TWI829601B - Manufacturing method of metal roller having seamless pattern - Google Patents

Abstract

The present invention provides a manufacturing method of a metal roller having seamless pattern. The manufacturing method includes: providing a metal roller and a photoresist layer that is formed on the metal roller and that has a predetermined three-dimensional (3D) pattern; anisotropic etching the photoresist layer to form a plurality of intermediate protrusions that are formed on the metal roller and that are spaced apart from each other; dry etching the metal roller to form a plurality of slots, in which inner walls of the slots are flush with the intermediate protrusions so as to jointly form an intermediate 3D pattern that corresponds in shape to the predetermined 3D pattern; and etching the intermediate 3D pattern to remove the intermediate protrusions and to form a stamping 3D pattern that is recessed in an outer surface of the metal roller and that corresponds in shape to the intermediate 3D pattern.

Description

Manufacturing method of seamless metal rolling wheel

The present invention relates to a manufacturing method of a rolling wheel, and in particular to a manufacturing method of a seamless metal rolling wheel.

The existing method of manufacturing a rolling wheel uses a metal roller as a carrier, whereby a rolling layer for rolling optical films is formed on the metal roller. That is to say, it is difficult to directly form a structure for rolling optical films on the metal roller using the existing rolling wheel manufacturing method. Therefore, the inventor believed that the above-mentioned defects could be improved, so he devoted himself to research and applied scientific principles, and finally proposed an invention that is reasonably designed and effectively improves the above-mentioned defects.

An embodiment of the present invention provides a method for manufacturing a seamless metal rolling wheel, which can effectively improve the possible defects caused by the existing manufacturing method of the rolling wheel.

An embodiment of the present invention discloses a method for manufacturing a seamless metal rolling wheel, which includes: a pre-step: providing a metal roller and a photoresist layer formed on the outer surface of the metal roller; wherein, the metal roller The material is copper metal or chromium metal, and the photoresist layer includes: a base layer formed on the outer surface of the metal roller, and the thickness of the base layer is not less than 3 microns (μm); and A prefabricated pattern layer, which is integrally formed on the base layer, and the thickness of the prefabricated pattern layer is no greater than the thickness of the base layer; wherein, the prefabricated pattern layer has a preset three-dimensional pattern, which includes A plurality of prefabricated protrusions connected to each other; a photoresist etching step: etching the photoresist layer in an anisotropic etching manner to remove the prefabricated pattern layer and shape the base layer into A plurality of intermediary protrusions located on the metal roller and separated from each other; wherein, the outer surface of the metal roller has a first forming area exposed outside the plurality of intermediary protrusions, and is connected to a plurality of intermediary protrusions. a second forming area of the intermediary protrusion; the appearance of each intermediary protrusion corresponds to the top of one of the prefabricated protrusions; a metal etching step: dry etching the outer surface of the metal roller Etching is performed in such a manner that the metal roller is concavely formed with a plurality of grooves in the first forming area; wherein the inner wall surfaces of the plurality of grooves are flush with the surfaces of the plurality of intermediary protrusions. Together, an intermediate three-dimensional pattern is formed, which corresponds to the preset three-dimensional pattern; and a forming etching step: etching from the intermediate three-dimensional pattern, removing a plurality of the intermediate protrusions, and making the outer surface of the metal roller The surface is concavely formed with a rolling three-dimensional pattern, which corresponds to the intermediate three-dimensional pattern.

Embodiments of the present invention also disclose a method for manufacturing a seamless metal rolling wheel, which includes: a pre-step: providing a metal roller and a photoresist layer formed on the outer surface of the metal roller; wherein, the metal The material of the roller is copper metal or chromium metal, and the photoresist layer includes: a base layer formed on the outer surface of the metal roller, and the thickness of the base layer is not less than 3 microns; and a prefabricated A pattern layer, which is integrally formed on the base layer, and the thickness of the prefabricated pattern layer is no greater than the thickness of the base layer; wherein the prefabricated pattern layer has a preset three-dimensional pattern, which includes interconnected A plurality of prefabricated protrusions; a photoresist etching step: etching the photoresist layer in an anisotropic etching manner to remove the prefabricated pattern layer and shape the base layer to be located on the metal roller A plurality of intermediary protrusions are provided above and separated from each other; wherein, the outer surface of the metal roller has a first forming area exposed outside the plurality of intermediary protrusions, and is connected to a plurality of said intermediary protrusions. a second forming area; the appearance of each intermediary protrusion corresponds to the top of one of the prefabricated protrusions; a metal etching step: etching the outer surface of the metal roller in a wet etching manner, The metal roller is recessed in the first forming area to form a plurality of grooves; wherein the inner wall surfaces of the plurality of grooves are flush with the surfaces of the plurality of intermediary protrusions to jointly form an intermediary a three-dimensional pattern, the top area of which corresponds to the preset three-dimensional pattern; and a shaping etching step: etching from the intermediate three-dimensional pattern, removing a plurality of the intermediate protrusions, and making the outer surface of the metal roller concave A rolling three-dimensional pattern is formed, which corresponds to the intermediate three-dimensional pattern.

In summary, the method for manufacturing a seamless metal rolling wheel disclosed in the embodiment of the present invention uses a thicker photoresist layer and a metal roller of a specific material to match multiple rollers with different functions. The etching step (such as the photoresist etching step, the metal etching step, and the shaping etching step) can form the rolling three-dimensional pattern on the outer surface of the metal roller, thereby overcoming the problem of Technical biases in existing rolling wheel manufacturing methods.

In order to further understand the characteristics and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, these descriptions and drawings are only used to illustrate the present invention and do not make any reference to the protection scope of the present invention. limit.

The following is a specific example to illustrate the implementation of the "seamless metal rolling wheel manufacturing method" disclosed in the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of the present invention. In addition, the drawings of the present invention are only simple schematic illustrations and are not depictions based on actual dimensions, as is stated in advance. The following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of the present invention.

It should be understood that although terms such as “first”, “second” and “third” may be used herein to describe various elements or signals, these elements or signals should not be limited by these terms. These terms are primarily used to distinguish one component from another component or one signal from another signal. In addition, the term "or" used in this article shall include any one or combination of multiple associated listed items, depending on the actual situation.

[Example 1]

Please refer to FIG. 1 to FIG. 7 , which is Embodiment 1 of the present invention. As shown in Figure 1, this embodiment discloses a method for manufacturing a seamless metal rolling wheel S100, which sequentially includes (or implements) a pre-step S110, a photoresist etching step S130, a metal etching step S150, and a forming etching step S170, but the invention is not limited thereto. For example, in other embodiments not shown in the present invention, the above-mentioned steps may be added or adjusted according to design requirements. The specific implementation of the seamless metal rolling wheel manufacturing method S100 in this embodiment will be further described below.

The pre-step S110: As shown in Figures 2 and 3, a metal roller 1 and a photoresist layer 2 formed on the outer surface 11 of the metal roller 1 are provided. The material of the metal roller 1 is copper metal or chromium metal; that is to say, any roller that is not copper metal or chromium metal is different from the metal roller 1 defined in this embodiment.

In more detail, the photoresist layer 2 includes a base layer 21 and a prefabricated pattern layer 22 integrally formed on the base layer 21 . Wherein, the base layer 21 is formed on the outer surface 11 of the metal roller 1 , and the thickness T21 of the base layer 21 is not less than 3 micrometers (μm) and preferably is not more than 5 μm. Furthermore, the thickness T22 of the prefabricated pattern layer 22 is not greater than the thickness T21 of the base layer 21, and (the surface of) the prefabricated pattern layer 22 has a preset three-dimensional pattern 221, which includes connected to each other. A plurality of prefabricated protrusions 222.

In this embodiment, the distance D222 between any two adjacent prefabricated protrusions 222 ranges from 0.8 microns to 1.2 microns (such as 1 micron), and the height H222 of each prefabricated protrusion 222 ranges from 0.2 microns to 0.6 Micron. Furthermore, the plurality of prefabricated protrusions 222 are three-dimensional structures composed of sinusoidal patterns formed on the surface of the photoresist layer 2 in multiple directions, but the present invention is not limited thereto.

The photoresist etching step S130: As shown in FIGS. 3 and 4 , the photoresist layer 2 is etched in an anisotropic etching manner to remove the prefabricated pattern layer 22 and make the The base layer 21 is formed into a plurality of intermediary protrusions 211 located on the metal roller 1 and spaced apart from each other. In this embodiment, the anisotropic etching method may be plasma etching, and the outer surface 11 of the metal roller 1 has an area exposed outside the plurality of intermediary protrusions 211 . A first forming area 111 and a second forming area 112 connected to a plurality of the intermediate protrusions 211 .

That is to say, the photoresist layer 2 is gradually thinned in the photoresist etching step S130, so that the preset three-dimensional pattern 221 can gradually move downward toward the direction of the metal roller 1, Until the outer surface 11 of the metal roller 1 exposes the first forming area 111 , and the top area of the preset three-dimensional pattern 221 is formed on the base layer 21 and falls on the second forming area 112 above.

To put it another way, the shape of each intermediary protrusion 211 corresponds to (e.g., is substantially the same as) the top 2221 of one of the prefabricated protrusions 222 (e.g., each intermediary protrusion 211 is formed on the corresponding prefabricated protrusion 222 ). directly below the protrusion 222), and the height H211 of each intermediary protrusion 211 is 40% to 60% of the height H222 of the corresponding prefabricated protrusion 222, and the height H211 of any two adjacent intermediary protrusions 211 The distance D211 is the same as the distance D222 of the two corresponding prefabricated protrusions 222 (eg, between 0.8 microns and 1.2 microns).

The metal etching step S150: As shown in Figures 4 and 5, the outer surface 11 of the metal roller 1 is etched in a dry etching manner, so that the metal roller 1 is in the first forming area 111 is concavely formed with a plurality of grooves 12 . Among them, the inner wall surfaces 121 of the plurality of grooves 12 are aligned with the surfaces 2111 of the plurality of intermediary protrusions 211 to jointly form an intermediary three-dimensional pattern M, which corresponds to (e.g., is approximately the same as) the preset Three-dimensional pattern 221 (eg: Figure 3).

Furthermore, the appearance of the part of the metal roller 1 located between any two adjacent grooves 12 corresponds to (e.g., is substantially the same as) the bottom 2222 of one of the prefabricated protrusions 222 (e.g.: Figure 3). That is to say, the height H211 of each intermediary protrusion 211 and the depth H12 of the adjacent groove 12 are roughly equal to the height H222 of the corresponding prefabricated protrusion 222 (such as : Figure 3), but the present invention is not limited to this.

The forming etching step S170: As shown in FIGS. 5 to 7 , etching is performed from the intermediate three-dimensional pattern M to remove a plurality of the intermediate protrusions 211 and make the outer surface 11 of the metal roller 1 concave. A rolling three-dimensional pattern 13 is formed, which corresponds to (eg, is substantially the same as) the intermediate three-dimensional pattern M (or the preset three-dimensional pattern 221 shown in FIG. 3 ). Among them, the appearance of a portion of the metal roller 1 formed by etching in the second forming area 112 corresponds to (eg, is substantially the same as) the plurality of intermediary protrusions 211 .

In more detail, the rolling three-dimensional pattern 13 includes a plurality of metal protrusions 131 connected to each other, and their shapes respectively correspond to the plurality of prefabricated protrusions 222 . In this embodiment, the distance D131 between any two adjacent metal protrusions 131 ranges from 0.8 microns to 1.2 microns, and the height H131 of each metal protrusion 131 ranges from 0.2 microns to 0.6 microns.

As mentioned above, as shown in FIGS. 1 to 7 , the seamless metal rolling wheel manufacturing method S100 in this embodiment adopts a thicker photoresist layer 2 and a specific material of the metal. The roller 1 is matched with multiple etching steps with different functions (such as the photoresist etching step S130, the metal etching step S150, and the forming etching step S170), so that the metal roller 1 can be The outer surface 11 is formed with the rolling three-dimensional pattern 13 to form a rolling wheel 100 for rolling optical films, thereby overcoming the technical prejudice of the existing rolling wheel manufacturing method.

[Example 2]

Please refer to FIG. 8 and FIG. 9 , which is Embodiment 2 of the present invention. Since this embodiment is similar to the above-mentioned Embodiment 1, the similarities between the two embodiments will not be described in detail (such as pre-steps and photoresist etching steps). However, the differences between this embodiment and the above-mentioned Embodiment 1 are roughly The instructions are as follows:

In this embodiment, the manufacturing method of the seamless metal rolling wheel mainly involves further adjusting the metal etching step S150 and the forming etching step S170 of the first embodiment. Next, the metal etching step S250 and the forming etching step S270 adopted in this embodiment of the seamless metal rolling wheel manufacturing method will be introduced.

The metal etching step S250: As shown in Figure 8, the outer surface 11 of the metal roller 1 is etched in a wet etching manner, so that the metal roller 1 is concave in the first forming area 111. It is assumed that a plurality of grooves 12 are formed. Among them, the inner wall surfaces 121 of the plurality of grooves 12 are aligned with the surfaces 2111 of the plurality of intermediary protrusions 211 to jointly form an intermediary three-dimensional pattern M, the top area of which (for example: approximately the same as) corresponds to the Default three-dimensional pattern (eg: Figure 3). Wherein, the top area of the intermediary three-dimensional pattern M is composed of the surfaces 2111 of a plurality of intermediary protrusions 211 .

Furthermore, a bottom area of the intermediate three-dimensional pattern M composed of the inner wall surfaces 121 of the plurality of grooves 12 does not correspond to (or is different from) the preset three-dimensional pattern (such as: Figure 3). Wherein, each of the grooves 12 is formed by the wet etching method, so that it has a wider and flatter groove bottom, so that the appearance of each of the grooves 12 is different from that of the predetermined groove. Set up the corresponding parts of the three-dimensional pattern (such as Figure 3).

The forming etching step S270: As shown in FIGS. 8 and 9 , etching is performed from the intermediate three-dimensional pattern M to remove a plurality of the intermediate protrusions 211 and make the outer surface 11 of the metal roller 1 concave. A rolling three-dimensional pattern 13 is formed, which corresponds to (eg, is substantially the same as) the intermediate three-dimensional pattern M (but different from the preset three-dimensional pattern 221 shown in FIG. 3 ). Among them, the appearance of a portion of the metal roller 1 formed by etching in the second forming area 112 corresponds to (eg, is substantially the same as) the plurality of intermediary protrusions 211 .

Furthermore, the rolled three-dimensional pattern 13 includes a plurality of metal protrusions 131 connected to each other, and the shape of the top of each metal protrusion 131 corresponds to the top of one of the prefabricated protrusions (such as: Figure 3 ), but the appearance of the bottom of each metal protrusion 131 is different from the bottom of the corresponding prefabricated protrusion (eg, Figure 3).

[Technical effects of the embodiments of the present invention]

In summary, the method for manufacturing a seamless metal rolling wheel disclosed in the embodiment of the present invention uses a thicker photoresist layer and a metal roller of a specific material to match multiple rollers with different functions. The etching step (such as the photoresist etching step, the metal etching step, and the shaping etching step) can form the rolling three-dimensional pattern on the outer surface of the metal roller, thereby overcoming the problem of Technical biases in existing rolling wheel manufacturing methods.

Furthermore, the manufacturing method of the seamless metal rolling wheel disclosed in the embodiment of the present invention can also further limit the size and spacing of the plurality of prefabricated protrusions, thereby facilitating the outer appearance of the plurality of prefabricated protrusions. The shape can be concavely formed on the outer surface of the metal roller as accurately as possible.

The contents disclosed above are only preferred and feasible embodiments of the present invention, and do not limit the patent scope of the present invention. Therefore, all equivalent technical changes made by using the description and drawings of the present invention are included in the patent scope of the present invention. within.

100:Rolling wheel

1:Metal roller

11:Outer surface

111: First forming area

112: Second forming area

12: Groove

121:Inner wall surface

13: Rolling three-dimensional pattern

131:Metal protrusion

2: Photoresist layer

21: Basal layer

211:The rise of intermediaries

2111:Surface

22: Premade pattern layer

221:Default three-dimensional pattern

222:Prefabricated protrusion

2221:Top

2222:Bottom

M: Intermediate three-dimensional pattern

S100: Manufacturing method of seamless metal rolling wheel

S110: Preliminary steps

S130: Photoresist etching step

S150, S250: Metal etching steps

S170, S270: Forming etching steps

T21, T22: Thickness

D222, D211, D131: Spacing

H222, H211, H12, H131: height

Figure 1 is a schematic flowchart of a manufacturing method of a seamless metal rolling wheel according to Embodiment 1 of the present invention.

FIG. 2 is a schematic plan view of the pre-steps in FIG. 1 .

FIG. 3 is an enlarged schematic diagram of area III in FIG. 2 .

FIG. 4 is a schematic plan view of the photoresist etching step in FIG. 1 .

FIG. 5 is a schematic plan view of the metal etching step in FIG. 1 .

FIG. 6 is a schematic plan view of the forming etching step in FIG. 1 .

FIG. 7 is an enlarged schematic diagram of area VII in FIG. 6 .

8 is a schematic diagram of the metal etching steps of the manufacturing method of a seamless metal rolling wheel according to Embodiment 2 of the present invention.

9 is a schematic diagram of the forming and etching steps of the manufacturing method of a seamless metal rolling wheel according to Embodiment 2 of the present invention.

S100: Manufacturing method of seamless metal rolling wheel

S110: Preliminary steps

S130: Photoresist etching step

S150: Metal etching step

S170: Forming etching step

Claims (3)

A method of manufacturing a seamless metal rolling wheel, which includes: a pre-step: providing a metal roller and a photoresist layer formed on the outer surface of the metal roller; wherein the material of the metal roller is copper metal or chromium metal, and the photoresist layer includes: a base layer formed on the outer surface of the metal roller, and the thickness of the base layer is not less than 3 microns (μm); and a prefabricated pattern layer, It is integrally formed on the base layer, and the thickness of the prefabricated pattern layer is no greater than the thickness of the base layer; wherein the prefabricated pattern layer has a preset three-dimensional pattern, which includes a plurality of connected to each other. Prefabricated protrusions; a photoresist etching step: etching the photoresist layer in an anisotropic etching manner to remove the prefabricated pattern layer and shape the base layer to be located on the metal roller A plurality of intermediary protrusions are provided above and separated from each other; wherein, the outer surface of the metal roller has a first forming area exposed outside the plurality of intermediary protrusions, and is connected to a plurality of said intermediary protrusions. a second forming area; the appearance of each intermediary protrusion corresponds to the top of one of the prefabricated protrusions; a metal etching step: etching the outer surface of the metal roller in a dry etching manner to The metal roller is recessed in the first forming area to form a plurality of grooves; wherein the inner wall surfaces of the plurality of grooves are aligned with the surfaces of the plurality of intermediary protrusions to jointly form an intermediary three-dimensional a pattern, which corresponds to the preset three-dimensional pattern; and a forming etching step: etching from the intermediary three-dimensional pattern, removing a plurality of the intermediary protrusions, and recessing the outer surface of the metal roller to form a Rolling three-dimensional pattern, which corresponds to the intermediate three-dimensional pattern; wherein, in the forming and etching step, the rolling three-dimensional pattern includes The appearance of a plurality of metal protrusions connected to each other corresponds to a plurality of the prefabricated protrusions respectively; wherein, the distance between any two adjacent prefabricated protrusions, the distance between any two adjacent intermediary protrusions, and the distance between any two adjacent intermediary protrusions. The distance between two adjacent metal protrusions ranges from 0.8 microns to 1.2 microns; wherein, the height of each prefabricated protrusion and the height of each metal protrusion range from 0.2 microns to 0.6 microns. The manufacturing method of a seamless metal rolling wheel as claimed in claim 1, wherein each of the intermediary protrusions is formed directly below the corresponding prefabricated protrusions, and the height of each of the intermediary protrusions is corresponding to 40% to 60% of the height of the prefabricated protrusion. The manufacturing method of a seamless metal rolling wheel as claimed in claim 1, wherein in the forming and etching step, a portion of the metal rolling wheel formed by etching in the second forming area is The outer shape corresponds to a plurality of said intermediate protrusions.

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