JP6785733B2 - Mold roll and manufacturing method of mold roll - Google Patents

Description

The present disclosure relates to a mold roll and a method for manufacturing a mold roll.

As a method for producing a film or the like having a regular fine uneven shape pattern (hereinafter referred to as "pattern") formed on the surface, a resin is applied to a mold roll having a pattern formed on the surface, and after the resin is cured. A method of producing a film by peeling it from a mold roll is known.

For this mold roll, for example, as shown in Patent Document 1, a plurality of nickel films (female molds) having a pattern formed on the surface are prepared by using an original plate (male mold) prepared by a method such as photolithography. , It is manufactured by adhering a plurality of nickel films to the outer peripheral surface of the roll type base material.

Japanese Unexamined Patent Publication No. 2003-25431

As shown in Patent Document 1, when an original plate is produced by using a photolithography method, the outer size of the nickel film that can be produced is limited to about 200 mm because the size of the original plate is limited.

For this reason, when manufacturing a large-area mold roll, it is necessary to bond many nickel films to the roll base material, and as the number of nickel films adhered to the roll base material increases, the nickel films are bonded to each other. It becomes difficult to arrange without gaps. Further, when there is a gap between the nickel films, when a resin film or the like is produced by using a mold roll, the resin may enter the gap and the peelability of the resin may decrease.

On the other hand, when the nickel films are welded to each other to form one roll in order to suppress the gap between the nickel films, the number of welding steps increases, which complicates the manufacturing process and increases the cost.

In the present disclosure, in consideration of the above facts, in a mold roll in which a plurality of sleeve rolls are arranged in the axial direction, the peelability of the resin is lowered when producing a resin film or the like while simplifying the manufacturing process. It is an object of the present invention to provide a mold roll and a method for producing a mold roll, which can suppress the above.

The mold roll according to the first aspect of the present disclosure includes a cylindrical raw tube roll and a plurality of cylindrical sleeve rolls that are fitted into the outer peripheral surfaces of the raw tube rolls and are in contact with each other at the end faces. The roll is composed of a plurality of metal plates welded to each other in the circumferential direction, and the surface roughness of the end face is 50 μm or less.

According to the above aspect, a sleeve roll is formed by a plurality of metal plates welded to each other, and the plurality of sleeve rolls are fitted into the raw pipe rolls to form a large-area mold roll.

Here, since the surface roughness of the end faces, which are the contact surfaces between the sleeve rolls, is 50 μm or less, it is possible to suppress an increase in the gap between the end faces without welding the sleeve rolls to each other. Therefore, the welding process can be reduced, and when a resin film or the like is produced using a mold roll, it is possible to prevent the resin from entering the gap between the end faces and reducing the peelability of the resin. it can.

The mold roll according to the second aspect of the present disclosure has a surface roughness of the end face of the sleeve roll of 1 μm or more in the mold roll according to the first aspect.

According to the above aspect, since the surface roughness of the end face of the sleeve roll is 1 μm or more, the polishing step of the end face can be reduced as compared with the configuration in which the surface roughness is less than 1 μm.

The mold roll according to the third aspect of the present disclosure is the mold roll according to the first or second aspect, and the plurality of sleeve rolls are detachably fitted to the raw tube rolls, respectively.

According to the above aspect, since the plurality of sleeve rolls are detachable from each other with respect to the raw tube roll, the bonding process between the sleeve roll and the raw tube roll can be reduced. Further, for example, when the sleeve roll is soiled, the soiled sleeve roll can be easily replaced.

The mold roll according to the fourth aspect of the present disclosure is the mold roll according to any one of the first to third aspects, and the inner diameter of the sleeve roll is the raw pipe in the state before being fitted into the raw pipe roll. The size is −300 μm or more and 100 μm or less with respect to the outer diameter of the roll.

According to the above aspect, since the inner diameter of the sleeve roll is −300 μm or more and 100 μm or less with respect to the outer diameter of the raw tube roll, the sleeve roll can be attached to the raw tube roll without adhering the sleeve roll and the raw tube roll. It can be fixed to the outer peripheral surface.

The mold roll according to the fifth aspect of the present disclosure is the mold roll according to any one of the first to fourth aspects, and at least one of the plurality of metal plates has a concave-convex pattern formed on the surface thereof. It is said to be a metal plate with a pattern.

According to the above aspect, by forming the sleeve roll with a patterned metal plate having a concave-convex pattern formed on the surface, it is possible to produce a film or the like having a pattern formed by using the mold roll. ..

The mold roll according to the sixth aspect of the present disclosure is the mold roll according to the fifth aspect, and the plurality of sleeve rolls are composed of a patterned sleeve roll composed of a patterned metal plate and a metal plate having a smooth surface. It is composed of a sleeveless roll with a pattern.

According to the above aspect, the sleeve roll is composed of a patterned sleeve roll having a pattern formed on the surface and a patterned sleeveless roll having a smooth surface. Therefore, for example, when producing a film or the like in which a pattern is formed by a sleeve roll with a pattern, the sleeveless roll with a pattern can be used as a receiving portion of a resin protruding outside the pattern.

In the present disclosure, the "metal plate having a smooth surface" refers to a metal plate having a smoother surface than a metal plate having an uneven pattern formed on the surface, and specifically, a pattern is formed on the surface. Refers to a metal plate that has not been made.

The mold roll according to the seventh aspect of the present disclosure is the mold roll according to the fifth or sixth aspect, and the patterned metal plate is made of a nickel electroplated plate.

According to the above aspect, since the patterned metal plate is made of a nickel electroplated plate, a plurality of patterned metal plates can be easily produced from one original plate.

In the method for manufacturing a mold roll according to the eighth aspect of the present disclosure, a plurality of metal plates are welded to each other in the circumferential direction to form a cylindrical sleeve roll, and the end face of the sleeve roll is processed to obtain the surface roughness of the end face. The length is 50 μm or less, and a plurality of sleeve rolls are fitted into a cylindrical raw tube roll so that the end faces are brought into contact with each other.

According to the above aspect, a large area mold roll can be formed by welding a plurality of metal plates to each other to form a sleeve roll and fitting the plurality of sleeve rolls into the raw pipe rolls.

Here, since the surface roughness of the end faces, which are the contact surfaces between the sleeve rolls, is processed to be 50 μm or less, by bringing the end faces of the sleeve rolls into contact with each other, a gap is created between the end faces without welding the sleeve rolls to each other. It is possible to suppress the vacancy. Therefore, the welding process can be simplified, and when a resin film or the like is produced using a mold roll, it is possible to prevent the resin from entering the gap between the end faces and reducing the peelability of the resin. Can be done.

The method for manufacturing a mold roll according to the ninth aspect of the present disclosure is a plurality of methods for manufacturing a mold roll according to the eighth aspect, while expanding the inner diameter of the sleeve roll by the pressure of air blown from the outer peripheral surface of the raw tube roll. The sleeve rolls are fitted into the raw pipe rolls, and the air pressure is reduced to fix the sleeve rolls to the raw pipe rolls.

According to the above aspect, the sleeve roll is fitted into the raw tube roll while expanding the inner diameter of the sleeve roll by the pressure of air. Therefore, the sleeve roll can be easily fitted into the raw tube roll as compared with the configuration in which the sleeve roll is fitted into the raw tube roll without expanding the inner diameter of the sleeve roll.

Further, by fitting the sleeve roll into the raw pipe roll and then reducing the air pressure, the sleeve roll can be brought into close contact with the outer peripheral surface of the raw pipe roll without adhering the sleeve roll to the raw pipe roll. Can be fixed.

In the method for producing a mold roll according to the tenth aspect of the present disclosure, in the method for producing a mold roll according to the eighth or ninth aspect, an uneven pattern is formed on the surface of at least one of the metal plates. A metal plate with a pattern.

According to the above aspect, by forming the sleeve roll with a patterned metal plate having a concave-convex pattern formed on the surface, it is possible to produce a film or the like having a pattern formed by using the mold roll. ..

In the method for manufacturing a mold roll according to the eleventh aspect of the present disclosure, in the method for manufacturing a mold roll according to the tenth aspect, a patterned sleeve roll is formed using a patterned metal plate, and a metal plate having a smooth surface is used. The patterned sleeveless roll is formed, and the patterned sleeveless roll and the patterned sleeveless roll are fitted into the raw tube rolls, respectively.

According to the above aspect, the patterned sleeve roll having a pattern formed on the surface and the patterned sleeveless roll having no pattern formed on the surface are fitted into the raw tube rolls, respectively. Therefore, for example, when producing a film or the like in which a pattern is formed by a sleeve roll with a pattern, the sleeveless roll with a pattern can be used as a receiving portion of a resin protruding outside the pattern.

According to the present disclosure, in a mold roll in which a plurality of sleeve rolls are arranged in the axial direction, it is possible to suppress a decrease in resin peelability when producing a resin film or the like while simplifying a manufacturing process. it can.

It is a perspective view which shows the mold roll in one example of an embodiment. It is an exploded perspective view which shows the mold roll in one example of an embodiment. It is a top view which shows the manufacturing process of the metal plate used for the mold roll in one example of embodiment. It is a top view which shows the metal plate used for the mold roll in one example of embodiment. It is a top view which shows the sleeve roll used for the mold roll in one example of embodiment. It is a process diagram which shows the manufacturing process of the mold roll in one example of Embodiment. It is a process diagram which shows the manufacturing process of the mold roll in one example of Embodiment. It is a partially enlarged view in FIG. 7A. It is a process diagram which shows the manufacturing process of the mold roll in one example of Embodiment. It is a partially enlarged view in FIG. 8A.

Hereinafter, an example of the embodiment of the mold roll according to the present disclosure will be described with reference to FIGS. 1 to 8B. In the drawing, the arrow X direction indicates the axial direction of the mold roll, and the arrow Y direction indicates the radial direction of the mold roll.

(Constitution)
The mold roll 10 of the present embodiment is used when producing a resin film such as a microlens array sheet or a lenticular sheet having a pattern formed on the surface such as a microlens array or a cylindrical lens. As shown in FIGS. 1 and 2, the mold roll 10 includes a cylindrical raw tube roll 12, a plurality of cylindrical sleeve rolls 14 detachably fitted to the outer peripheral surface 12A of the raw tube roll 12, and a plurality of cylindrical sleeve rolls 14. have.

Further, the sleeve roll 14 is composed of a plurality of patterned sleeve rolls 16 having a pattern formed on the surface and a plurality of patterned sleeveless rolls 18 having a smooth surface, that is, a plurality of patterned sleeveless rolls 18 having no pattern formed on the surface. There is.

Specifically, the patterned sleeve roll 16 is formed by welding a plurality of rectangular patterned metal plates 20 having a pattern P formed on the surface to each other in the circumferential direction. Similarly, the pattern sleeveless roll 18 is formed by welding a plurality of rectangular metal plates 22 having a smooth surface, that is, having no pattern formed on the surface, to each other in the circumferential direction.

The patterned sleeve roll 16 and the patterned sleeveless roll 18 are arranged side by side in the axial direction of the raw tube roll 12. In the present embodiment, as an example, the patterned sleeveless roll 18 is arranged on the axially outer side of the raw pipe roll 12, and the patterned sleeveless roll 16 is arranged on the inner side in the axial direction.

Further, in the patterned sleeve roll 16 and the patterned sleeveless roll 18, the surface roughness (Ra) of the end faces 16A and 18A is 1 μm or more and 50 μm or less, and the raw tube rolls are in a state where the end faces 16A and 18A are in contact with each other. Each of them is fitted in 12. The surface roughness (Ra) of the end faces 16A and 18A is more preferably 10 μm or more and 40 μm or less, and particularly preferably 20 μm or more and 35 μm or less.

(Production method)
Next, an example of a method for manufacturing the mold roll 10 according to the present disclosure will be described. The following manufacturing method is an example, and the order of the processes may be different.

When manufacturing the mold roll 10, first, the patterned metal plate 20 shown in FIG. 4 is manufactured. Specifically, for example, a photolithography technique is used to form a pattern on the surface of an original plate (not shown). Then, the electrolyzed nickel ions are electrodeposited on the surface of the original plate to form a plating layer, and the plating layer is peeled off from the original plate to form a disk shape in which a pattern P is formed on the surface, as shown in FIG. A plurality of nickel electroplated plates 24 are produced.

In this embodiment, as an example, the diameter of the nickel electroplated plate 24 is about 200 mm. The thickness of the nickel electroplated plate 24 is preferably 0.1 mm or more and 0.4 mm or less, more preferably 0.15 mm or more and 0.35 mm or less, and 0.2 mm or more and 0. It is particularly preferable that the thickness is 3 mm or less.

By setting the thickness of the nickel electroplated plate 24 to 0.1 mm or more, the nickel electroplated plate 24 may be broken or foreign matter may be broken during the processing process as compared with the nickel electroplated plate having a thickness of less than 0.1 mm. It is possible to prevent the surface of the nickel electroplated plate 24 from being uneven due to biting. Further, by setting the thickness of the nickel electroplated plate 24 to 0.4 mm or less, the nickel electroplated plate 24 can be easily bent as compared with the nickel electroplated plate having a thickness of more than 0.4 mm. it can.

An electroformed plate is produced by electroforming copper (Cu) other than nickel (Ni), gold (Au), silver (Ag), hard chromium (HCr), or a combination of these metals. You may.

After that, the nickel electroplated plate 24 is shear-cut into a rectangular shape to produce a plurality of patterned metal plates 20 shown in FIG. Next, as shown in FIG. 5, a cylindrical patterned sleeve roll 16 is produced by welding a plurality of patterned metal plates 20 to each other and connecting them in an annular shape with the surface on which the pattern P is formed as the outside. .. Further, the end surface 16A of the patterned sleeve roll 16 is polished or ground so that the surface roughness is 1 μm or more and 50 μm or less.

Similarly, a plurality of rectangular metal plates 22 having a smooth surface, that is, having no pattern P formed on the surface, are welded to each other and connected in an annular shape, and the end face 18A is polished or ground to have a surface roughness of 1 μm or more and 50 μm. By processing as follows, the cylindrical pattern sleeveless roll 18 shown in FIG. 2 is produced.

The metal plate 22 may be made of the same material as the patterned metal plate 20 (nickel in the present embodiment), or may be made of a different material. Further, the thickness of the metal plate 22 is substantially the same as the thickness of the patterned metal plate 20. Further, from the viewpoint of handleability and fitting workability, the width of the patterned sleeve roll 16 and the patterned sleeveless roll 18 in the axial direction is preferably 30 mm or more, and more preferably 50 mm or more. ..

Next, the produced patterned sleeve roll 16 and the patterned sleeveless roll 18 are fitted into the raw tube roll 12, respectively. Specifically, as shown in FIG. 6, the raw pipe roll 12 communicates with the introduction port 26 formed on one end surface in the axial direction and the introduction port 26, and the air extending inside the raw pipe roll 12 in the axial direction. It has a passage 28 and a plurality of outlet holes 30 that communicate with the air passage 28 and open to the outer peripheral surface 12A of the raw pipe roll 12.

Further, an air supply pipe 32 extending from an air supply means (not shown) is connected to the introduction port 26, and the air supplied from the air supply means is introduced into the air passage 28 from the air supply pipe 32 through the introduction port 26. , It is blown out from the blowout hole 30 of the outer peripheral surface 12A of the raw pipe roll 12.

In the present embodiment, the inner diameter of the sleeve roll 14, that is, the inner diameter of the patterned sleeve roll 16 and the inner diameter of the patterned sleeveless roll 18 is the outer diameter of the raw pipe roll 12 in the state before being fitted into the raw pipe roll 12. The size is -300 μm or more and 100 μm or less.

Here, when the sleeve roll 14 is fitted into the raw pipe roll 12 while blowing air from the blowout hole 30 on the outer peripheral surface 12A of the raw pipe roll 12, as shown in FIGS. 7A and 7B, the sleeve is subjected to the air pressure. The inner diameter of the roll 14 is slightly expanded.

Then, while the inner diameter of the sleeve roll 14 is expanded by the pressure of air, the sleeve roll 14 is fitted into the raw pipe roll 12, respectively, and arranged at a position where the end faces 16A and 18A of the sleeve roll 14 come into contact with each other. After that, by lowering the air pressure or stopping the air supply, as shown in FIGS. 8A and 8B, the inner diameter of the sleeve roll 14 is returned to the state before being fitted into the raw pipe roll 12, and the sleeve roll 14 is fixed to the raw pipe roll 12.

(Action and effect)
The mold roll 10 of the present embodiment is formed by fitting a plurality of sleeve rolls 14 into the outer peripheral surface of the raw pipe roll 12, and the sleeve roll 14 has a plurality of metal plates 22 or patterns welded to each other. It is formed by a metal plate 20. Therefore, the large-area mold roll 10 can be formed by the plurality of metal plates 22 or the patterned metal plates 20.

Here, in the present embodiment, the plurality of sleeve rolls 14 are arranged so that the end faces 16A and 18A are in contact with each other, and the surface roughness of the end faces 16A and 18A of the sleeve rolls 14 is 50 μm or less. Therefore, as compared with the configuration in which the surface roughness of the end faces is made larger than 50 μm, it is possible to suppress the increase in the gap between the end faces 16A and 18A without welding the sleeve rolls 14 to each other.

As a result, the welding process between the sleeve rolls 14 can be reduced, and when the resin film or the like is produced by using the mold roll 10, the resin enters the gap between the end faces 16A and 18A and the resin is peelable. Can be suppressed from decreasing.

Further, according to the present embodiment, the surface roughness of the end faces 16A and 18A of the sleeve roll 14 is set to 1 μm or more. Therefore, the polishing steps of the end faces 16A and 18A can be reduced as compared with the configuration in which the surface roughness of the end face is less than 1 μm.

Further, according to the present embodiment, the sleeve roll 14 is detachably fitted to the raw tube roll 12. Therefore, the bonding process between the sleeve roll 14 and the raw tube roll 12 can be reduced, and when the sleeve roll 14 is soiled, for example, the soiled sleeve roll 14 can be easily replaced.

Further, according to the present embodiment, the inner diameter of the sleeve roll 14 before being fitted into the raw pipe roll 12 is set to −300 μm or more and 100 μm or less with respect to the outer diameter of the raw pipe roll 12. Therefore, the sleeve roll 14 can be easily fitted into the raw tube roll 12 as compared with the configuration in which the inner diameter of the sleeve roll 14 is less than −300 μm with respect to the outer diameter of the raw tube roll 12.

Further, as compared with the configuration in which the inner diameter of the sleeve roll 14 is larger than 100 μm with respect to the outer diameter of the raw pipe roll 12, it is possible to suppress the formation of a gap between the sleeve roll 14 and the raw pipe roll 12. The sleeve roll 14 can be fixed without being adhered to the outer peripheral surface 12A of the raw pipe roll 12.

In particular, in the present embodiment, air is blown out from the outlet hole 30 of the outer peripheral surface 12A of the raw pipe roll 12, and the plurality of sleeve rolls 14 are fitted into the raw pipe roll 12 while expanding the inner diameter of the sleeve roll 14 by the pressure of the air. It is crowded. Therefore, the sleeve roll 14 can be easily fitted by the raw tube roll 12 as compared with the configuration in which the sleeve roll 14 is fitted into the raw tube roll 12 without expanding the inner diameter.

Further, after the sleeve roll 14 is fitted into the raw pipe roll 12, the air pressure is reduced or the air supply is stopped to fix the sleeve roll 14 to the raw pipe roll 12. Therefore, the sleeve roll 14 can be brought into close contact with the outer peripheral surface 12A of the raw pipe roll 12.

Further, according to the present embodiment, the patterned sleeve roll 16 is formed by the patterned metal plate 20 on which the uneven pattern is formed on the surface. Therefore, it is possible to produce a resin film or the like having a pattern formed by using the mold roll 10 having the sleeve roll 16 with a pattern.

In particular, in the present embodiment, the sleeve roll 14 is composed of a patterned sleeve roll 16 and a patterned sleeveless roll 18. Therefore, for example, when producing a film or the like in which a pattern is formed by a sleeve roll 16 with a pattern, the sleeveless roll 18 with a pattern can be used as a receiving portion of a resin protruding outside the pattern.

Further, according to the present embodiment, the patterned metal plate 20 is manufactured by processing the nickel electroplated plate 24. Therefore, it is possible to easily manufacture a plurality of patterned metal plates 20 in which the same pattern P is formed by using one original plate. By using the photolithography method, it is possible to form a fine pattern having a three-dimensional shape of several tens of μm or less on the surface of the original plate.

(Other embodiments)
Although an example of the embodiment has been described with respect to the present disclosure, the present disclosure is not limited to the embodiment, and various other embodiments are possible within the scope of the present disclosure.

For example, in the above embodiment, four sleeve rolls 14 are fitted into the raw tube roll 12. However, the number of sleeve rolls 14 is not limited to four, and may be two or more.

Similarly, the sleeve roll 14 is composed of the patterned sleeve roll 16 and the patterned sleeveless roll 18, but even if the sleeve roll 14 is composed of only the patterned sleeve roll 16 or only the patterned sleeveless roll 18. Good. Further, one sleeve roll 14 may be formed by welding the patterned metal plate 20 and the metal plate 22 to each other in the circumferential direction.

Further, the arrangement of the patterned sleeve roll 16 and the patterned sleeveless roll 18 is not limited to the above embodiment, and for example, the patterned sleeve roll 16 and the patterned sleeveless roll 18 are alternately arranged in the axial direction of the mold roll 10. May be good.

Further, in the above embodiment, a plurality of sleeve rolls 14 are arranged so that the welded portions of the patterned metal plate 20 or the metal plate 22 coincide with each other in the axial direction, but the patterned metal plate 20 or the metal plate 22 is welded. The locations do not have to match in the axial direction.

Further, in the above embodiment, the raw pipe roll 12 is provided with a blowout hole 30, and the sleeve roll 14 is fitted into the raw pipe roll 12 while expanding the inner diameter of the sleeve roll 14 by the pressure of the air blown from the blowout hole 30. There was. However, the sleeve roll 14 may be fitted into the raw pipe roll 12 by press-fitting the sleeve roll 14 into the raw pipe roll that is not provided with the blowout hole 30.

Further, the numerical values of the diameter and thickness of the nickel electroplated plate 24 and the numerical values of the width and inner diameter of the sleeve roll 14 in the above embodiment are examples, and may be values other than the numerical values in the above embodiment. ..

Hereinafter, Examples 1-13 of the present disclosure, and Comparative Examples 1 to be specifically described with the present disclosure is not limited to the following examples. In Examples and Comparative Examples, the performance of the mold roll was evaluated for three items: suitability for manufacturing the sleeve roll, ease of replacing the sleeve roll, and ease of resin peeling after pattern shaping.

Regarding the manufacturing suitability of the sleeve roll, the processing difficulty of end face polishing during the manufacturing time of the sleeve roll was sensory evaluated. Evaluation A is when the processing difficulty is low, evaluation B is when the processing difficulty is low to medium, evaluation C is when the processing difficulty is medium, and evaluation D is when the processing difficulty is high. C was set as an acceptable range as a product.

The ease of replacement of the sleeve roll was evaluated by measuring the replacement work time of the sleeve roll. Evaluation A when the replacement work time is within 1 hour, evaluation B when the replacement work time exceeds 1 hour and within 2 hours, and evaluation when the replacement work time exceeds 2 hours and is within 4 hours C. Evaluation D was defined as the case where the replacement work time exceeded 4 hours, and evaluations A to C were defined as acceptable ranges for the product.

The ease of resin peeling after pattern shaping was evaluated by observing between the end faces of the sleeve rolls on the surface of the mold roll after pattern shaping with a microscope and evaluating the amount of resin adhesion. Evaluation A when no resin adhesion is seen between the sleeve roll end faces of the mold roll, evaluation B when the resin adhesion that does not protrude from the mold roll surface is within 1/10 of the roll circumference, from the mold roll surface Evaluation C is when the resin adhesion that does not protrude is in the range exceeding 1/10 of the roll circumference, evaluation D is when there is resin adhesion that protrudes from the mold roll surface, and evaluations A to C are acceptable ranges as a product. And said.

The evaluation results are shown in Table 1 below.

As can be seen from Table 1, in Comparative Example 1 in which the surface roughness (Ra) of the end face of the sleeve roll is 55 μm, there is a gap between the end faces of the sleeve roll, and a resin film or the like is produced using a mold roll. At that time, the resin entered between the end faces and the peelability of the resin was lowered. Therefore, the ease of resin peeling after pattern shaping was reduced as compared with the examples.

10-inch roll 12 Raw pipe roll 12A Outer peripheral surface 14 Sleeve roll 16 Patterned sleeve roll 16A End surface 18 Patternless sleeve roll 18A End surface 20 Patterned metal plate 22 Metal plate 24 Nickel electroformed plate 26 Inlet port 28 Air passage 30 Blow-out hole 32 Air supply pipe P pattern

Claims (11)

Cylindrical raw tube roll and
A plurality of cylindrical sleeve rolls that are fitted into the outer peripheral surfaces of the raw tube rolls and are in contact with each other at the end faces,
Have,
The sleeve roll is composed of a plurality of metal plates welded to each other in the circumferential direction, and the surface roughness of the end face is 50 μm or less.
Mold roll. The mold roll according to claim 1, wherein the surface roughness of the end face of the sleeve roll is 1 μm or more. The mold roll according to claim 1 or 2, wherein the plurality of sleeve rolls are detachably fitted to the raw tube rolls. Any one of claims 1 to 3, wherein the inner diameter of the sleeve roll is −300 μm or more and 100 μm or less with respect to the outer diameter of the raw tube roll before being fitted into the raw tube roll. The mold roll described in the section. The mold roll according to any one of claims 1 to 4, wherein at least one of the plurality of metal plates is a patterned metal plate having a concave-convex pattern formed on its surface. The fifth aspect of claim 5, wherein the plurality of sleeve rolls are composed of a patterned sleeve roll made of the patterned metal plate and a patterned sleeveless roll made of the metal plate having a smooth surface. Mold roll. The mold roll according to claim 5 or 6, wherein the patterned metal plate is made of a nickel electroplated plate. Multiple metal plates are welded together in the circumferential direction to form a cylindrical sleeve roll.
The end face of the sleeve roll is processed so that the surface roughness of the end face is 50 μm or less.
A plurality of the sleeve rolls are fitted into a cylindrical raw tube roll to bring the end faces into contact with each other.
Mold roll manufacturing method. A plurality of the sleeve rolls are fitted into the raw pipe rolls while expanding the inner diameter of the sleeve rolls by the pressure of air blown from the outer peripheral surface of the raw pipe rolls.
The pressure of the air is reduced to fix the sleeve roll to the raw tube roll.
The method for manufacturing a mold roll according to claim 8. A concave-convex pattern is formed on the surface of at least one of the metal plates to form a patterned metal plate.
The method for producing a mold roll according to claim 8 or 9. A patterned sleeve roll is formed using the patterned metal plate.
A patterned sleeveless roll is formed using the metal plate having a smooth surface.
The patterned sleeve roll and the patterned sleeveless roll are fitted into the raw tube rolls, respectively.
The method for manufacturing a mold roll according to claim 10.