JPH04219168A - Device for producing film having rugged surface - Google Patents

Abstract

PURPOSE:To easily and surely form sharp and fine ruggednesses on a film substrate by applying a curable resin on a temp. -controllable roll intaglio having a rugged pattern, allowing the film substrate to firmly contact with the intaglio and curing the resin held in the recess of the intaglio. CONSTITUTION:A curable resin 3 in applied by a coating device 10 on a temp. -controllable roll intaglio 1 having a rugged pattern. The intaglio is allowed to firmly contact with a film substrate 4 by a pressing roll 5. The resin 3 held in the recess 2 of the intaglio 1 is cured by a curing device 7 (e.g. ionizing radiation irradiation device). Consequently, sharp and fine ruggednesses are easily and surely formed on the substrate, and a film excellent in releasablity, surface properties, etc., and having a rugged surface is produced.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for producing a film having an uneven surface.

0002

BACKGROUND OF THE INVENTION Conventionally, films with uneven surfaces have been used for embossing films, decorative films, and the like. Methods for producing this film include: 1. A method in which the film base material is produced with an uneven surface by raised printing, 2. A method in which a UV-curable resin is printed in a raised manner on the film base material, and then it is cured by irradiating it with ultraviolet rays. A method of manufacturing by adding an uneven surface is known. As the manufacturing equipment used in the above manufacturing method, a printing equipment such as ordinary screen printing or gravure printing has been used.

0003

[Problems to be Solved by the Invention] However, when attempting to manufacture a film with surface irregularities using the above-mentioned conventional manufacturing equipment, for example, in case (2), the liquid ink transferred from the plate onto the film base material flows. Therefore, it is difficult to print a sharp and fine embossed shape, and since the ink for raised printing is generally made of a thermoplastic resin, only an uneven surface with poor mold releasability and surface properties can be obtained. Furthermore, in the case of (2) above, the resin caused by the raised printing flows before irradiation with ultraviolet rays and the uneven shape collapses, making it impossible to provide particularly sharp and fine uneven shapes. The present invention was made in order to eliminate the drawbacks of the above-mentioned conventional technology, and it is possible to easily and reliably form sharp and fine uneven shapes on a film base material, and it also has excellent mold releasability, surface properties, etc. It is an object of the present invention to provide a manufacturing apparatus capable of manufacturing a film having an uneven surface.

0004

[Means for Solving the Problems] The present invention provides a roll intaglio plate having an uneven pattern, a coating device for coating the roll intaglio plate with a curable resin, and a press roll for bringing the roll intaglio plate into close contact with a film base material. This is an apparatus for producing a film having an uneven surface, which is equipped with a curing device for curing a curable resin held in the recesses of a roll intaglio. Further, in the above manufacturing apparatus of the present invention, a nozzle coating device may be used as the curable resin coating device, or an ionizing radiation irradiation device or a dielectric heating device may be used as the curing device. The present invention also provides an apparatus for manufacturing a film having an uneven surface, which is equipped with a plurality of sets of the above-mentioned roll intaglio, a coating device, a pressure roll, and a curing device, and furthermore, the film is peeled off from the roll intaglio and the integrated curable resin is cured. It is also possible to provide a curing device for this purpose. Further, in the apparatus of the present invention, the roll intaglio plate can be provided with a cooling device or a heating device.

[0005]

Embodiments Hereinafter, embodiments of the present invention will be explained based on the drawings. FIG. 1 shows an embodiment of the present invention, in which 1 is a roll intaglio plate on which desired unevenness is formed, 2 is a concave portion of the roll intaglio plate 1, 3 is a curable resin, 4 is a film base material, and 5 is a recessed part of the roll intaglio plate 1. 6 indicates a press roll that presses the roll intaglio 1 by contacting the roll intaglio, and 6 indicates a feed roll. In addition, 7 in the figure is curable resin 3
10 is a coating device for coating the roll intaglio plate 1 with the curable resin 3.

Further, in the apparatus of the present invention, although not particularly shown in the drawings, the roll intaglio plate 1 is provided with a drive device so as to be driven to rotate. The pressure roll 5 and the feed roll 6 are rotatable in order to feed the film base material. These may be of a type that rotates with the roll intaglio 1, but they may also be driven by a drive device. The apparatus of the present invention may further include a film feeding device for feeding out the film base material 4 and a winding device for winding up the film having the uneven pattern formed thereon.

The roll intaglio plate 1 used in the present invention has the desired recesses 2 formed by electronic engraving, etching, mill pressing,
Any material may be used as long as the predetermined recess 2 is provided by a method such as electroforming. Further, as the material of the roll intaglio plate 1, metals such as copper chromium, synthetic resins such as NBR, epoxy, ebonite, etc., ceramics such as glass, etc. can be used. The size of the roll intaglio 1 is not particularly limited, and can be provided as appropriate depending on the size of the film having the uneven surface to be manufactured.

Further, the size, shape, pattern, etc. of the recess 2 are not particularly limited, but the size is usually 10 to 100 μm.
The thickness is preferably about 30 μm. Moreover, the depth is preferably about 0.1 to 100 μm. Furthermore, the pattern of the concave portion 2 may be a reproduction of the uneven shape of natural materials such as various known wood grains, stone grains, cloth grains, character symbols, parallel lines, various abstract patterns, etc.
Examples include various matte surfaces, mirror gloss, etc. Examples of the above-mentioned line patterns include, for example, a group of unevenness or grooves forming parallel straight lines or curves, and a group of parallel lines or straight lines in adjacent patterns that share a closed boundary line that surrounds the group and have different directions. Examples include patterns such as a collection of straight lines or curved lines in a closed area.

FIG. 4 shows an example of a temperature control device for a roll intaglio plate, and is a sectional view of the roll intaglio plate 1 in the direction of its rotational axis. Figure 5
6 is a sectional view showing another example of a temperature control device for a roll intaglio plate, and FIG. 7 is a partially enlarged view showing a surface portion (part A) of the roll intaglio plate in FIG. 1. In the manufacturing apparatus of the present invention, it is preferable to provide a temperature control device for cooling and/or heating the roll intaglio. The temperature control device for roll intaglio is shown in Figures 4 to 6.
As shown in FIG. 1, a heat medium such as water or chlorofluorocarbon for controlling the temperature of the roll intaglio plate 1 is passed through the inside of the roll intaglio plate 1, and the roll intaglio plate 1 can be cooled or heated by heat conduction. Further, the temperature of the heat medium can be arbitrarily adjusted by a heat medium heating device or cooling device provided outside the roll intaglio plate 1, although not particularly shown. In order to control the temperature of the rolled intaglio plate, the shape of the rolled intaglio plate is changed by providing a pipe 22 for passing a heat medium inside the roll intaglio plate 1 as shown in FIG. 4, and passing the heat medium in the direction shown by the arrow. It is possible to control the temperature using a heating medium from the inside of the roll intaglio plate by passing it in the direction opposite to the arrow. Alternatively, as shown in FIG. 5, it is also possible to simply form the roll intaglio 1 so that the heat medium can pass through both ends thereof, and to pass the temperature-controlled heat medium from one end of the roll intaglio to the opposite end. In addition, as shown in FIG. 6, a jacket 23 is provided inside the roll intaglio 1 to control the temperature.
The inside of the roll intaglio is formed into a hollow shape, and the inside is
It is also possible to pass the heat medium only through the inside of the jacket 23.

In the apparatus of the present invention, as shown in FIG.
It has a double structure in which an etchable material such as a copper plate 25 is bonded to the surface side of the core material (roll intaglio outside C side), and after forming an uneven pattern 8 on the copper plate 25, a release layer 26 is applied to the surface. can be formed. The release layer 26 is provided to improve the abrasion resistance and release properties of the roll intaglio plate, and is made of metal plating such as chromium, silicone resin, fluororesin, or the like.

[0011] The temperature of the roll intaglio plate 1 can be appropriately determined by a temperature controller, but for example, when using a base film that is sensitive to heat or when using a paint with a slow curing speed, the roll intaglio plate is cooled. By doing so, deterioration of the film base material due to heat can be avoided.

[0012] Furthermore, by heating the roll intaglio,
The viscosity of the paint decreases, making it easier to completely fill the roll intaglio with the paint, improving the reproducibility of the uneven shape. This is particularly effective when the recesses of a rolled intaglio plate are filled with a highly viscous paint, such as when a solvent-free paint or a solvent is volatilized through a drying process. Furthermore, since heating of the roll intaglio plate allows annealing while curing the base film, residual stress during curing can be released, making it difficult for curls and distortions to occur after the film is formed with an uneven surface. . In addition, when using a paint containing a matting agent, antifogging agent, conductive agent, abrasive, mold release agent, etc., the temperature between the film base side and the roll intaglio side can be increased by heating and curing the roll intaglio. Using thermal convection inside the coating film due to the difference, it is possible to change the concentration of the additive in the thickness direction of the coating film (the larger the temperature difference, the higher the additive concentration on the film base side).

The press roll 5 only needs to be able to press the film base material, but it usually has a diameter of about 140 mm and can be made of silicone rubber, NBR, EPT, or the like.

The curing device 7 can be selected depending on the type of resin forming the surface irregularities. For example, when the resin is an ionizing radiation curable resin, an ionizing radiation irradiation device can be used. Further, when a thermosetting resin is used as the resin, a dielectric heating device can be used.

The above-mentioned ionizing radiation irradiation device includes light sources such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light lamp, and a metal halide lamp in the case of ultraviolet rays, and a Cockroft-Walton type, etc. in the case of electron beams. Examples include devices equipped with an irradiation source such as a Van de Graaff type, a resonant transformer type, an insulated core transformer type, or various electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type. Further, a known dielectric heating device can be used, such as a roller electrode type, a parallel plate electrode type, and the like.

As the coating device 10 for coating the curable resin onto the roll intaglio plate, it is desirable to use a nozzle coating device (method shown in FIG. 1). The nozzle coating device has a nozzle that rotates in a direction perpendicular to the rotation direction of the roll intaglio plate 1 with a constant width.
It is provided like a curtain in the width direction) and includes a discharge device for pressurizing and discharging the curable resin. Figures 8 and 9
shows an example of a nozzle coating device, (a) is a longitudinal cross-sectional view when viewed from the side direction of the roll intaglio, and (b) is a vertical cross-sectional view (width direction) along the line bb in (a). be. In the nozzle coating device, a cavity or groove 12 (shaded portion) may be provided in the middle of the nozzle as shown in the figure in order to alleviate unevenness in discharge amount and changes over time. It is preferable to form the groove in the shape of a hanger as shown in FIG. 8, since uneven discharge of the resin from the resin supply port 14 before reaching the slit 15 at the tip of the nozzle is reduced. Further, as shown in FIG. 9, a linear groove 13 may be provided on the slit 15 side at the end of the hanger-shaped groove 12, and the groove 12 on the hanger and the linear groove 13 may be combined. Unevenness can be reduced. Further, as the coating device for coating the curable resin, in addition to the above-mentioned coating device, a coating device that uses an appropriate method such as a roll coating method or a knife coating method on the film may be employed. FIG. 2 shows another embodiment of the present invention in which a roll coater is used as the coating device.

Further, in the present invention, a solvent drying device 11 may be provided for volatilizing the solvent of the resin. This drying device 11 can use hot air, an infrared heater, or the like. By providing the solvent drying device 11, a solvent-type resin can be used, so the range of selection of the resin to be used is expanded, and coating properties can be easily adjusted.

Next, a method for manufacturing a film having an uneven surface using the apparatus of the present invention will be explained. First, the recesses 2 of the roll intaglio 1 are filled with curable resin 3 using the coating device 10, and the resin 3 is filled with the film base material 4 in the roll intaglio 1.
make contact so that it touches the Here, as a method for filling the recesses with the curable resin, as shown in FIG.
When the base material film 4 is supplied to the roll intaglio plate 1, the curable resin 3 coated on the base material is distributed and filled into the recesses 2 by pressing from the back surface of the base material with the press roll 5. Further, when the apparatus is configured as shown in FIG. 2, the surface of the base film 4 may be coated with the curable resin 3.

In this case, a solvent-type curable resin can be used, and the resin 3 coated on the film base material 4 is dried in a drying device 1 in order to control the fluidity to some extent.
1, the solvent used for dilution is removed by drying, and the curable resin from which the solvent has been dried is semi-cured by a curing device 7a. Note that when a solvent-free curable resin is used, the drying device 11 is not necessary.

Next, while the film base material 4 is in contact with the roll intaglio 1 (specifically, when it is located between the pressure roll 5 and the feed roll 6 in the figure), it is cured by the curing device 7. The resin 3 is cured. Generally, when an ionizing radiation irradiation device is used as a curing device, the ionizing radiation is irradiated from the film base material 4 side as shown in the figure. It is also possible to irradiate from the inside of the intaglio 1 (specifically, by using an irradiation device installed inside the roll hollow). Alternatively, irradiation may be performed from both sides, including the film substrate side and the inside of the intaglio plate. Further, even when a dielectric heating device is used as the curing device 7, curing can be performed in the same manner as described above.

The curing device 7 cures the recesses 2 of the roll intaglio 1.
The curable resin 3a inside is brought into close contact with the film base material 4. The degree of curing at this time may be at least as long as it causes the resin 3 to lose its fluidity and to develop adhesion to the film base material. After passing through the curing device 7, the film base material 4 is peeled off from the intaglio plate 1. As a result, the cured curable resin 3a is integrated with the film base material and detached from the recesses 2, yielding a film 9 having an uneven surface.

In the present invention, as shown in FIG. 1, a curing device 7b may be further provided on the desorbed curable resin to completely cure the curable resin. Further, a plurality of the above-mentioned roll intaglio plates 1, press rolls 5, and curing devices 7 can be combined into one line. For example, with this combination, raised color printing, surface raised printing, registered multicolor raised printing, etc. can be efficiently performed.

FIG. 3 shows an example of a film having surface irregularities produced using the apparatus of the present invention. In the present invention, the roll intaglio 1
By providing a device for adjusting the gap and pressure between the press roll 5 and the press roll 5, it is possible to control the thickness of the resin film 8b on the uneven surface, which is composed of the convex part 8a and the resin film 8b which becomes the bottom surface of the concave part. preferred. Of course, the pattern of only the convex portions 8a may be formed by removing the resin other than those filling the concave portions with a doctor blade or the like.

The film base material 4 used in the present invention includes polyesters such as polyethylene terephthalate, polyamides such as nylon, acrylic resins such as polyvinyl chloride, polymethyl methacrylate, polycarbonates,
Examples include plastic films made of polystyrene, polyacrylate, fluororesin, polypropylene, cellulose triacetate, cellophane, etc., metal foils of copper, iron, aluminum, etc., paper, etc., and these can be used alone or laminated as appropriate. It may also be used as a base material. However, when irradiating ionizing radiation from the base material 4 side, the base material 4 needs to be transparent to ionizing radiation. Furthermore, as the base material 4, it is also possible to use a material formed by laminating other layers depending on the purpose, for example, a material having a printed layer etc. laminated (in this case, the printed layer has unevenness) It may be formed on the opposite side of the pattern 8 or on the same side, but
It is necessary to select the material of the printing layer or the irradiation direction so as not to inhibit the ionizing radiation from reaching the curable resin 3). The thickness of the base material 4 is appropriately selected depending on the application, but is generally 10 to 100 μm, preferably 25 to 5 μm.
It is 0 μm.

Further, as the curable resin 4, known ionizing radiation curable resins or thermosetting resins can be used. The above-mentioned ionizing radiation-curable resins include prepolymers such as urethane acrylate and polyester acrylate, which have a polymerizable unsaturated bond or an epoxy group in the molecule;
There are compositions in which oligomers and/or monomers are appropriately mixed.

[0026] The thermosetting resins mentioned above include phenol resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, unsaturated polyester resins,
Examples include polyurethane resins, epoxy resins, aminoalkyd resins, melamine/urea cocondensation resins, silicone resins, and polysiloxane resins.

[0027] A film having an uneven surface produced using the production apparatus of the present invention can be used for various purposes such as a decorative film, a molding film, and a transfer film.

Next, the present invention will be explained in more detail with reference to specific examples. Example 1 Using an easily adhesive polyester film (manufactured by Teijin: HP-7) with a thickness of 28 μm as a film base material, a film having an uneven surface was manufactured using the manufacturing apparatus shown in FIG. 1 based on the following conditions and materials. did. The obtained film having an uneven surface had excellent heat resistance, solvent resistance, stain resistance, etc., and was good when used for applications such as decorative films and excipient films.・Ultraviolet curable resin: Dainichiseika, Seikabeam EX-
880926B (viscosity: 750 cps).・Roll intaglio plate: A cylinder whose surface layer is made of copper, with unevenness of 15 μm in depth formed by direct etching, and equipped with a cooling device as shown in Figure 5.・Ultraviolet irradiation device: High pressure mercury lamp with ozone, output: 1
20 W/cm.

[0029]

Effects of the Invention The manufacturing apparatus of the present invention comprises a roll intaglio having an uneven pattern, a coating device for coating the roll intaglio with a curable resin, and a press roll for bringing the roll intaglio and the film base into close contact. By being equipped with a curing device that hardens the curable resin held in the recesses of the roll intaglio, the curable resin is held in the recesses of the roll intaglio, and the resin is free from damage, compared to conventional printing devices. It does not flow easily and has the effect of easily and reliably providing sharp unevenness corresponding to the shape of the recessed portions on the film surface. Furthermore, when a nozzle coating device is used as the above-mentioned coating device, there is no risk of entraining air when coating the curable resin on the roll intaglio, and the curable resin can be coated uniformly and evenly within the recesses. This allows the uneven pattern to be more reliably formed in a stable shape. Further, in the above-mentioned apparatus, if an ionizing radiation irradiation device is used as the curing device, an ionizing radiation-curable resin can be used, so that the resin can be cured in an extremely short time, improving workability. Furthermore, thermosetting resins such as phenol resins, polyamide resins, and melamine resins can be used by using a dielectric heating device in the curing device. In addition, if the configuration is equipped with multiple sets of roll intaglio, coating device, pressure roll, and curing device, it becomes an optimal device for applications such as raised color printing, surface raised printing, etc., where uneven patterns are formed with many colors. The scope of use of this device is further expanded, and work efficiency is further improved when, for example, the above combinations are provided on the same line. In addition, by providing a curing device for curing the curable resin that has been peeled off from the roll intaglio and is integrated, the resin can be peeled off from the recesses without being completely cured. Peeling can be easily performed. Furthermore, by completely curing the resin, the physical properties of the uneven surface due to the cured resin can be further improved. In the production apparatus of the present invention, when the roll intaglio is provided with a cooling device, the influence of heat on the film base material can be avoided. Furthermore, when a heating device is provided on the roll intaglio, the reproducibility of the uneven shape is further improved, curling and distortion of the processed film are less likely to occur, and a more beautiful film can be obtained. Furthermore, when additives are used in the coating material, the additive concentration can be arbitrarily changed in the direction of the coating film thickness.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing an embodiment of the device of the present invention.

FIG. 2 is an explanatory diagram showing another embodiment of the device of the present invention.

FIG. 3 is a longitudinal cross-sectional view of a film having surface irregularities produced using the production apparatus of the present invention.

FIG. 4 shows an example of a temperature control device for a roll intaglio, and is a sectional view in the direction of the rotation axis of the roll intaglio.

FIG. 5 shows another example of a temperature control device for a roll intaglio, and is a sectional view in the direction of the rotation axis of the roll intaglio.

FIG. 6 shows another example of the temperature control device for a roll intaglio, and is a sectional view in the direction of the rotation axis of the roll intaglio.

FIG. 7 is a partially enlarged view showing a surface portion of a roll intaglio cross section.

FIG. 8 shows an example of a coating device, and (a) is a longitudinal cross-sectional view when viewed from the side direction of the roll intaglio, and (b) is a vertical cross-sectional view (width direction) taken along line bb in (a). .

FIG. 9 shows an example of a coating device, in which (a) is a vertical cross-sectional view when viewed from the side direction of the roll intaglio plate, and (b) is a vertical cross-sectional view (width direction) taken along the line bb in (a). be.

[Explanation of symbols]

1 Roll intaglio 2 Recess 3 Curable resin 4 Film base material 5 Press roll 6. Feeding roll 7. Curing device 9 Film with uneven surface 10 Coating equipment

Claims (8)

[Claims] 1. A roll intaglio plate having an uneven pattern, a coating device for coating the roll intaglio plate with a curable resin, a press roll for bringing the roll intaglio plate into close contact with a film base material, and a roll intaglio plate held in the recesses of the roll intaglio plate. and a curing device for curing a curable resin. 2. The apparatus for manufacturing a film having an uneven surface according to claim 1, wherein the curable resin coating apparatus is a nozzle coating apparatus. 3. The apparatus for producing a film having an uneven surface according to claim 1 or 2, wherein the curing apparatus is an ionizing radiation irradiation apparatus. 4. The apparatus for producing a film having an uneven surface according to claim 1 or 2, wherein the curing device is a dielectric heating device. 5. The apparatus for producing a film having an uneven surface according to claim 1, comprising a plurality of sets of an intaglio roll, a coating device, a pressure roll, and a curing device. [Claim 6] Claim 1, further comprising a curing device for curing the curable resin peeled off from the roll intaglio plate and integrated into one piece.
, 2, 3, 4, or 5. An apparatus for producing a film having an uneven surface. 7. The apparatus for producing a film having an uneven surface according to claim 1, wherein the roll intaglio is provided with a cooling device. 8. The apparatus for producing a film having an uneven surface according to claim 1, wherein the roll intaglio is provided with a heating device.