JP5840585B2 - Fully automatic roll production system with pattern - Google Patents

Description

  The present invention relates to a fully automatic production system for a patterned roll patterned by DLC (diamond-like carbon).

  There is a roll for gravure printing as a roll with a pattern. In gravure printing, for a gravure printing roll (gravure cylinder), a micro concave portion (gravure cell) corresponding to the plate making information is formed to produce a plate surface, and the gravure cell is filled with ink and transferred to a printing material. is there. In a general gravure plate-making roll, a copper plating layer (plate material) for forming a plate surface is provided on the surface of a plate base material such as aluminum or iron, and a number of minute concave portions are formed on the copper plating layer according to plate making information by etching. (Gravure cell) is formed, and then a hard chromium layer is formed by chromium plating for increasing the printing durability of the gravure plate making roll to form a surface-enhanced coating layer, and plate making (plate surface production) is completed. The applicant of the present application has proposed, for example, a gravure printing roll described in Patent Document 1.

  Moreover, there exists an embossing roll for shaping | molding as a roll with a pattern. Embossing thermoplastic film to produce electronic parts such as prism sheet, lenticular sheet, Fresnel sheet, anti-reflection film used for LCD backlights and rear projection screens, and embossing metal plate For example, it is possible to improve the design and to provide an anti-slip function. The applicant of the present application has proposed an embossing roll described in Patent Document 2, for example.

  Moreover, there exists a roll for continuous plating as a roll with a pattern. The roll for continuous plating is used for a continuous plating apparatus. For example, a continuous plating is performed by continuously winding a strip-shaped workpiece such as a steel sheet wound around a reel through a plating bath. is there. As an example of the roll for continuous plating, there exist rolls, such as a sink roll disclosed by patent document 3 or patent document 4, for example.

  When manufacturing a roll with a pattern as described above, if a photosensitive material is applied to a substrate and exposed, developed, burned, and etched, there is a problem that over etching called so-called side etching occurs. As the patterning becomes finer, the problem of side etching becomes more obvious.

  Therefore, the applicant of the present application has proposed a roll with a pattern and a method for manufacturing the same, which have solved the problem of side etching (Patent Document 6).

  However, there has not yet been a fully automatic system for efficiently manufacturing the above-described patterned roll in a fully automatic manner.

International Publication WO2008 / 120789 JP 2009-72828 A JP 2006-283044 A JP 2001-89836 A JP 2009-093170 A JP 2012-154964 A International Publication WO2007 / 135898

  The present invention has been made in view of the above-described problems of the prior art, and an object of the present invention is to provide a fully automatic system for efficiently and fully manufacturing a patterned roll that solves the problem of side etching. .

In order to solve the above-described problems, a fully automatic roll manufacturing system with a pattern according to the present invention includes an industrial robot, a photosensitive material coating unit, an exposure unit, a development unit, a DLC coating film forming unit, and a film removal unit. The DLC coating film forming unit includes a first revolving unit and a second revolving unit, and the revolving unit is one of the first revolving unit and the second revolving unit. While the cylinder base material is being carried in / out, the other revolving unit performs the DLC coating film forming process, and the processing unit group is installed on the arm turning path of the industrial robot. the cylinder substrate for each processing unit of the processing unit group using only the industrial robot From the next transfer, a photosensitive material is applied to the surface of the cylinder base material, exposed and developed to form a resist pattern, and a DLC coating film is formed on the surface of the cylinder base material and the resist pattern. The DLC coating film formed on the resist pattern is peeled off together with the resist pattern to form a DLC pattern on the surface of the cylinder base material to produce a patterned roll.

  Thus, since the DLC coating film formed on the resist pattern is peeled off together with the resist pattern, there is an advantage that the problem of side etching is solved. That is, in the present invention, since a technique called so-called lift-off is used instead of etching, the conventional side etching problem does not occur.

  It is preferable that a cylinder stocker device with a turntable for stocking the cylinder base material is further installed on the arm turning path of the industrial robot.

  The cylinder base material is preferably made of at least one material selected from the group consisting of Ni, stainless steel, Ti, Cu, Al, and CFRP (carbon fiber reinforced resin). In particular, when the cylinder base material is a CFRP cylinder base material, there is an advantage that the industrial robot is lightweight when handled. In the production of a printed board, the plate is frequently changed, which is particularly advantageous when producing a printed board using a patterned roll.

  The cylinder substrate preferably includes a cushion layer made of rubber or a resin having cushioning properties. As the cushion layer, a synthetic rubber such as silicone rubber, or a synthetic resin having elasticity such as polyurethane or polystyrene can be used. The thickness of the cushion layer is not particularly limited as long as it can provide cushioning properties, that is, elasticity. For example, a thickness of about 1 cm to 5 cm is sufficient. As an example of a gravure plate provided with a cushion layer made of rubber or a resin having cushioning properties, there is, for example, Patent Document 5.

  You may comprise so that the base material with which the said photosensitive material is apply | coated may consist of the material which has cushioning properties which consist of rubber | gum or resin which has cushioning properties. More specifically, a synthetic rubber such as silicon rubber, or an elastic synthetic resin such as polyurethane or polystyrene can be used as the base material.

  As the photosensitive material, either a positive photosensitive composition or a negative photosensitive composition is applicable, but a negative photosensitive composition is preferable.

  The thickness of the DLC coating film is preferably 0.1 μm to several tens of μm. More specifically, 0.1 μm to 20 μm is preferable, and 0.1 μm to 5 μm is more preferable.

  It is preferable that the roll with a pattern is a roll for gravure printing. This is because there is no problem of side etching, so that the concentration range can be expanded as compared with the conventional case.

  The product according to the present invention is printed by the gravure roll.

  The patterned roll is preferably an embossing roll for molding.

  The product according to the present invention is characterized by being molded by the molding embossing roll.

  It is preferable that the roll with a pattern is a roll for continuous plating.

  The product according to the present invention is plated by the roll for continuous plating.

  The manufacturing method of the roll with a pattern of this invention is a method of manufacturing a roll with a pattern using the said roll automatic manufacturing system with a pattern, The process of preparing a base material, and apply | coating a photosensitive material to the surface of this base material A step of forming a resist pattern by exposing and developing, a step of forming a DLC coating film on the surface of the substrate and the resist pattern, and a DLC coating film formed on the resist pattern. And a step of peeling them together.

  According to the present invention, it is possible to provide a fully automatic system for efficiently and fully manufacturing a patterned roll that has solved the problem of side etching that has solved the problem of side etching. .

It is a schematic plan view which shows one embodiment of the roll automatic manufacturing system with a pattern which concerns on this invention. It is explanatory drawing which shows typically an example of the roll with a pattern manufactured with the roll automatic manufacturing system with a pattern which concerns on this invention, (a) is principal part sectional drawing of the state which apply | coated the photosensitive material on the surface of the base material (B) is a fragmentary cross-sectional view of a state where a resist pattern is formed by exposure and development, (c) is a fragmentary cross-sectional view of a state where a DLC coating film is formed on the surface of the substrate and the resist pattern, ) Is an essential part cross-sectional view showing a state in which the DLC coating film formed on the resist pattern is peeled off together with the resist pattern. It is a flowchart which shows the manufacturing process order of the roll with a pattern shown in FIG.

  Embodiments of the present invention will be described below, but these embodiments are exemplarily shown, and it goes without saying that various modifications can be made without departing from the technical idea of the present invention.

  An embodiment of a fully automatic roll manufacturing system with a pattern according to the present invention will be described with reference to the accompanying drawings. In FIG. 1, the code | symbol 10 shows the roll automatic manufacturing system with a pattern which concerns on this invention.

  The fully-rolled roll manufacturing system 10 includes an industrial robot 12, a photosensitive material coating unit 14, an exposure unit 16, a development unit 18, a film removal unit 20, and a DLC coating film forming unit 22. A processing unit group 24 is provided. The processing unit group 24 is installed on the turning path of the arm 32 of the industrial robot 12. As the photosensitive material coating unit 14, the exposure unit 16, and the development unit 18, conventionally known apparatuses can be used, for example, those described in Patent Document 7 can be used. For example, the DLC coating film forming unit 22 described in Patent Document 7 can be applied. Furthermore, for the film removal unit 20, for example, a resist stripping unit described in Patent Document 7 can be used.

  In the illustrated example, a two-story unit structure in which the exposure unit 16 is placed on the photosensitive material coating unit 14 is employed. Further, a two-story unit structure in which the film removal unit 20 is placed on the developing unit 18 is adopted.

  As the DLC coating film forming unit 22, in the illustrated example, a CVD (Chemical Vapor Deposition) apparatus for forming a DLC coating film is shown. The DLC coating film forming unit 22 includes a first revolving unit 26a and a second revolving unit 26b, and can sequentially store the cylinder base 30 by rotating the storage cases 28a and 28b. ing.

  In the illustrated example, when the cylinder base material 30 is arranged on the first revolving unit 26a, the CVD process for forming the DLC coating film is performed, and when the cylinder base material 30 is arranged on the second revolving unit 26b, the DLC is performed. A CVD process for forming a coating film is performed.

  In these revolving units, the DLC coating film forming process is performed by the other revolving unit while the cylinder base material 30 is being carried in / out by the revolving unit of either the first revolving unit 26a or the second revolving unit 26b. It is preferable to perform (for example, a CVD process). This is because time loss between processes is reduced.

  Moreover, cylinder stockers 34a and 34b with a turntable are also installed. In any one of the cylinder stockers with a turntable, a cylinder base material 30 that has not been subjected to any processing is stocked, and the other In the roll stock apparatus, the cylinder base material 30 after finishing all the processing steps can be stocked. The cylinder stocker devices 34a and 34b with turntables are configured such that the turntables can rotate, and the cylinder base material 30 can be sequentially placed thereon. As the cylinder stocker devices 34a and 34b with a turntable, for example, a roll stock device described in Patent Document 7 can be applied.

  Then, by sequentially transferring the cylinder base material 30 to each processing unit of the processing unit group 24, a photosensitive material is applied to the surface of the cylinder base material 30, and exposed and developed to form a resist pattern. Then, a DLC coating film is formed on the surfaces of the cylinder base material and the resist pattern, the DLC coating film formed on the resist pattern is peeled off together with the resist pattern, and the DLC pattern is formed on the surface of the cylinder base material 30. It can be formed to produce a patterned roll.

  The operating room A and the processing room B are separated by a wall 40 with doors 36 and 38, and the processing room B is further separated from the processing room C by a wall 44 with a door 42. It has been. In the illustrated example, the processing room C is a clean room.

  Reference numeral 46 is a main control panel, and reference numeral 48 is a computer. Reference numeral 50 denotes a patterned roll manufactured after the processing in each processing unit is completed.

  A symbol Q indicates a turning range of the arm 32 which is a handling area of the industrial robot 12.

  Next, based on FIGS. 1-3, the effect | action of the roll automatic manufacturing system with a pattern of this invention is demonstrated. The industrial robot 12 chucks the cylinder base material 30 (in the illustrated example, an aluminum hollow cylinder base material) placed on one of the cylinder stocker devices 34a and 34b with a turntable, and moves to the photosensitive material coating unit 14. The cylinder base material 30 is carried and set. In the photosensitive material application unit 14, the photosensitive material 52 is applied to the surface of the cylinder base material 30 (FIG. 2A, step 100 in FIG. 3). The photosensitive composition used as the photosensitive material can be either a negative type or a positive type, but a negative photosensitive composition is preferred.

  The industrial robot 12 chucks the cylinder base material 30 coated with the photosensitive material 52 and carries the cylinder base material 30 to the exposure unit 16 for setting. In the exposure unit 16, the surface of the cylinder base material 30 coated with the photosensitive material 52 is exposed.

  Next, the industrial robot 12 chucks the exposed coated cylinder base material 30, and carries the cylinder base material 30 to the developing unit 18 for setting. In the developing unit 18, the exposed surface of the cylinder base material 30 is developed. In this way, a resist pattern 54 is formed on the surface of the cylinder base 30 (FIG. 2B, step 102 in FIG. 3).

  The industrial robot 12 chucks the cylinder base 30 on which the resist pattern 54 is formed, and carries the cylinder base 30 to the DLC coating film forming unit 22 for setting. In the DLC coating film forming unit 22, the DLC coating film 56 is formed on the surfaces of the cylinder base material 30 and the resist pattern 54 by the CVD method (FIG. 2C, step 104 in FIG. 3). The DLC coating film 56 can also be formed by sputtering. The thickness of the DLC coating film 56 is preferably 0.1 μm to several tens of μm, particularly 0.1 μm to 20 μm.

  The industrial robot 12 chucks the cylinder base material 30 on which the DLC coating film 56 is formed, and carries the cylinder base material 30 to the film removal unit 20 for setting. In the film removal unit 20, the DLC coating film 56 is peeled together with the resist pattern 54 by immersing the cylinder base material 30 on which the DLC coating film 56 is formed in the liquid, and a DLC pattern 58 is formed (FIG. 2). (D) Step 106 of FIG. In addition, the film removal liquid put into the film removal unit 20 can use the well-known resist stripping solution used for a gravure plate making apparatus. In this way, the patterned roll 50 is manufactured.

  As the cylinder base material 30, one made of at least one material selected from the group consisting of Ni, stainless steel, Ti, Cu, Al, and CFRP can be used. Moreover, you may make it provide the cushion layer which consists of resin which has rubber | gum or cushioning properties. Furthermore, it can also comprise so that a base material may consist of the material which has cushioning properties which consist of rubber | gum or resin which has cushioning properties. The cushion layer is made of rubber or a resin having cushioning properties, and a sheet-like material having a uniform thickness of about 1 mm to 10 cm and a high surface smoothness is formed on the cylinder base material 30 so as not to open a gap at the seam. Bonded firmly, then precision cylindrical grinding and mirror polishing.

  The roll 50 with a pattern thus produced is suitable as a gravure printing roll, a molding embossing roll, a continuous plating roll, or the like.

10: Patterned roll fully automatic manufacturing system, 12: Industrial robot, 14: Photosensitive material coating unit, 16: Exposure unit, 18: Development unit, 20: Film removal unit, 22: DLC coating film forming unit, 24: Processing unit group, 26a: first revolving unit, 26b: second revolving unit, 28a, 28b: storage case, 30: cylinder base, 32: arm, 34a, 34b: cylinder stocker device with rotary table, 36, 38, 42, 44: Door, 40: Wall, 46: Main control panel, 48: Computer, 50: Roll with pattern, 52: Photosensitive material, 54: Resist pattern, 56: DLC coating film, 58: DLC pattern, A: Operating room, B, C: Processing room, Q: Arm turning range.

Claims (10)

Industrial robots,
A photosensitive material coating unit, an exposure unit, a development unit, a DLC coating film forming unit, a film removal unit,
A processing unit group including
The DLC coating film forming unit includes a first revolving unit and a second revolving unit,
While the cylinder base material is being carried in / out by one of the first revolving unit and the second revolving unit, the other revolving unit performs the DLC coating film forming process.
The processing unit group is installed on the arm turning trajectory of the industrial robot , and the cylinder base material is sequentially transferred to each processing unit of the processing unit group using only the industrial robot. Then, a photosensitive material is applied to the surface of the cylinder base material, exposed and developed to form a resist pattern, a DLC coating film is formed on the surface of the cylinder base material and the resist pattern, and formed on the resist pattern. A fully automatic roll manufacturing system with a pattern in which a DLC coating film is peeled off together with the resist pattern, and a DLC pattern is formed on the surface of a cylinder substrate to manufacture a roll with a pattern.   The fully automatic manufacturing system for a roll with a pattern according to claim 1, wherein a cylinder stocker device with a turntable for stocking a cylinder base material is further installed on an arm turning path of the industrial robot.   The fully automatic manufacturing system with a patterned roll according to claim 1 or 2, wherein the cylinder base material is made of at least one material selected from the group consisting of Ni, stainless steel, Ti, Cu, Al, and CFRP. .   The said cylinder base material is provided with the cushion layer which consists of resin which has rubber | gum or cushioning property, The roll automatic manufacturing system with a pattern of Claim 1 or 2 characterized by the above-mentioned. The fully automatic manufacturing system with a patterned roll according to any one of claims 1 to 4, wherein the photosensitive material is a negative photosensitive composition. The fully automatic manufacturing system with a patterned roll according to any one of claims 1 to 5, wherein a thickness of the DLC coating film is 0.1 µm to 20 µm.   The said roll with a pattern is a roll for gravure printing, The roll automatic roll production system with a pattern of any one of Claims 1-6 characterized by the above-mentioned.   The said roll with a pattern is an embossing roll for shaping | molding, The roll automatic manufacturing system with a pattern of any one of Claims 1-6 characterized by the above-mentioned.   The said roll with a pattern is a roll for continuous plating, The fully automatic manufacturing system with a pattern roll of any one of Claims 1-6 characterized by the above-mentioned. 1-9 The method of producing a patterned roll with either 1 patterned roll fully automatic manufacturing system according Section
A step of preparing a substrate, a step of applying a photosensitive material to the surface of the substrate, exposing and developing to form a resist pattern, and a step of forming a DLC coating film on the surfaces of the substrate and the resist pattern And a step of peeling the DLC coating film formed on the resist pattern together with the resist pattern.

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