JP4659222B2 - Embossed endless belt manufacturing method - Google Patents

Description

[0001]
The present invention, emboss pattern is applied to the surface, directed to the production how the embossing endless belts used to manufacture an embossed sheet.
[0002]
[Background]
Conventionally, so-called embossed sheets in which a three-dimensional uneven pattern (embossed pattern) is formed on the surface of a resin sheet or film have been manufactured.
In general, in the production of such an embossed sheet, an emboss is formed on the surface of a metal roll or a flat metal plate, and this is transferred to the surface of a resin sheet or film, or an endless wound around a plurality of rolls. A method of forming an emboss pattern on the surface of the resin sheet or film by a so-called belt process in which emboss is formed on the surface of the belt is employed.
[0003]
As a conventional method using a belt process, an uneven pattern is formed by engraving or the like on the endless belt surface, and this embossed endless belt is wound around a plurality of rolls including a heating roll and a cooling roll, There is a method in which embossing is continuously formed on the sheet surface by pressure (prior art 1 US Pat. No. 4,740,258).
In addition, as a method for forming an uneven groove on an embossed endless belt, when an uneven groove is formed on a polyimide resin thin film on an embossed endless belt, the uneven groove is formed on the surface by pressing with a transfer roll while the thin film is in a molten state. There is a transfer method (conventional technique 2 Japanese Patent Laid-Open No. 10-337806).
[0004]
[Problems to be solved by the invention]
However, each of the above-described conventional techniques has the following problems. That is, in the method according to the prior art 1, it is difficult to apply a fine three-dimensional pattern such as wood grain or fabric texture to the metal belt surface by means of engraving or the like, and even if engraving is performed, it takes time. There is a problem of being an economy. Further, when embossing the resin sheet on the surface of the metal belt, there is a problem that the sheet softened by heating is welded to the surface of the belt, making it difficult to peel off and causing the sheet to be damaged when it is forcibly peeled off.
On the other hand, in the method according to the prior art 2, when the embossed endless belt is manufactured, the mold reproducibility at the time of transferring the embossed pattern onto the polyimide surface is poor, so it is necessary to increase the pressure during pressing when trying to apply a fine pattern. There is a problem that processing is difficult. Further, in order to improve the mold reproducibility, there is a problem that when the polyimide is softened and pressed, the polyimide adheres to the transfer roll and the transfer efficiency of the emboss pattern deteriorates.
[0005]
An object of the present invention, conveniently, quickly, and with can be manufactured at low cost, can be reliably transferred a precise pattern, yet to provide a manufacturing how the good embossing endless belt releasability during embossed sheet processing There is.
[0006]
[Means for Solving the Problems]
An embossed endless belt manufacturing method according to claim 1 is an embossed endless belt manufacturing method used for manufacturing an embossed sheet having an embossed pattern on an outer surface, wherein a thermosetting resin is formed on the outer surface of the endless belt. A liquid permeability having a water permeability of 1 × 10 ⁻² (cm / s) or more on the thermosetting resin , and a concavo-convex pattern on the thermosetting resin. A second application step of applying a thermosetting resin on the film-shaped pattern material so as to have a thickness of 0.05 to 1.0 mm ; And a curing step of heating and curing the thermosetting resin while the film-like pattern material is adhered.
[0007]
Here, the endless belt can be made of a metal material such as steel, stainless steel, or copper. Further, the number of rolls around which the endless belt is wound is arbitrary as long as it is 2 or more, and the kind of roll can be appropriately selected such as a heating roll and a cooling roll.
And as a thermosetting resin used for a 1st application process and a 2nd application process, a polyimide resin, an epoxy resin, an unsaturated polyester resin, a phenol resin, a urea melamine resin, a polyurethane resin, a silicone resin, etc. are employable. Of these, polyimide resin is preferred.
[0008]
As the polyimide resin, non-thermoplastic polyimide, thermoplastic linear polyimide, thermosetting polyimide, modified polyimide, polyamideimide, polyetherimide, polyesterimide, or the like can be used. Since the same extruder etc. can be used as a polyimide used for the 1st application process and the 2nd application process, it is preferred to use the same kind of polyimide.
The thickness of the thermosetting resin applied in the second application step is preferably 0.05 to 1.0 mm. If it is less than 0.05 mm, there is a possibility that it is insufficient to precisely cover the unevenness of the embossed pattern of the film-like pattern material. If it is more than 1.0 mm, the amount of thermosetting resin increases. There is a risk that the unevenness of the embossed pattern of the film-like pattern material is buried too much.
[0009]
Moreover, in a sticking process, as a film-form pattern material provided with the embossing pattern stuck to a thermosetting resin, if it has liquid permeability, there will be no limitation in particular, A cloth, a race place, a nonwoven fabric, porous Various materials such as a conductive sheet, foam sheet, bark, wire mesh, porous foil, and tatami mat can be employed. What has liquid permeability has a property which can permeate | transmit liquids, such as water and alcohol. As an example, the liquid permeability can be expressed by “water permeability coefficient” defined in JIS A1218. The fiber products usually have a water permeability of 1 × 10 ⁻² (cm / s) or more, but such products can be preferably used. Since the film-shaped pattern material has liquid permeability, the polyimide obtained in the first coating process and the polyimide in the second coating process communicate with each other, and the film-shaped pattern material is firmly and securely fixed.
[0010]
Furthermore, there is no restriction | limiting in particular as thickness of a film-form pattern material, However, Preferably it is 0.1 mm or more and 5 mm or less.
Furthermore, as a pressing means for pressing the film-like pattern material on the polyimide film in the attaching step, for example, a method of pressing the sheet toward the endless belt with a nip roll provided outside the endless belt can be adopted. .
[0011]
Furthermore, in the curing step, a heating means is necessary to cure the thermosetting resin by heating. The heating means can be appropriately selected, for example, from the inside or the outside of the endless belt, or from both sides, but it is preferable to heat from the inside of the belt.
By heating from the inside of the belt, the sheet fixed to the heated endless belt can be directly heated, and the heating efficiency can be improved.
[0012]
Here, as the heating means from the inside of the endless belt, for example, heating is performed by a method in which at least one of a plurality of rolls around which the belt is wound is a heating roll, an electric heater installed on the inside of the belt, or the like. Methods and the like. On the other hand, examples of the heating means from the outside of the belt include a method of heating with an electric heater installed on the outside, a method of directly heating the sheet with a heating roll also serving as a nip roll provided on the outside of the belt, and the like. It is done.
In addition, heating efficiency can be improved by appropriately combining heating with hot air.
[0013]
According to this invention, by providing the first coating step, the sticking step, the second coating step, and the curing step, it is possible to reflect the embossed pattern of the film-like pattern material having the embossed pattern on the endless belt. Compared to engraving directly on an endless belt or coated polyimide, an embossed endless belt can be produced simply, quickly and at low cost.
[0014]
The embossed endless belt according to claim 2 is the manufacturing method of the embossed endless belt according to claim 1, wherein the thermosetting resin is preferably polyimide.
According to this invention, the polyimide on the surface of the embossed endless belt is easily applied to the endless belt because the liquid-permeable film-like pattern material is adhered to the applied polyimide and the polyimide is further applied. Since it has peelability, it is possible to easily peel off the sheet during emboss sheet processing. Since the polyimide on the surface of the embossed endless belt has easy releasability, the sheet can be easily peeled during the embossed sheet processing.
[0015]
The embossed endless belt according to the present invention is obtained by the method for manufacturing an embossed endless belt according to claim 1 or 2. If the embossed endless belt according to the present invention is manufactured by the method for manufacturing an embossed endless belt according to claim 1 or 2, the film-like pattern material is buried in polyimide, can do.
[0016]
The embossed sheet manufacturing apparatus according to the present invention includes a plurality of rolls, an embossed endless belt according to the present invention wound around these rolls, and pressing means for pressing the sheet.
[0017]
Here, one or more heating rolls and cooling rolls can be employed as the plurality of rolls, respectively.
On the outside of the embossed endless belt wound around these rolls, as a pressing means, a means using a nip roll or a means for sandwiching and pressing a workpiece by another belt provided in parallel to the embossed endless belt is adopted. You can also
[0018]
According to this invention, since it is a manufacturing apparatus using the embossed endless belt obtained by the above-described method, the releasability at the time of embossed sheet processing is improved, the unevenness difference is large, and the high added value having a precise embossed pattern The embossed sheet manufacturing apparatus which can manufacture this embossed sheet can be provided.
[0019]
The embossed sheet concerning this invention was manufactured using the embossed sheet manufacturing apparatus concerning this invention , It is characterized by the above-mentioned. As the thermoplastic resin constituting the sheet to be processed of the present invention, any thermoplastic resin can be employed, for example, a polyolefin resin such as polyethylene or polypropylene, and a copolymer of two or more olefins. , Ethylene-acrylic acid copolymer, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polyester, polyvinyl chloride, ionomer and the like can be employed. The thermoplastic resin may contain a filler (calcium carbonate, talc, etc.), a lubricant, an antistatic agent, a plasticizer, a colorant, a thermal decomposable foaming agent, etc., if necessary. .
[0020]
The above sheet may be embossed by laminating two or more kinds of sheets on the apparatus, or a sheet laminated in advance may be supplied onto the endless belt.
Moreover, as a method of previously laminating, for example, a laminating method such as thermal lamination or dry lamination, a co-extrusion method, a calendering method, or the like can be used.
In addition, the sheet | seat in this invention is a concept also including a film with comparatively thin thickness.
[0021]
According to the present invention, the polyimide on the surface of the embossed endless belt and the sheet to be processed are attached, and the embossed pattern is transferred to the sheet. Therefore, the completed sheet can be easily peeled off. Furthermore, various highly accurate embossed sheets, such as a cube corner prism type, can be provided.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a manufacturing apparatus 1 used for manufacturing an embossed endless belt 10 according to an embodiment of the present invention.
The manufacturing apparatus 1 includes a first heating roll 110, a second heating roll 111, and a cooling roll 120 arranged at predetermined intervals, an endless belt 10A wound around each of the rolls 110, 111, 120, and a bar coater 30. And an extruder 40, a nip roll 50, and a peeling roll 60.
[0023]
Here, the heating rolls 110 and 111 incorporate heating means such as a heater, and the surface temperature thereof can be adjusted.
Moreover, the cooling roll 120 incorporates cooling means such as a water cooling type, and the surface temperature thereof can be adjusted.
At least one of these rolls is connected to a rotation driving means such as a motor so as to be rotatable.
[0024]
Endless belt 10A is formed from stainless steel, and polyimide 10B as a thermosetting resin is applied to the surface thereof. The polyimide 10B is made of polyimide dispersed in a solvent, and the concentration is preferably 33% by weight or more. The viscosity is preferably 40 to 700 Poise. If the viscosity is less than 40 Poise, it is difficult to coat the film-like pattern material on the polyimide, and if it is greater than 700 Poise, there is a possibility that the unevenness of the embossed pattern cannot be obtained so much.
[0025]
When the polyimide 10B is applied, the liquid polyimide 10B is extruded from the extruder 40. If the viscosity is low, the polyimide 10B is poured and adjusted to a predetermined thickness by the bar coater 30. The extruder 40 is preferably one that can be extruded even when the viscosity of the polyimide 10B is high.
Further, the bar coater 30 is preferably formed of plastic, rubber, or the like in order to adjust the polyimide 10B to a predetermined thickness. In the present embodiment, a plastic bar coater 30 is used.
[0026]
The nip roll 50 is made of rubber, and a surface material made of silicone rubber is mounted on the outer peripheral surface thereof. The nip roll 50 is adjusted so as to press the first heating roll 110 with an appropriate pressure. Here, the film pattern material 70 is pressed and adhered by the nip roll 50 and the first heating roll 110. The pressing force can be appropriately set according to the thickness, width, resin material, and the like of the sheet to be processed.
Further, the peeling roll 60 is also formed of rubber, and a surface material made of silicone rubber is mounted on the outer peripheral surface thereof.
[0027]
A method for manufacturing the embossed endless belt 10 according to this embodiment using the manufacturing apparatus 1 of FIG. 1 will be described with reference to FIGS.
(1) The liquid polyimide 10B is applied onto the endless belt 10A operating in the direction of the arrow by the extruder 40. At that time, the thickness of the polyimide 10B is adjusted to about 0.2 mm by the bar coater 30 (first coating step).
[0028]
In FIG. 2, in addition to FIG. 1, a feeding roll 51 for feeding the film-like pattern material 70 is provided on the nip roll 50 side. The film-like pattern material 70 is in a state in which the same length as the circumferential length of the endless belt 10 </ b> A is wound around the feed roll 51 in advance.
[0029]
(2) The film-like pattern material 70 having an embossed pattern that is a concavo-convex pattern is sent out from the sending roll 51, and is sandwiched between the nip roll 50 and the endless belt 10A, and is pressed and stuck (sticking step).
[0030]
After the process in FIG. 2 is finished, in FIG. 3, the film-like pattern material 70 is stuck on the endless belt 10A via the polyimide 10B.
(3) The liquid polyimide 10B is further applied onto the film-like pattern material 70 stuck on the endless belt 10A operating in the arrow direction by the extruder 40. At that time, the thickness of the polyimide 10B is adjusted to about 0.1 mm by the bar coater 30 (second coating step).
[0031]
In FIG. 4, the bar coater and the extruder are removed from FIG. Further, the film-like pattern material 70 is stuck on the endless belt 10A via the polyimide 10B, and the polyimide 10B is applied on the film-like pattern material 70.
[0032]
(4) Then, the temperature of the first heating roll 110 and the second heating roll 111 is raised, the cooling function of the cooling roll 120 is turned off, the rotational speed of the endless belt 10A is adjusted, and the endless belt 10A is turned on for 1 hour. The polyimide 10B applied on the endless belt 10A is rotated to cure (curing step).
(5) Thereafter, the temperature of the first heating roll 110 and the second heating roll 111 is further increased, the rotational speed of the endless belt 10A is adjusted, the endless belt 10A is rotated for 1 hour, and the coating is applied onto the endless belt 10A. The cured polyimide 10B is completely cured (curing process).
[0033]
As described above, the polyimide 10B applied in the first application step on the endless belt 10A, the film-like pattern material 70 attached on the polyimide 10B in the attachment step, and the film-like pattern material in the second application step. An embossed endless belt 10 comprising polyimide 10B applied on 70 is completed. Further, an uneven emboss pattern reflecting the emboss pattern of the film-like pattern material 70 is formed on the polyimide 10B applied on the film-like pattern material 70 in the second application step.
[0034]
The embossed endless belt 10 manufactured in this way is used as an embossed sheet manufacturing apparatus as it is as shown in FIG.
The manufacturing apparatus 1 includes a first heating roll 110, a second heating roll 111, and a cooling roll 120 arranged at predetermined intervals, an embossed endless belt 10 wound around each of the rolls 110, 111, 120, and a nip roll 50. The feeding roll 52, the peeling roll 60, and the take-up roll 62 are provided.
[0035]
Here, a sheet 71 that is a workpiece of the present invention is wound around the feed roll 52, and the nip roll 50 and the embossed endless belt 10 are inserted and pressed from here on the embossed endless belt 10. The emboss pattern is transferred onto the sheet 71. In the present embodiment, the sheet 71 is a polypropylene sheet having a thickness of about 0.5 mm.
Further, the sheet 71 on which the emboss pattern is transferred is inserted into the take-up roll 62 between the peeling roll 60 and the embossed endless belt 10 and further peeled off.
[0036]
A method for manufacturing the embossed sheet 72 according to the present embodiment using the manufacturing apparatus 1 of FIG. 5 will be described.
(6) First, the temperatures of the first heating roll 110 and the second heating roll 111 are raised and cooled by the cooling roll 120. The rotational speed of the embossed endless belt 10 is adjusted.
(7) Thereafter, the emboss pattern on the embossed endless belt 10 is transferred to the sheet 71 by inserting and pressing the sheet 71 wound around the feed roll 52 between the nip roll 50 and the embossed endless belt 10.
(8) Further, the sheet 71 having the embossed pattern transferred thereon is inserted between the peeling roll 60 and the embossed endless belt 10 and peeled off.
Thus, the embossed sheet 72 is completed. As shown in FIG. 6, the obtained embossed sheet 72 includes an embossed surface 72 </ b> A that forms an uneven embossed pattern.
[0037]
According to this embodiment as described above, the following effects are obtained.
According to the present invention, a liquid-permeable film-like pattern material is adhered to the polyimide 10B applied on the endless belt 10A, and the polyimide 10B is further applied to provide an embossed pattern on the endless belt 10A. Therefore, the embossed endless belt 10 can be manufactured simply, quickly, and at low cost.
Moreover, since the polyimide 10B is further applied on the film-like pattern material 70 having the emboss pattern, the target emboss pattern can be accurately formed on the endless belt 10A.
[0038]
Furthermore, since the embossed pattern of the cured polyimide 10B is transferred to the sheet 71 that is the workpiece, the embossed sheet 72 is not attached to the polyimide 10B when the embossed sheet 72 is peeled off during the embossed sheet processing. 72 can be peeled off.
Since this embossed endless belt 10 is further coated with polyimide 10B on the film-like pattern material 70 having the target embossed pattern, the target embossed pattern is accurately formed on the embossed endless belt 10. Therefore, a precise emboss pattern can be transferred to the sheet 71.
Moreover, since the manufacturing apparatus 1 provided with the embossed endless belt 10 according to the present invention is used, the embossed sheet 72 on which the embossed pattern is accurately transferred can be provided.
[0039]
It should be noted that the present invention is not limited to the above-described embodiment, and modifications and improvements within a scope that can achieve the object of the present invention are included in the present invention. For example, as the endless belt 10A, stainless steel is used in the above-described embodiment, but the endless belt 10A is not limited thereto, and a metal material such as steel or copper can be used.
[0040]
Moreover, although polyimide 10B was employ | adopted as the thermosetting resin in the said embodiment, it is not restricted to this, Other than epoxy resin, unsaturated polyester resin, phenol resin, urea melamine resin, polyurethane resin, silicone resin, etc. The thermosetting resin can be used.
[0041]
Furthermore, as the heating rolls 110 and 111, in the above-described embodiment, a heating roll incorporating an electric heater is adopted. However, the heating roll is not limited to this. A method of directly heating the sheet 70 with a heating roll or the like that also serves as the nip roll 50 provided in the above can be adopted.
[0042]
And as the sheet | seat 71 used as a to-be-processed object, although the polypropylene sheet was employ | adopted in the said embodiment, it is not restricted to this, Other thermoplastic resin sheets, such as polyethylene, or two or more said thermoplastic resins are laminated | stacked The resin sheet etc. which were made can be adopted.
In addition, the specific structure, shape, and the like when carrying out the present invention may be other structures and the like as long as the object of the present invention can be achieved.
[0043]
【Example】
In the said embodiment, the specific conditions of manufacture of an embossed endless belt and an embossed sheet were as follows.
[1] Manufacture of embossed endless belt Perimeter of endless belt 10A: 2000 mm
Inner diameter of heating roll and cooling roll: 250 mm
Polyimide 10B to be applied: FS-510T manufactured by Ube Industries, Ltd.
Viscosity of polyimide 10B to be applied: 351 Poise
Solid content concentration of polyimide 10B to be applied: 66.3% by weight
Temperature of heating rolls 110 and 111 (FIG. 4): 80 ° C.
Temperature of heating rolls 110 and 111 (FIG. 4): 170 ° C.
Endless belt 10A rotation speed (FIGS. 1, 2, and 3): 0.5 m / min
Endless belt 10A rotation speed (FIG. 4): 1 m / min
Embossed pattern of film pattern material 70: floral lace pattern
The surface of the resulting embossed endless belt 10 on the polyimide 10B side reflects the irregularities of the floral lace pattern, is almost the same height as the surface of the fabric having the floral lace pattern, and the embossed pattern is accurately formed. It was.
[0045]
[2] Production of embossed sheet Raw material of sheet 71 used: Polypropylene (F-744NP manufactured by Idemitsu Petrochemical Co., Ltd.)
Temperature of heating roll 110 (FIG. 5): 170 ° C.
Temperature of heating roll 111 (FIG. 5): 200 ° C.
Temperature of the cooling roll 120 (FIG. 5): Rotating speed of the embossed endless belt 10 cooled with normal temperature water (FIG. 5): 2 m / min
[0046]
On the embossed surface 72A side of the obtained embossed sheet 72, the floral pattern lace pattern was accurately transferred.
[0047]
【The invention's effect】
According to the present invention, a liquid-permeable film-like pattern material is attached to the thermosetting resin applied on the endless belt, and then the thermosetting resin is applied to form an emboss pattern on the endless belt. Since the method is provided, the embossed endless belt can be manufactured simply, quickly, and at a low cost as compared with engraving directly on the endless belt or the applied polyimide.
Further, since the thermosetting resin is further applied on the film-shaped pattern material having the target emboss pattern, an emboss pattern having a large unevenness can be accurately formed on the endless belt.
[0048]
Furthermore, in the process of transferring the embossed pattern of the cured thermosetting resin to the sheet that is the workpiece, the embossed sheet can be peeled off without attaching the embossed sheet to the polyimide when the embossed sheet is peeled off during the embossed sheet processing. it can.
Since this embossed endless belt is further coated with a thermosetting resin on a film-like pattern material having the target embossed pattern, the target embossed pattern is accurately placed on the embossed endless belt. Since it is formed, a precise emboss pattern with a large unevenness difference can be reliably transferred to the sheet.
[Brief description of the drawings]
FIG. 1 is a view showing a first coating step of a method for producing an embossed endless belt according to the present invention.
FIG. 2 is a view showing a sticking step of the method for manufacturing an embossed endless belt according to the present invention.
FIG. 3 is a diagram showing a second coating step of the method for manufacturing an embossed endless belt according to the present invention.
FIG. 4 is a diagram showing a curing step of the method for producing an embossed endless belt according to the present invention.
FIG. 5 is a view showing an embossed sheet manufacturing apparatus according to the present invention.
FIG. 6 is a view showing an embossed sheet according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 10 Embossed endless belt 10A Endless belt 10B Polyimide 30 Bar coater 40 Extruder 50 Nip roll 60 Peeling roll 70 Film-like pattern material 71 Sheet 72 Embossed sheets 110 and 111 Heating roll 120 Cooling roll

Claims (2)

An embossed endless belt manufacturing method having an embossed pattern on an outer surface and used for manufacturing an embossed sheet, the first applying step of applying a thermosetting resin to the outer surface of the endless belt, and the thermosetting resin On top of this, a sticking step of sticking a film-like pattern material having a liquid permeability having a water permeability of 1 × 10 ⁻² (cm / s) or more as defined in JIS A1218, and having a concavo-convex pattern; A second application step of applying a thermosetting resin on the film-shaped pattern material to a thickness of 0.05 to 1.0 mm, and thermosetting with the film-shaped pattern material adhered. And a curing step of heating and curing the functional resin.   2. The method of manufacturing an embossed endless belt according to claim 1, wherein the thermosetting resin is polyimide.

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