JPH05238196A - Shaped sheet and production thereof - Google Patents

Abstract

PURPOSE:To easily and certainly form a shaped sheet having a sharp and fine uneven shape. CONSTITUTION:The recessed parts 11 of a roll intaglio 10 are filled with an ionizing radiation curable resin 12 and a film base material 2 is brought into contact with the resin 12 and the resin 12 is irradiated with ionizing radiation in such a state that the resin 12 is held between the film base material 2 and the roll intaglio 10 to be cured to form a sharp and fine uneven shape 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an imprint sheet for impressing a concavo-convex pattern excellent in design effect on the surface of various products and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a shape-imparting sheet has been suitably used for forming a hologram and forming an uneven pattern on the surface of a decorative plate or a molded product. For example, in the case of a hologram, a hologram master plate corresponding to the uneven shape of the hologram is manufactured,
There is known a method of manufacturing by using the original plate to shape the original plate on the surface of various materials. A shaping sheet is used as this original plate. Further, in the case of a decorative plate, when the decorative sheet is manufactured, the pattern sheet is pressed against the resin-coated surface and then peeled off, whereby the uneven pattern of the pattern sheet can be transferred and imparted to the surface of the decorative plate. Conventionally, the structure of these shape-imparting sheets consists of a base film and an uneven pattern formed on the surface of the film, for example, 1) using a thermoplastic resin film as the base film, and heating embossing or the like on the surface of the film. 2) Forming with the method of 2), using the ink with the thermosetting resin or the ultraviolet curable resin as the vehicle on the surface of the base film, the rising printing using the printing device such as screen printing or gravure printing. After that, a shaped sheet formed by a method of curing the ink or the like is known.

[0003]

However, in the case of 1), the conventional patterning sheet described above has a possibility that the embossed shape may be deformed or disappeared due to aging because the embossing is imparted to the thermoplastic resin by heating. was there. Further, there is a defect that the reproducibility of imparting unevenness is not so good when the embossed shape is too fine or the unevenness is deep. In the case of 2) above, the liquid ink transferred from the plate onto the film substrate flows, and the resin due to the embossing printing flows before irradiating with ultraviolet rays and the uneven shape collapses, resulting in sharp and fine unevenness. It was very difficult to give the shape of the pattern. When a shaped sheet is manufactured by the above printing method, the viscoelastic behavior of the ink changes and the edges of the uneven pattern are deformed due to variations in the ink production lot and changes in printing conditions such as printing temperature. Therefore, it is difficult to mass-produce a shaped sheet having stable and reproducible patterns of the same shape. The present invention has been made to solve the above-mentioned drawbacks of the prior art, and is to manufacture a shaping sheet having a sharp and fine concave-convex shape and a shaping sheet capable of easily and surely forming the shaping sheet. The purpose is to provide a method.

[0004]

Means for Solving the Problems The present invention relates to a patterning sheet having an uneven pattern on the surface of a film substrate, in which at least the concave portion of a roll intaglio is filled with an ionizing radiation-curable resin and the resin is contacted with the film substrate. A shaped sheet having an uneven pattern formed by irradiating ionizing radiation to cure the resin while the resin is held between the film base material and the roll intaglio plate. Further, the shaped sheet of the present invention may contain 3 to 7% by weight of silicone oil in the above ionizing radiation curable resin. The method for producing a shaped sheet according to the present invention is such that at least a concave portion of a roll intaglio plate is filled with an ionizing radiation-curable resin and a film substrate is brought into contact with the roll intaglio plate and the filled ionizing radiation-curable resin, and the film substrate is an intaglio plate. Of the ionizing radiation from the film substrate side and / or the inside of the intaglio plate to cure the ionizing radiation curable resin interposed between the intaglio plate and the film substrate while being in contact with the resin and the film substrate. Is adhered, and then the film substrate is peeled from the intaglio plate to form an uneven pattern made of an ionizing radiation curable resin on the surface of the film substrate.

[0005]

Embodiments of the present invention will be described below with reference to the drawings. As shown in FIGS. 1 and 2, the patterning sheet 1 of the present invention has an uneven pattern 3 on the surface of the film substrate 2, and the uneven pattern 3 is formed of an ionizing radiation curable resin. Examples of the film substrate 1 used in the present invention include polyesters such as polyethylene terephthalate, polyamides such as nylon, polyvinyl chloride, acrylic resins such as polymethylmethacrylate, polycarbonate, polystyrene, polyacrylate, fluorine resin, polypropylene, Examples thereof include plastic films made of cellulose triacetate, cellophane, and the like, metal foils such as copper, iron, and aluminum, and paper, which may be used alone or may be used as a base material appropriately laminated. The thickness of the film substrate 2 is appropriately selected according to the application, but is generally 10 to 100 μm.
m, preferably 25 to 50 μm. When the film substrate 1 is used for molding under heat and pressure such as simultaneous molding of melamine decorative plate, polyethylene terephthalate,
A material having high heat resistance and film strength such as polyarylate, polyetheretherketone, or polyimide is used. Further, when it is inserted into a mold at the time of injection molding and used for simultaneous injection molding, polyamide such as nylon 6, nylon 6,6, polyolefin such as polyethylene and polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate-isophthalate copolymer is used. A low crystallinity polyester such as a polymer, a flexible thermoplastic resin film such as polyvinyl chloride or vinylon, or a laminated body thereof is preferable.

The shape, pattern, etc. of the uneven pattern 3 used in the pattern-formed sheet 1 of the present invention are not particularly limited, but the known uneven patterns of natural products such as wood grain, stone grain, and cloth grain, letter symbols, Lines, various abstract patterns, diffraction gratings such as holograms, various matte surfaces, and specular gloss.
Examples of the parallel line pattern include, for example, a group of irregularities or grooves forming parallel straight lines or curves and a parallel straight line or a group of straight lines of adjacent patterns which share a closed boundary line surrounding the group and have different directions. An example of the pattern is an aggregate having straight lines or curved lines in the closed region. The width W of the convex portion and the height H of the convex portion of the concavo-convex pattern 3 are usually formed to be about 0.1 to 100 μm. The ratio of the width W of the convex portion to the height of the convex portion C = H / W is 0.1
It can be formed to about 10 to 10. In the present invention, the shape of the convex portion can be accurately reproduced even if the ratio C is increased. A preferable ratio C of the width W of the convex portion to the height of the convex portion is 0.5 to
It is about 1.0. Moreover, the shape of the convex portion is the actual shape of the convex portion as compared to the ideal shape 31 (shown by the dotted line) as shown in FIG.
Although 32 is what the edge part collapses, the shape-imparting sheet of the present invention shows the reproducibility of the actual convex shape 32 with respect to the convex shape 31 of the original uneven pattern, and the width of the tip of the ideal convex portion. W,
When the width of the tip of the actual convex part is X, X is 85% of W
It is more preferable to form the concave and convex pattern 3 formed as described above in order to give a desired shape with good reproducibility.

As shown in FIG. 1, the uneven pattern 3 has a convex portion 3A.
And the resin layer 3B which becomes the bottom surface of the concave portion, or may be constituted only by the convex portion 3A as shown in FIG. As the ionizing radiation curable resin for forming the uneven pattern 3 described above, an ionizing radiation curable resin such as a known ultraviolet ray and electron beam curable resin can be used. For example, a polymerizable unsaturated bond or an epoxy group in the molecule. There is a composition in which a prepolymer having a group, an oligomer and / or a monomer are appropriately mixed. Especially for simultaneous molding and shaping of melamine decorative steel sheets, those having high heat resistance and hardness, for example, polyester acrylate, epoxy acrylate, silicone acrylate, high cross-linking density type having polyfunctional monomer such as siloxane as a main component, for example, It is advisable to use a prepolymer or oligomer such as urethane acrylate, more preferably a low-functional one, to have a low cross-linking density. A releasing agent is added to the ionizing radiation curable resin, if necessary, in order to enhance the releasing property at the time of shaping.
Examples of the releasing agent include wax, wax such as polyethylene wax, silicone resin, and fluororesin.

The shape-imparting sheet of the present invention can contain silicone oil in the ionizing radiation curable resin. The addition of silicone oil improves the releasability between the shape-imparting sheet and the product to be processed, and is particularly effective for a melamine molded product or in the case of forming a shape-imparting sheet having a complicated shape. If the content of silicone oil is less than 3% by weight, the effect of releasability is not sufficiently exerted, and if the content exceeds 7% by weight, a repelling phenomenon occurs, so the content is in the range of 3 to 7% by weight. It is preferably around 5% and most preferably.

FIG. 3 is an explanatory view showing a method for manufacturing the shaped sheet of the present invention. As shown in FIG. 3, the method for producing the shaped sheet 1 of the present invention is as follows. First, the concave portion 11 of the roll intaglio plate 10 is filled with the ionizing radiation curable resin 12 by the coating device 13, and the roll intaglio plate 10 is filled with the film substrate 2. The pressure roll 21 is also used to make contact with the resin 12 so as to contact it. Here, as a method for filling the recess 11 with the ionizing radiation curable resin 12, for example, a T-die type nozzle coating device can be used as shown in FIG. In the nozzle coating device, the nozzle has a constant width in the rotation direction of the roll intaglio 10 and is orthogonal to the rotation direction (width direction).
Further, it is provided with a discharge device which is provided in a curtain shape so as to cover both ends of the roll intaglio and pressurizes and discharges the curable resin. In addition, the nozzle coating device is
A cavity 19 may be provided in the middle of the nozzle in order to reduce the change over time. As the coating device, a coating device having an appropriate means such as a roll coating method or a knife coating method for the film may be adopted in addition to the above nozzle coating device.

Next, while the film substrate 2 is in contact with the roll intaglio 10 (specifically, when it is located between the pressing roll 21 and the feed roll 22 in the figure), the ionizing radiation irradiation device 17 is provided. Irradiation with ionizing radiation by
The curable resin 14 in 11 is brought into close contact with the film substrate 2. That is, while the ionizing radiation curable resin 12 is held between the base film 2 and the recess 11 of the roll intaglio plate 10, the ionizing radiation is irradiated and cured. At this time, the degree of curing may be at least such that the fluidity of the resin 12 is lost and the adhesiveness with the film substrate 2 is generated. Irradiator 17
After passing through, the film substrate 2 is peeled off from the roll intaglio 11. As a result, the cured ionizing radiation curable resin 12 is integrated with the film base material 2 and is detached from the recess 11 to obtain the shaped sheet 1.

As the ionizing radiation, for example, ultraviolet rays emitted from a light source such as an ultrahigh pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light lamp, a metal halide lamp, a Cockloft-Walton type, a Van de Graaff type, a resonance transformer type, An electron beam emitted from an irradiation source such as an insulating core transformer type, various types of electron beam accelerators such as a linear type, a dynamitron type, and a high frequency type can be used. In the present invention, a solvent type ionizing radiation curable resin can be used in order to control the fluidity to some extent. In that case, as shown in FIG. 3, a solvent drying device 16 is provided to dry the solvent in the resin before irradiation with ionizing radiation. This dryer
For 16, hot air or an infrared heater can be used. When a solvent type resin is used, the range of selection of the resin to be used is widened and the coating property can be easily adjusted. When a solventless ionizing radiation curable resin is used, the drying device 16 is unnecessary.

In the present invention, as shown in FIG. 3, the ionizing radiation curable resin once cured and released from the concave portion of the roll intaglio is further irradiated with ionizing radiation using the ionizing radiation device 18,
Further, the ionizing radiation curable resin can be cured.
In the manufacturing method of the present invention, the thickness and the thickness of the concave / convex pattern 3 composed of the convex portion 3A and the resin film 3B serving as the concave bottom surface can be controlled by adjusting the gap or pressure between the roll intaglio 10 and the pressing roll 21. .. Further, by removing the resin other than the resin filled in the concave portion with a doctor blade or the like, it is possible to form the uneven pattern 3 having only the convex portion 3A as shown in FIG. In the present invention, the ionizing radiation is generally irradiated from the film substrate 2 side as shown in the figure. However, the roll intaglio plate 10 is made of an ionizing radiation transparent material such as quartz or glass, and is irradiated from the inner side of the intaglio plate 10. It is also possible (specifically by an irradiation device installed in the roll hollow). Irradiation may be performed from both the film substrate side and the intaglio inner side. However, when the film substrate 2 is irradiated with ionizing radiation, the film substrate 2
Must be transparent to ionizing radiation. Further, as the film base material 2, it is also possible to use one formed by laminating other layers according to the application, and for example, one formed by laminating a printing layer or the like can be used (in this case, the printing layer is uneven). Although it may be formed on the surface opposite to the pattern 3 or on the same surface, the material of the printing layer is selected so as not to prevent the ionizing radiation from reaching the resin 12, or the irradiation direction. Must be selected).

In the present invention, in order to form the shape of the convex portion with good reproducibility as shown in FIG. 4, it is more preferable to use a resin having a relatively low viscosity (5000 cps or less) at the time of coating the concave portion. This is preferable because it is possible to form a recess with good reproducibility. In order to obtain a resin having a relatively low viscosity as described above, for example, a resin having a low viscosity is used originally, the intaglio or resin is heated, the solvent is diluted with a solvent and applied to the intaglio, and the solvent is dried to obtain a substrate. Examples include a method of laminating films. In using the patterning sheet of the present invention, for example, a patterning sheet having an uneven shape corresponding to a desired uneven shape is produced by the above method, and this film is used as an original plate, and the surface of this patterning sheet is polyvinyl chloride sol. Injecting or casting a molten resin or resin solution such as the above to cure and then peeling off the shaping sheet, or mounting the film on an injection mold to inject the resin, or a melamine resin decorative plate By press-molding a thermosetting resin decorative plate such as, for example, by inserting and shaping the shaped film, it is possible to form products having various surface irregularities such as formation of holograms and decorative plates. As described above, the shaped film of the present invention can be transferred simultaneously with casting by using the shaped film of the present invention on the process paper during casting of vinyl chloride sol or urethane resin.

The present invention will be described in more detail with reference to specific examples. Example 1 Using a device similar to the device shown in FIG. 3, the following recesses of the roll intaglio were filled with the following ionizing radiation curable resin by a nozzle coating device, and the roll intaglio was filled with the following film base material. The resin is contacted with a pressing roll so as to contact it. Then, while the film base material was in contact with the roll intaglio plate, the resin was cured by irradiating it with ionizing radiation using the following ionizing radiation irradiation device to obtain a patterning sheet. The winding speed was 20 m / min. The above-mentioned shaping sheet is used as a molding original plate for a wood grain conduit, a molding film is attached to an injection molding die to press-mold a melamine decorative board, and after molding, the film is peeled off to form a wood grain conduit pattern. A product having irregularities could be formed. At this time, the release of the shaped sheet from the melamine molded product was good.

[Materials and equipment used] -Ionizing radiation curable resin ... Seika Beam 903-16 (manufactured by Dainichiseika) containing 5% by weight of silicone oil-Roll intaglio ... Convex conduit part of wood grain pattern by electroforming A plate formed into a shape was used. In addition, the said convex part becomes a concave part in a shaping sheet.・ Ionizing radiation irradiation device ... High pressure mercury lamp with ozone (2 lamps), irradiation intensity is 160 W / cm. Film base material ... Polyethylene terephthalate film (HP7 made by Teijin), thickness 38 μm.

[0016]

As described above, the shaped sheet of the present invention is such that the ionizing radiation-curable resin is filled in at least the concave portion of the roll intaglio plate, and the resin is brought into contact with the film base material so that the resin is the film base material and the roll intaglio plate. By having an uneven pattern formed by curing the resin by irradiating it with ionizing radiation while being held between the edges, the edge is sharper compared to the conventional printing sheet formed by printing. It has an uneven pattern with good properties and has the effect of excellent design reproducibility. The shape-imparting sheet of the present invention is, for example, a hologram because a good shape can be obtained without the edge shape being crushed even when the height of the convex portion is relatively large with respect to the width of the convex portion in the shape of the uneven pattern. It can be optimally used as a shaped sheet for forming an uneven pattern on the surface of a decorative plate or the like.

Further, since the surface unevenness pattern is formed of the ionizing radiation curable resin, the embossing disappears due to a change with time as compared with the conventional thermoplastic resin formed by heating embossing or the like. Without heat resistance,
It has excellent solvent resistance. Therefore, when the molded sheet of the present invention is used for forming a molded product, a hologram, a transfer foil, etc., it is possible to impart a fine embossed pattern excellent in decorativeness. Further, when the ionizing radiation curable resin contains 3 to 7% by weight of silicone oil, the releasability between the shape-imparting sheet and the target object can be further improved.
The ionizing radiation-curable resin to which the silicone oil is added can be favorably used for a shaping sheet having a complicated uneven shape, a shaping sheet for molding a melamine resin, and the like.

Further, in the method for producing a patterned sheet of the present invention, at least the concave portion of the roll intaglio plate is filled with an ionizing radiation curable resin, and a film substrate is brought into contact with the roll intaglio plate and the filled ionizing radiation curable resin, While the film base material is in contact with the intaglio plate, ionizing radiation is applied from the film base material side and / or the intaglio plate interior side to cure the ionizing radiation curable resin interposed between the intaglio plate and the film base material. By using a method in which the resin and the film substrate are brought into close contact with each other, and then the film substrate is peeled from the intaglio to form an uneven pattern made of an ionizing radiation-curable resin on the film substrate surface, conventional ordinary printing is performed. Compared with the method of manufacturing with the device, the resin held in the recess cures as it is, so the unevenness is not affected by changes in the physical properties of the ink or changes in manufacturing conditions. To be able to form a like, it can always be produced with good reproducibility stably shaping sheet. Further, there is an effect that the shaped sheet having the above excellent designability can be reliably manufactured.

[Brief description of drawings]

FIG. 1 is a schematic vertical cross-sectional view showing an example of the shaped sheet of the present invention.

FIG. 2 is a schematic vertical cross-sectional view showing an example of the shaped sheet of the present invention.

FIG. 3 is an explanatory view showing one embodiment of the manufacturing method of the present invention.

FIG. 4 is a partially enlarged view showing a convex portion having an uneven pattern.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Shaped sheet 2 Film base material 3 Concavo-convex pattern 10 Roll intaglio 11 Recessed portion 12 Ionizing radiation curable resin

[Procedure amendment]

[Submission date] March 1, 1993

[Procedure Amendment 1]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

[Figure 1]

[Fig. 2]

[Figure 3]

[Figure 4]

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Masafumi Toyoizumi 1-1-1, Ichiya-Kagacho, Shinjuku-ku, Tokyo Dai Nippon Printing Co., Ltd. No. 1 Dai Nippon Printing Co., Ltd.

Claims (3)

[Claims] 1. A shape-imparting sheet having an uneven pattern on the surface of a film substrate, which comprises filling an ionizing radiation-curable resin into at least the recesses of a roll intaglio plate and bringing the resin into contact with the film substrate. A shaped sheet having a concavo-convex pattern formed by irradiating ionizing radiation while being held between roll intaglios to cure the resin. 2. The patterning sheet according to claim 1, wherein the ionizing radiation curable resin contains 3 to 7% by weight of silicone oil. 3. A roll intaglio plate is filled with an ionizing radiation-curable resin at least in the recess, and a film substrate is brought into contact with the roll intaglio plate and the filled ionizing radiation-curable resin.
While the film base material is in contact with the intaglio plate, ionizing radiation is applied from the film base material side and / or the intaglio plate interior side to cure the ionizing radiation curable resin interposed between the intaglio plate and the film base material. A method for producing a shaped sheet, characterized in that a resin and a film substrate are brought into close contact with each other, and then the film substrate is peeled from the intaglio plate to form an uneven pattern made of an ionizing radiation curable resin on the surface of the film substrate. ..