, a sheet having a regular fine concavo-convex pattern formed on the surface has been conventionally known. As a method for forming such a regular fine uneven pattern, various methods are conventionally known (see Patent Documents 1 to 4).

  For example, in an apparatus configured as shown in FIG. 6, a resin is applied to the surface of a stamper roll 1 having a regular uneven pattern formed on the surface by the application means 2, and the continuously running sheet 3 is applied to the stamper roll. 1 and the nip roll 4, the resin of the stamper roll 1 is in contact with the sheet 3, and the resin is irradiated with ionizing radiation to be cured, and then the sheet 3 is wound around the release roll 5 and peeled off from the stamper roll 1. The content to be made is disclosed (see Patent Documents 1 to 3).

  Further, in the apparatus configured as shown in FIG. 7, a resin is applied in advance to the surface of the continuously running sheet 3, and this sheet 3 is used as a stamper roll 1 on which a regular uneven pattern is formed. Contents in which the sheet is sandwiched between the nip rolls 4 and the uneven pattern of the stamper roll 1 is transferred to the resin to be cured by irradiating the resin with ionizing radiation, and then the sheet 3 is wound around the release roll 5 and peeled off from the stamper roll 1 Is disclosed (see Patent Documents 3 and 4).

In such a manufacturing method, in order to form a regular fine concavo-convex pattern, it is important that the release property between the stamper roll 1 and the resin is in a good state. In order to ensure this release property, the stamper roll Therefore, it is necessary to devise a surface condition of 1 and to select a resin material.
Japanese Patent No. 2533379 JP 2000-141481 A JP 2002-333508 A Japanese Patent No. 32186662

  However, in the conventional configuration as shown in FIG. 6, there is a problem that it is difficult to form a resin layer uniformly if the peelability is ensured. That is, in order to improve the peelability between the stamper roll 1 and the resin, when the surface of the stamper roll 1 is made liquid repellent, it is very difficult to apply the resin with a uniform film thickness because of the liquid repellent property of the roll surface. It becomes difficult. Also, resin application defects are likely to occur.

  Further, in the conventional configuration as shown in FIG. 7 described above, there is a problem that if the peelability is ensured, the adhesion between the sheet 3 and the resin is lowered. That is, when a resin that is easily peeled off from the stamper roll 1 is selected, this resin is easily peeled off from the sheet 3, and it is very difficult to ensure the adhesion between the resin and the sheet 3. Moreover, the trouble which resin peels from the sheet | seat 3 after commercialization will also arise.

  The present invention has been made in view of such circumstances, and a method for producing a concavo-convex sheet suitable for producing a concavo-convex sheet having a regular fine concavo-convex pattern formed on the surface with high quality without defects. And it aims at providing a manufacturing apparatus.

The present invention, in order to achieve the object, the surface of the sheet product, substantially in the manufacturing method of the indented sheet to transfer form irregularities of uneven roll surface, an adhesive and a radiation-curable resin is a radiation curable resin by simultaneously coated, the uneven adhesive layer on said surface, a sheet-like body of the band-shaped flexible resin layer is made form the adhesive layer is continuously running, the sheet-like body, rotating Wrapping around a roll, transferring irregularities on the surface of the concave-convex roll onto the resin layer, and irradiating the adhesive layer and the resin layer once with the sheet-like body being wound around the concave-convex roll to provide a method of manufacturing indented sheet, characterized in that cured by.

In addition, for this purpose, the present invention applies a sheet-shaped body supply means for feeding a belt-shaped flexible sheet-shaped body, and an adhesive and a radiation-cured resin, which are radiation-cured resins, to the surface of the sheet-shaped body at substantially the same time. And a transfer means for transferring and forming the irregularities on the surface of the uneven roll onto the surface of the sheet-like body while the sheet-like body running continuously is wound around a rotating uneven roll, and the sheet-like body is Provided is a concavo-convex sheet manufacturing apparatus comprising: a resin curing unit that cures the adhesive layer and the resin layer by one-time radiation irradiation in a state of being wound around a concavo-convex roll. .

  According to the present invention, a belt-like flexible sheet-like body in which an adhesive layer and a resin layer are formed in two or more layers is continuously run, wound around a rotating concavo-convex roll, and the surface of the concavo-convex roll is wrapped around the resin layer. The unevenness is transferred, and the resin layer is cured in this state. Therefore, even if a resin of a material that is more easily peeled than the uneven roll is selected, the resin layer of the sheet-like body is formed on the adhesive layer, so that the adhesion between the sheet-like body and the resin can be ensured. It becomes easy and the resin does not peel from the sheet-like body. Thereby, the uneven | corrugated sheet | seat in which the regular fine uneven | corrugated pattern was formed in the surface can be manufactured with high quality without a defect.

  In this specification, the term “concave / convex roll” refers to not only an embossed roll having an uneven pattern (embossed shape) formed on the surface of a cylindrical roll, but also an uneven pattern (embossed) on the surface of a belt-like body such as an endless belt. Including a shape). This is because even such a belt-like body acts in the same manner as a cylindrical embossing roll, and the same effect can be obtained.

In the present invention, the resin is a radiation curable resin, the curing of the resin layer is Ru done by applying radiation to the resin layer. By using such a radiation curable resin, curing of the resin becomes easy. Details of the radiation curable resin will be described later.

Further, in the present invention, substantially applied simultaneously with the adhesive resin. It is possible to apply an adhesive to the belt-like flexible sheet-like body in advance and apply a resin thereon, but by simultaneously applying in this way, not only the productivity is improved, The effect that a coating defect hardly arises is also acquired. In addition, the cost of the apparatus can be reduced, and the work space is small.

Further, in the present invention, the adhesive is a radiation curable resin, curing of the adhesive layer is Ru done by applying radiation to the adhesive layer. If a radiation curable resin is also used for the adhesive, the merit of simultaneous application can be utilized, and the effect of improving productivity can be obtained by curing by radiation irradiation. It is also possible to irradiate radiation after applying the adhesive and form a resin layer thereon.

  Moreover, in this invention, it is preferable that the viscosity of the said adhesive agent is lower than the viscosity of the said resin. If the viscosity of the adhesive is lower than the viscosity of the resin, application is easy, and variations in the thickness of the adhesive layer can be suppressed.

  In the present invention, the adhesive and the resin are preferably applied by an extrusion type hopper or a slide type hopper. Such an application method is suitable for application of the adhesive and resin of the present invention, and is particularly effective for simultaneous application.

  As described above, according to the present invention, since the resin layer of the sheet-like body is formed on the adhesive layer, it becomes difficult for the resin to be peeled from the sheet-like body. The uneven sheet on which the fine uneven pattern is formed can be manufactured with high quality without any defects.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a conceptual diagram showing a configuration of an embossed sheet manufacturing apparatus 10 to which the present invention is applied. The embossed sheet manufacturing apparatus 10 includes a sheet-like body supply unit 11, a coating unit 12, an embossing roll 13 that is a concavo-convex roll, a nip roll 14, a resin curing unit 15, a release roll 16, and a protective film supply unit. 17 and sheet winding means 18, etc.

  The sheet supply means 11 which is a sheet-like body supply means is for sending out the sheet W which is a sheet-like body, and includes a delivery roll on which the sheet W is wound.

  The application means 12 is an apparatus that forms an adhesive layer and a resin layer in two layers by sequentially applying an adhesive and a resin to the surface of the sheet W, and an adhesive supply source 12A that supplies the adhesive; A resin supply source 12B for supplying resin, a coating head 12C, a support roller 12D for winding and supporting the sheet W at the time of coating, an adhesive supply source 12A and a resin supply source 12B, respectively. And a pipe for supplying to the coating head 12C, a pump, and the like. Details of the coating head 12C will be described later.

  The embossing roll 13 is required to have an uneven pattern accuracy, mechanical strength, roundness, and the like that can transfer and form the unevenness of the roll surface on the surface of the sheet W. Such an embossing roll 13 is preferably a metal roll.

  A regular fine uneven pattern is formed on the outer peripheral surface of the embossing roll 13. Such a regular fine concavo-convex pattern is required to have a shape obtained by inverting the fine concavo-convex pattern on the surface of an embossed sheet as a product.

  As an embossed sheet as a product, for example, a lenticular lens in which fine concavo-convex patterns are arranged two-dimensionally, or a fine cone such as a fly-eye lens, cone, or pyramid in which fine concavo-convex patterns are arranged three-dimensionally in the XY direction A flat lens or the like laid on the surface is a target, and the regular fine uneven pattern on the outer peripheral surface of the embossing roll 13 corresponds to this.

  As a method for forming a regular fine uneven pattern on the outer peripheral surface of the embossing roll 13, a method of cutting the surface of the embossing roll 13 with a diamond bit (single point), photoetching, electron beam drawing on the surface of the embossing roll 13, The method of forming irregularities directly by laser processing etc. can be adopted, and irregularities are formed on the surface of thin metal plate by photo etching, electron beam drawing, laser processing, stereolithography, etc. Can be used as the embossing roll 13 by winding the wire around the roll. In addition, uneven surfaces are formed on the surface of materials that are easier to process than metal by photo-etching, electron beam drawing, laser processing, stereolithography, etc., and a reversal of this shape is formed by electroforming etc. to make a thin metal plate A method of creating an embossing roll 13 by creating a body and winding and fixing the plate-like body around the roll can also be adopted. In particular, when the inversion mold is formed by electroforming or the like, there is a feature that a plurality of plate-like bodies having the same shape can be obtained from one master (mother).

  It is preferable to perform a mold release process on the surface of the embossing roll 13. Thus, the shape of the fine concavo-convex pattern can be favorably maintained by performing the mold release process on the surface of the embossing roll 13. As the mold release treatment, various known methods such as coating treatment with a fluororesin can be employed. The embossing roll 13 is preferably provided with driving means. The embossing roll 13 rotates counterclockwise (CCW) as shown in the figure.

  The nip roll 14 forms a roll while pressing the sheet W while being paired with the embossing roll 13, and is required to have predetermined mechanical strength, roundness, and the like. The longitudinal elastic modulus (Young's modulus) on the surface of the nip roll 14 is set to an appropriate value because roll forming is insufficient if it is too small, and if it is too large, it reacts sensitively to the inclusion of foreign substances such as dust and tends to cause defects. It is preferable. The nip roll 14 is preferably provided with a driving means. The nip roll 14 rotates in the clockwise direction (CW) as shown in the figure.

  In order to apply a predetermined pressing force between the embossing roll 13 and the nip roll 14, it is preferable to provide a pressing means on either the embossing roll 13 or the nip roll 14. Similarly, it is preferable to provide fine adjustment means on either the embossing roll 13 or the nip roll 14 so that the gap (clearance) between the embossing roll 13 and the nip roll 14 can be accurately controlled.

  The resin curing means 15 is a light irradiation means provided facing the embossing roll 13 on the downstream side of the nip roll 14. The resin curing means 15 transmits the sheet W by light irradiation and cures the resin layer and the adhesive layer. The resin curing means 15 can irradiate light having a wavelength according to the curing characteristics of the resin and the adhesive, and transport the sheet W. It is preferable that light of a light amount corresponding to the speed can be irradiated. As the resin curing means 15, a cylindrical lamp having a length substantially the same as the width of the sheet W can be adopted. Further, a plurality of the cylindrical lamps can be provided in parallel, and a reflector can be provided on the back surface of the cylindrical lamp.

  The peeling roll 16 is a pair of the embossing roll 13 and peels the sheet W from the embossing roll 13, and is required to have predetermined mechanical strength, roundness, and the like. The sheet W is peeled off from the embossing roll 13 and wound around the peeling roll 16 while being sandwiched between the rotating embossing roll 13 and the peeling roll 16 at the peeling location. In order to ensure this operation, the peeling roll 16 is preferably provided with a driving means. The peeling roll 16 rotates in the clockwise direction (CW) as shown in the figure.

  In addition, when the temperature of resin etc. rises by hardening, the structure which provides a cooling means in the peeling roll 16 can also be employ | adopted in order to cool the sheet | seat W at the time of peeling, and to ensure peeling.

  Although not shown, a plurality of backup rolls are provided to face each other between the pressing location (9 o'clock position) of the embossing roll 13 and the peeling location (3 o'clock position). A configuration in which the curing process is performed while pressing the sheet W with the roll 13 can also be adopted.

  The sheet winding means 18 stores the peeled sheet W, and includes a winding roll that winds the sheet W or the like. In this sheet winding means 18, the protective film H supplied from the adjacent protective film supply means 17 is supplied to the surface of the sheet W, and is stored in the sheet winding means 18 in a state where both films overlap. The

  In the embossed sheet manufacturing apparatus 10, a guide roller or the like that forms a conveyance path of the sheet W may be provided between the coating unit 12 and the embossing roll 13, between the peeling roll 16 and the sheet winding unit 18, or the like. In addition, a tension roller or the like can be provided as needed to absorb slack during conveyance of the sheet W.

  Next, the details of the coating means 12 in the embossed sheet manufacturing apparatus 10 will be described. FIG. 2 is a conceptual diagram showing a configuration of an extrusion type hopper as the coating head 12 </ b> C of the coating unit 12. Among these, (a) is a perspective view showing a part of the coating head 20 by cutting, and (b) is a schematic cross-sectional view showing the positional relationship between the tip of the coating head 20 and the sheet W.

  As shown in FIG. 2, the coating head 20 is provided with two sets of independent liquid supply systems so that two types of coating liquids can be supplied. Hereinafter, the structure of the two liquid supply systems will be described. The adhesive liquid supply system is distinguished by attaching A to the member number, and the resin liquid supply system is distinguished by attaching B to the member number. And

  The main body 22 of the coating head 20 communicates with the liquid reservoirs 24A and 24B extending in the longitudinal direction (the width direction of the sheet W) and the liquid reservoirs 24A and 24B, and in the longitudinal direction (the width direction of the sheet W). The slits 26A and 26B that face the sheet W and apply the coating liquid from the openings, the liquid supply ports 28A and 28B that supply the coating liquid to the liquid reservoirs 24A and 24B, and the coating liquid from the liquid reservoirs 24A and 24B. Liquid outlets 30A and 30B for pulling out the water.

  The liquid reservoirs 24A and 24B are also referred to as “pockets” or “manifolds”, and their cross sections are substantially circular, and have substantially the same cross sectional shape in the width direction of the sheet W as shown in FIG. It is a cavity having an extended liquid storage function. The effective length is usually set equal to or slightly longer than the coating width. As shown in FIG. 2 (a), both end openings through which the liquid reservoirs 24A and 24B penetrate are closed by closing plates 32 and 34 attached to both ends of the main body 22, respectively. The liquid supply ports 28A and 28B described above are provided in the closing plate 32, and the liquid discharge ports 30A and 30B are provided in the closing plate 34, respectively.

  The slits 26A and 26B are directed from the liquid reservoirs 24A and 24B toward the sheet W, and normally penetrate the inside of the main body 22 of the coating head 20 with an opening width of 0.05 to 1.0 mm, and the liquid reservoirs 24A and 24B Similarly, it is a relatively narrow channel extending in the width direction of the sheet W, and the opening length in the width direction of the sheet W is set substantially equal to the coating width.

  In addition, the length of the flow path toward the sheet W in the slits 26A and 26B can be appropriately set in consideration of various conditions such as the liquid composition, physical properties, supply flow rate, supply liquid pressure, and the like of the coating liquid. That is, it is only necessary that the coating liquid can be supplied from the slits 26 </ b> A and 26 </ b> B in a laminar flow with a uniform flow rate and hydraulic pressure distribution in the width direction of the sheet W.

  Next, the tip portions of the slits 26A and 26B will be described with reference to FIG. The slit 26 </ b> A is formed by the front edge 36 and the first doctor edge 38 of the main body 22 (see FIG. 2A) of the coating head 20. The slit 26 </ b> B is formed by the first doctor edge 38 and the second doctor edge 40 of the main body 22 of the coating head 20. A front edge surface 36a, a first doctor edge surface 38a, and a second doctor edge surface 40a are formed on the upper surface of the main body 22 of the coating head 20 (the surface facing the sheet W) from the upstream side.

  As shown in FIG. 2 (b), the front edge surface 36a has a substantially linear cross section, and the first doctor edge surface 38a and the second doctor edge surface 40a have predetermined local radii R1 and R2, respectively. It is formed in an arc shape. Further, a predetermined step is provided between the rear edge portion of the front edge surface 36a and the front edge portion of the first doctor edge surface 38a, and the rear edge portion of the first doctor edge surface 38a and the second doctor edge surface 40a. A predetermined step is provided on the tip edge portion of the film, and a film having a predetermined thickness of the coating liquids F1 (adhesive) and F2 (resin) can be formed.

  Next, the operation of the application unit 12 will be described with the application head 20 as a main component. As shown in FIG. 2 (a), the coating liquids F1 and F2 are supplied by a constant-quantity liquid feeding means capable of feeding continuously and at a constant flow rate, generally by a quantitative pump (not shown). The liquid is supplied to the liquid reservoirs 24A and 24B through the ports 28A and 28B. As the metering pump, for example, a flow rate variable liquid feeding means such as a plunger pump or a gear pump can be preferably used.

  A predetermined amount of the coating liquids F1 and F2 supplied to the liquid reservoirs 24A and 24B is discharged from the tip portions of the slits 26A and 26B, and the remaining amount is discharged from the liquid discharge ports 30A and 30B, and is supplied to the quantitative liquid feeding means. To be recovered. By performing such an operation, it is possible to prevent the coating liquids F1 and F2 from staying significantly in the liquid reservoirs 24A and 24B. However, the liquid discharge ports 30A and 30B may not be provided, and a predetermined amount discharged from the tip portions of the slits 26A and 26B may be supplied from the liquid supply ports 28A and 28B.

  A sheet W continuously supported by a travel guide means such as a guide roller (not shown) has a substantially constant tension between each travel guide means such as a guide roller and can be slightly bent in the thickness direction. As shown in FIG. 2B, it is moved at a predetermined speed in the direction of the arrow in the drawing while being pressed against the upper surface of the coating head 20 (the surface facing the sheet W). Thereby, the coating liquid F1 discharged from the front end portion of the slit 26A is applied to a predetermined thickness with a uniform flow rate and pressure distribution in the width direction of the sheet W. Then, on the downstream side, the coating liquid F2 discharged from the tip portion of the slit 26B is applied to the coating liquid F1 with a predetermined thickness with a uniform flow rate and pressure distribution in the width direction of the sheet W.

  Next, the detail of the other application | coating means 12 in the embossing sheet manufacturing apparatus 10 is demonstrated. FIG. 3 is a conceptual diagram showing a configuration of a slide type hopper 50 as the application head 12 </ b> C of the application unit 12.

  As shown in FIG. 3, two types of coating liquids F1 (adhesive) and F2 (resin) are fed into the coating head 50 by a liquid feed pump (see FIG. 1) via the liquid feed lines 52 and 54, respectively. The liquid is sent to the manifolds 56 and 58. The coating liquids F1 and F2 fed to the manifolds 56 and 58 are spread in the coating width direction and then pushed out to the slide surface 64 inclined downward on the top surface of the coating head 50 through the slits 60 and 62. The coating liquids F1 and F2 pushed out onto the slide surface 64 become two layers of coating liquid without being mixed with each other, flow down the slide surface 64, and reach the lip 66 at the tip of the slide surface 64. The coating liquids F1 and F2 that have reached the lip 66 form a bead portion 70 in the gap between the lip 66 and the sheet W that runs around the backup roller 68 (corresponding to the support roller 12D in FIG. 1).

  In the bead portion 70, the sheet W travels from below to above along the peripheral surface of the backup roller 68. Accordingly, the coating liquids F1 and F2 in the bead unit 70 are stretched and thinned by receiving the action of being pulled up on the sheet W surface. As a result, the coating liquids F1 and F2 flowing down the slide surface 64 are simultaneously applied in two layers in a thinned state on the traveling sheet W surface.

  Next, each material applied to the present invention will be described. As the sheet W, a resin film, paper (resin coated paper, synthetic paper, etc.), metal foil (aluminum web, etc.) and the like can be used. As the material of the resin fill, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyester, polyolefin, acrylic, polystyrene, polycarbonate, polyamide, PET (polyethylene terephthalate), biaxially stretched polyethylene terephthalate, Known materials such as polyethylene naphthalate, polyamideimide, polyimide, aromatic polyamide, cellulose acylate, cellulose triacetate, cellulose acetate propionate, and cellulose diacetate can be used. Of these, polyester, cellulose acylate, acrylic, polycarbonate, and polyolefin can be preferably used.

  The sheet W generally has a width of 0.1 to 3 m, the sheet W has a length of 1000 to 100,000 m, and the sheet W has a thickness of 1 to 300 μm. However, application of other sizes is not impeded.

  These sheets W may be previously subjected to corona discharge, plasma treatment, easy adhesion treatment, heat treatment, dust removal treatment and the like. The surface roughness Ra of the sheet W is preferably 3 to 10 nm at a cutoff value of 0.25 mm.

  The sheet W may be a sheet W provided with a base layer such as an adhesive layer in advance and dried and cured, or a sheet having another functional layer formed in advance on the back surface. Similarly, as the sheet W, not only a one-layer structure but also a structure having two or more layers can be adopted. Moreover, it is preferable that the sheet | seat W is a transparent body and anti-transparent body which can permeate | transmit light.

  As the adhesive, for example, an ultraviolet curable resin (product No .: XNR5540FL) manufactured by Nagase ChemteX Corporation can be used.

  As the resin, for example, an ultraviolet curable resin (product No: PAK-01) manufactured by Toyo Gosei Co., Ltd. can be used.

  Next, returning to FIG. 1, the operation of the embossed sheet manufacturing apparatus 10 will be described. The sheet W is sent out from the sheet-like body supply means 11 at a constant speed. The sheet W is fed into the application unit 12 and the adhesive and the resin are sequentially applied to the surface of the sheet W, whereby the adhesive layer and the resin layer are formed in two layers. Next, the sheet W is fed into a forming unit composed of an embossing roll 13 and a nip roll 14. Thus, roll forming is performed while pressing the continuously running sheet W with the rotating embossing roll 13 and the nip roll 14 at the 9 o'clock position of the embossing roll 13. That is, the sheet W is wound around the rotating embossing roll 13 and the unevenness on the surface of the embossing roll 13 is transferred to the resin layer.

  Next, in a state where the sheet W is wound around the embossing roll 13, the resin curing means 15 transmits the sheet W and irradiates the resin layer and the adhesive layer with radiation, thereby curing the resin layer and the adhesive layer. . Thereafter, the sheet W is peeled off from the embossing roll 13 by winding the sheet W around the peeling roll 16 at the 3 o'clock position of the embossing roll 13.

  In addition, although not shown in FIG. 1, in order to further accelerate hardening after peeling the sheet | seat W, radiation irradiation can also be performed again.

  The peeled sheet W is conveyed to the sheet take-up means 18 and the protective film H supplied from the protective film supply means 17 is supplied to the surface of the sheet W. It is wound up and stored by a winding roll.

  Thus, since the resin layer of the sheet | seat W is formed on the adhesive bond layer, it becomes easy to ensure the adhesiveness of the sheet | seat W and resin, and resin does not peel from the sheet | seat W. Thereby, the uneven | corrugated sheet | seat in which the regular fine uneven | corrugated pattern was formed in the surface can be manufactured with high quality without a defect.

  As mentioned above, although the example of embodiment of the manufacturing method and manufacturing apparatus concerning this invention was demonstrated, this invention is not limited to the example of the said embodiment, Various aspects can be taken.

  For example, in the example of the present embodiment, an embodiment using the roll-like embossing roll 13 is adopted, but an embodiment using an uneven pattern (embossed shape) formed on the surface of a belt-like body such as an endless belt may also be used. Can be adopted. This is because even such a belt-like body acts in the same manner as a cylindrical roll, and the same effect can be obtained.

  Examples of the present invention will be described. As an example of the present invention, an embossed sheet was manufactured using the embossed sheet manufacturing apparatus 10 having the configuration shown in FIG.

  As the sheet W, a transparent PET (polyethylene terephthalate) film having a width of 500 mm and a thickness of 100 μm was used.

  As the embossing roll 13, a roll made of S45C having a length (width direction of the sheet W) of 700 mm and a diameter of 300 mm and having a surface material of nickel was used. Grooves having a pitch of 50 μm in the roll axis direction were formed on the entire circumference of the roll surface with a width of about 500 mm by cutting using a diamond tool (single point). The cross-sectional shape of the groove is a triangular shape with an apex angle of 90 degrees, and the bottom of the groove is a triangular shape of 90 degrees with no flat portion. That is, the groove width is 50 μm and the groove depth is about 35 μm. Since this groove is endless without a seam in the circumferential direction of the roll, the embossing roll 13 can form a lenticular lens having a triangular cross section on the sheet W. The surface of the roll was subjected to nickel plating after the groove processing. A schematic sectional view of the embossing roll 13 is shown in FIG.

  As the coating head 12C of the coating means 12, a slide type hopper 50 shown in FIG. 3 was used.

  As the coating solution F1 (adhesive), an ultraviolet curable resin (product No .: XNR5540FL) manufactured by Nagase ChemteX Corporation was used.

  As the coating solution F2 (resin), an ultraviolet curable resin (product No: PAK-01) manufactured by Toyo Gosei Co., Ltd. was used.

  The slide type hopper 50 has a traveling speed of the sheet W of 2 m / min so that the wet thickness of the coating liquid F1 (adhesive) is 20 μm and the wet thickness of the coating liquid F2 (resin) is 60 μm. The supply amount of the coating liquids F1 and F2 was controlled. The viscosity of the coating liquid F1 was adjusted to 80 mPa · sec, the viscosity of the coating liquid F2 was adjusted to 300 mPa · sec, and the viscosity of the adhesive was made lower than the viscosity of the resin to ensure the stability of the coating layer. .

As the nip roll 14, a roll having a diameter of 200 mm and a silicon rubber layer having a rubber hardness of 90 formed on the surface thereof was used. The nip pressure (effective nip pressure) for pressing the sheet W with the embossing roll 13 and the nip roll 14 was 3.92 × 10 ⁶ Pa (40 kg / cm ² ).

A metal halide lamp was used as the resin curing means 15 and irradiation was performed with an energy of 500 mJ / cm ² .

  The evaluation of the embossed shape transfer rate was performed by cutting the sheet W on which the concavo-convex pattern was formed, and measuring the cross-sectional shapes at a plurality of locations of the concavo-convex pattern with an SEM (scanning electron microscope). A schematic sectional view of the embossed sheet is shown in FIG.

  From the above results, it was confirmed that the uneven sheet having a regular fine uneven pattern formed on the surface can be produced with high quality without any defects.

The conceptual diagram which shows the structure of the manufacturing apparatus of the embossed sheet applied to this invention Conceptual diagram showing the configuration of an extrusion type hopper as a coating device Sectional drawing which shows the outline | summary of the slide type hopper as a coating device Sectional view showing the outline of the embossing roll Sectional view showing the outline of the embossed sheet The conceptual diagram which shows the structure of the manufacturing apparatus of the embossed sheet of a prior art example The conceptual diagram which shows the other structure of the manufacturing apparatus of the embossed sheet | seat of a prior art example

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Embossed sheet manufacturing apparatus, 11 ... Sheet supply means, 12 ... Coating means, 13 ... Emboss roll, 14 ... Nip roll, 15 ... Resin curing means, 16 ... Release roll, 17 ... Protective film supply means, 18 ... Sheet winding Removing means, H ... protective film, W ... sheet

Claims (5)

In the method for producing a concavo-convex sheet that transfers the concavo-convex on the surface of the concavo-convex roll to the surface of the sheet-like body,
By substantially simultaneously coated with adhesive and a radiation-curable resin is a radiation curable resin, the adhesive layer on the surface, a sheet-like body of the band-shaped flexible resin layer is made form the adhesive layer Let it run continuously,
Wrapping the sheet-like body around the rotating concavo-convex roll, transferring the concavo-convex on the surface of the concavo-convex roll to the resin layer,
Method for manufacturing indented sheet, characterized in that curing by the adhesive layer with radiation of one and the resin layer in a state in which the sheet product is wound into the concave convex roll. The method for producing a concavo-convex sheet according to claim 1, wherein the viscosity of the adhesive is lower than the viscosity of the radiation curable resin of the resin layer . The method for producing a concavo-convex sheet according to claim 1 or 2 , wherein the radiation curable resin and the radiation curable resin are applied by an extrusion type hopper or a slide type hopper. Sheet-like body supply means for feeding out a belt-like flexible sheet-like body;
Substantially applying means for applying simultaneously an adhesive and a radiation-curable resin is a radiation curable resin to the surface of the sheet product,
Transfer means for transferring the irregularities on the surface of the uneven roll onto the surface of the sheet-like body while winding the continuous sheet-like body around a rotating uneven roll,
A resin curing means for curing the adhesive layer and the resin layer by one-time radiation irradiation in a state where the sheet-like body is wound around the uneven roll;
An apparatus for producing an uneven sheet, comprising: 5. The uneven sheet manufacturing apparatus according to claim 4, wherein the coating means is an extrusion type hopper or a slide type hopper.

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