WO2010143524A1 - Method for forming knurling portion, and flexible strip-shaped base - Google Patents

Abstract

Disclosed is a method for forming a knurling portion with a reduced running cost, wherein a knurling portion with a wide versatility is formed without mechanically forming recesses and projections and without being affected by the kind, coating or surface modification of a base on which the knurling portion is formed, said knurling portion having a shape which does not affect products much when the knurling portion is formed thereon or the products are wound up. Specifically disclosed is a method for forming a knurling portion, wherein a knurling portion is formed at least along the side edges of a flexible strip-shaped base in the width direction, which is orthogonal to the longitudinal direction of the flexible strip-shaped base. The method for forming a knurling portion is characterized in that the knurling portion is composed of dome-shaped projections that are formed by ejecting a knurling portion-forming liquid from an inkjet head.

Description

Knurling part forming method, flexible strip substrate

This invention relates to the knurling part formation method which provides a knurling part continuously along the conveyance direction of the at least side edge part of the width direction orthogonal to the conveyance direction of a flexible strip | belt-shaped base material. More specifically, the present invention relates to a knurling part forming method in which a knurling part forming liquid is ejected onto a flexible belt-like substrate that moves using an ink jet head to provide a dome-shaped knurling part.

Conventionally, when performing various treatments such as applying a functional liquid to a flexible belt-like base material or performing surface modification, it is generally carried out continuously by conveying in order to increase productivity. is there. At this time, after various treatments, the surface property of the flexible belt-like base material changes, or the operation of the transport and winding device varies, causing various problems when winding the flexible belt-like base material. There is a case. At the time of winding, a flexible belt-like substrate is wound around a cylindrical winding core called a core. At the time of winding, the position of the flexible belt-like substrate is not stable, meandering and the end face is displaced. Or wrinkles or creases may occur on the surface of the flexible belt-like substrate.

Also, at the beginning of winding, the tip of the flexible strip substrate is fixed to the core with a tape or an adhesive, etc., but when the core is rotated and wound, it overlaps with the tip of the flexible strip substrate, A level difference due to so-called “winding core transfer” or the like is generated in the second and subsequent flexible belt-like base materials. This may occur over several tens of turns, depending on the type of flexible belt-like base material and the conditions of conveyance and winding.

Furthermore, when the surface smoothness of the flexible belt-like base material is excellent, the surface may be scratched by rubbing between the base materials. In addition, in the case of such a flexible belt-like base material, it is difficult for an air layer to exist between the surfaces of the flexible belt-like base material. The phenomenon that the material sticks may occur. When this phenomenon occurs, the winding shape may be deteriorated or the flexible belt-shaped substrate may be deformed.

In order to avoid the above-mentioned problems during winding, the side edge of the flexible belt-like substrate is called a knurling process (also called a knurling process), and a thickening process is performed by minute uneven patterning. Application has been studied so far. For example, Japanese Patent Application Laid-Open Nos. 9-244180, 9-319029, 2002-68538, 2002-21803, 2007-91784, and 2007-313754 disclose a knurling formation portion. Regulations such as variations in height and height of adjacent convex portions are disclosed. Japanese Laid-Open Patent Publication No. 2000-272003 discloses a ratio regulation of the area of the deformed portion with respect to the area for forming the knurling portion. Japanese Patent Application Laid-Open No. 2007-70514 discloses the definition of the ratio between the friction coefficient of the knurling formation portion and the friction coefficient other than the knurling formation portion.

As a method for forming such a knurling portion, a method of forming irregularities by pressing a rough surface formed with a large number of protrusions such as an embossing ring and a knurling roller against a flexible belt-like substrate is common. In order to make it easy to form irregularities at this time, it has been studied so far to carry out heating. For example, the film surface portion on the end side in the width direction of the film (corresponding to a flexible belt-like substrate) is formed in a tapered shape, the top of the protrusion is rounded, and the curvature radius of the top surface is set. A method is known in which a concavo-convex portion is formed on a film surface portion by pressing with a roller with a projection set to 0.4 mm or less (see Patent Document 1).

When the end of the web (corresponding to a flexible belt-like substrate) is sandwiched between a pair of rollers, at least one of which is a knurled roller, when the surface of at least one of the web ends is deformed into a concavo-convex shape, A thickness-thickening processing method in which a method of pressing a roller onto a base material, a peripheral speed, and the like is defined is known (see Patent Document 2).

A method for forming an embossed pattern in a strip shape by pressing an embossed belt formed with an embossed pattern on the side edge of a thermoplastic resin film (corresponding to a flexible strip-shaped base material) along the conveying direction is known. (See Patent Document 3).

In the methods described in Patent Literature 1 to Patent Literature 3, a concavo-convex structure formed by deforming a flexible belt-like base material with a rough surface by pressure is used as a knurling formation portion. All of these methods have low running costs and require only an initial equipment cost, and therefore have a high cost advantage, but have the following problems.

1) Since the flexible belt-like base material itself is deformed, the thickness that can be earned is limited in the first place. For this reason, it has been found that there is a limit in producing a necessary and sufficient height of the knurling portion.

2) It was found that the flexible strip-like base material having a small thickness is further disadvantageous, and that the deformation of only the end portion further affects the inside in order to increase the height of the knurling formation portion.

3) It was found that when the knurling height was increased by mechanical deformation, the amount of deformation became too large, and part of the flexible belt-shaped substrate could be removed. Even if only a small part of the flexible belt-like substrate is peeled off, the influence on the winding itself is slight, but the problem is that the part of the flexible belt-like substrate that has been peeled off adheres to the flexible belt-like substrate as garbage. This is very likely to happen. If such dust adheres to the flexible belt-like base material, it is rolled up as it is, and a push-like deformation centered on that portion occurs in the flexible belt-like base material, which significantly reduces the quality.

4) Furthermore, when there are a plurality of treatments such as application to the flexible belt-shaped substrate or application to the flexible belt-shaped substrate and surface modification, it is necessary to change the knurling formation conditions according to each of them. It is done. This is relatively easy if the condition change is a change in the pressure or temperature of the knurling roller, but in the case of a change in the shape of the rough surface, difficult work such as replacement of the knurling roller is required. It turned out that.

In recent years, there has been an increasing demand for higher quality in the subsequent development of flexible strip-like base materials to final products. Specifically, there are many cases where rubbing due to slight contact between the front and back of the flexible belt-like base material is not permitted, and in such a case, it is necessary to increase the thickness of the knurling part, It is also important that the contact resistance between the knurling portion and the flexible belt-like base material is small during the winding process.

From such a situation, it is highly versatile without mechanically forming uneven shapes, and the running cost is suppressed, and the type of flexible strip substrate to be used and the application / surface to the flexible strip substrate A knurling part forming method for forming a knurling part having a shape that has little influence on the product at the time of forming and winding the knurling part without being affected by modification, etc., and the knurling part is formed by this knurling part forming method Development of such a flexible belt-like base material is desired.

JP 2000-219369 A Japanese Patent Laid-Open No. 2002-1813 Japanese Patent Laid-Open No. 2007-261013

The present invention has been made in view of the above situation, and its purpose is not to form a concave-convex shape mechanically, it has high versatility, and the running cost is suppressed, and the type of base material used and the application to the base material -A knurling part forming method for forming a knurling part having a shape with little influence on the product at the time of forming and winding the knurling part without being affected by surface modification, etc., and a knurling part in this knurling part forming method It is providing the flexible strip | belt-shaped base material which formed.

The above object of the present invention has been achieved by the following constitution.

1. In a knurling part forming method in which a knurling part is provided along at least a side edge part in a width direction orthogonal to the longitudinal direction of a flexible belt-like substrate, the knurling part is ejected with a knurling part forming liquid from an inkjet head, and a dome is formed. A method for forming a knurling part, comprising forming a convex part of a mold.

2. 2. The knurling part forming method according to 1 above, wherein the thickness of the flexible belt-shaped substrate is 5 μm to 80 μm.

3. 3. The method for forming a knurling part according to 1 or 2, wherein the density of the protrusions is 10 pieces / cm ² to 200 pieces / cm ² .

4. 4. The knurling part forming method according to any one of 1 to 3, wherein the height of the convex object is 20 μm to 500 μm.

5. The flexible belt-like base material having a knurling portion along at least both side edges in the width direction orthogonal to the longitudinal direction of the flexible belt-like base material, wherein the knurling portion is any one of items 1 to 4 above. A flexible belt-like substrate formed by the knurling part forming method described in 1.

Forming a knurling part without mechanically forming an uneven shape, high versatility and low running costs, and without being affected by the type of base material used, application to the base material, surface modification, etc. It was possible to provide a knurling part forming method for forming a knurling part having a shape with little influence on the product at the time of winding and winding, and a flexible belt-like substrate having a knurling part formed by this knurling part forming method. .

It is a schematic diagram which shows an example of the manufacturing process of the flexible strip | belt-shaped base material which formed the knurling part using the knurling part forming apparatus using an inkjet head. It is a schematic diagram which shows the order which forms a knurling part. It is a general | schematic enlarged plan view of the knurling part formation process shown in FIG. FIG. 4 is a schematic enlarged view of a portion indicated by K in FIG. 3. It is a schematic perspective view including the partial fracture surface which shows an example of the inkjet head shown in FIG.

Embodiments according to the present invention will be described with reference to FIGS. 1 to 5, but the present invention is not limited thereto.

FIG. 1 is a schematic view showing an example of a manufacturing process of a flexible belt-like base material having a knurling part using a knurling part forming apparatus using an inkjet head.

In the figure, reference numeral 1 denotes a manufacturing process of a flexible belt-like substrate on which a knurling portion is formed. The manufacturing process 1 of the flexible strip-shaped base material in which the knurling part is formed includes a supply process 2 of the flexible strip-shaped base material, an undercoat coating process 3, a knurling part forming process 4, and a winding process 5. ing. The undercoating step 3 can be arranged as necessary.

Supplied step 2 uses an unwinding device (not shown) for the flexible belt-like substrate 201. Reference numeral 202 denotes a roll-shaped flexible belt-like substrate wound around a winding core.

The undercoating application process 3 uses a holding member 301 that holds the flexible belt-like substrate 201, an undercoating machine 302, a drying device 303, and a curing processing device 304. The holding member 301 can be selected by maintaining the flatness of the flexible belt-like base material 201 and in relation to the undercoat coater 302, and this figure shows a case where a backup roll is used. ing. The position of the undercoat application in the undercoat application process 3 may be the entire surface of the flexible belt-like substrate 201 or the position where the knurling portion is formed, and can be appropriately selected as necessary. is there.

There is no particular limitation on the undercoat coater, for example, after applying a certain coating solution, the unnecessary part is removed to form a coating film after the measurement type coating method, the coating solution is applied in an amount that forms the required coating solution film. It may be a pre-weighing type coating method in which the coating liquid is ejected and applied onto the support, and can be appropriately selected as necessary. As a post-measuring type coating method, a blade coating method, an air knife coating method, a wire bar coating method, a gravure coating method, a reverse coating method, and a reverse roll coating method are known.

As the pre-weighing type coating method, an extrusion coating method using a slit type die coater, a slide coating method using a slide coater, a curtain coating method, and a coating method using an inkjet head are known. This figure has shown the case where it apply | coats by the pre-measurement type | mold application method.

The drying device 303 is not particularly limited as long as the solvent of the undercoat coating film can be removed, and examples thereof include a hot air spraying device and a heating device.

The curing processing device 304 can be set as appropriate according to the coating solution applied by the undercoat coater 302. For example, in the case of an active energy ray curable resin, an active energy ray irradiating device, and in the case of a thermosetting resin, a heat applying device may be mentioned.

As the active energy ray, any energy source that activates the active energy ray-curable resin with ultraviolet rays, electron beams, γ rays or the like can be used without limitation, but ultraviolet rays and electron beams are preferable. In particular, ultraviolet rays are preferable because they are easy to handle and high energy can be easily obtained. As the ultraviolet light source, any light source that generates ultraviolet light can be used. For example, a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a carbon arc lamp, a metal halide lamp, a xenon lamp, or the like can be used. An ArF excimer laser, a KrF excimer laser, an excimer lamp, synchrotron radiation, or the like can also be used.

The knurling part forming step 4 uses an inkjet head 401, a holding member 402, a drying device 403, and a curing processing device 404.

The inkjet head 401 is not particularly limited. For example, a thermal type head that has a heating element and discharges ejected liquid from the nozzle by a sudden volume change due to film boiling of the coating liquid by heat energy from the heating element may be used. A shear mode type (piezo type) head that has a vibration plate including a piezoelectric element in the ink pressure chamber and discharges the ejected liquid by a pressure change in the ink pressure chamber by the vibration plate may be used.

Reference numeral 405 denotes a supply tank for supplying the knurling part forming liquid to the inkjet head 401. Normally, the supply tank 405 is provided with a mechanism that always keeps the knurling portion forming liquid pressure in the ink jet head 401 constant in order to make the amount of droplets ejected from the ink jet head 401 constant. There is no particular limitation on the mechanism for keeping the pressure constant, and there are various mechanisms. As an example, there is a mechanism that uses a liquid level sensor to make the liquid level of the liquid in the tank constant, a mechanism that measures the mass and keeps it constant.

The knurling part forming liquid supplied to the inkjet head 401 is preferably allowed to pass through a filter medium having an absolute filtration accuracy or semi-absolute filtration accuracy of 0.05 μm to 50 μm at least once. Further, a heat exchanger may be provided between the supply tank 405 and the ink jet head 401 in order to keep the temperature of the knurling part forming liquid in the ink jet head 401 constant. A mechanism for keeping the temperature of the knurling part forming liquid constant may be provided.

The drying device 403 is not particularly limited, and examples thereof include a hot air blowing device and a heating device.

The curing processing device 404 can be appropriately set according to the knurling part forming liquid applied by the ink jet head 401. For example, in the case of an active energy ray curable resin, an active energy ray irradiating device, and in the case of a thermosetting resin, a heat applying device is used, and the same apparatus as the curing processing device 304 used in the undercoating step 3 is used Is possible.

The winding process 5 uses a winding device (not shown) that winds the flexible belt-like base material 201 in which the knurling parts are formed on both side edges of the flexible belt-like base material 201 in the knurling part forming step 4. Yes. Reference numeral 501 denotes a roll-shaped flexible belt-like substrate wound around a winding core.

This figure shows a case where a knurling part is formed on a flexible belt-like substrate that has been produced and wound up in a roll shape, and a functional layer is applied except for the knurling part that is formed after this, but the knurling part is formed. The order is not particularly limited, and for example, the order shown in FIG.

FIG. 2 is a schematic diagram showing the order of forming the knurling portion.

In the figure, 6 is a pretreatment step, 7 is a knurling portion forming step, 8 is various treatment steps, and 9 is a flexible strip substrate.

Examples of the treatment in the pretreatment step 6 include surface modification treatment such as corona discharge treatment, atmospheric pressure plasma treatment, UV irradiation treatment, and undercoating. The undercoat coating process 3 shown in FIG. 1 corresponds to the pretreatment process 6 shown in the figure.

The knurling part forming step 7 is the same as the knurling part forming step 4 shown in FIG.

Examples of the processing in the various processing steps 8 include a coating / drying step and a curing processing step for forming various functional layers excluding the knurling portion.

A description will be given in the case of (a).

The case where the flexible strip-like base material 9 formed in the film formation process (not shown) is processed online in the order of the pretreatment process 6 and the knurling part formation process 7 is shown.

A description will be given in the case of (b).

The case where the flexible belt-like substrate 9 formed in the film forming step (not shown) is temporarily stored and then processed in the order of the pretreatment step 6 and the knurling portion forming step 7 is shown.

This will be explained in the case of (c).

The case where the flexible strip-like base material 9 formed in the film forming process (not shown) is once stored and then processed in the order of the pre-processing process 6, the knurling part forming process 7, and the various processing processes 8 is shown. .

This will be described in the case of (d).

The case where the flexible belt-like base material 9 formed in the film forming step (not shown) is temporarily stored and then processed in the order of various processing steps 8, the preprocessing step 6, and the knurling portion forming step 7 is shown. .

A description will be given in the case of (e).

The case where the flexible belt-like base material 9 formed in the film forming step (not shown) is temporarily stored and then processed in the order of the pre-processing step 6, various processing steps 8, and the knurling portion forming step 7 is shown. .

The order shown in (a) to (e) can be appropriately selected as necessary.

FIG. 3 is a schematic enlarged plan view of the knurling portion forming step shown in FIG.

The inkjet head 401 has an inkjet head 401A and an inkjet head 401B. The ink jet head 401A is disposed to form a knurling portion 201a on the side edge on the left side (upper side in the drawing) with respect to the conveyance direction (the arrow direction in the drawing) of the flexible belt-like substrate 201. The inkjet head 401B is disposed to form a knurling portion 201b on the side edge on the right side (lower side in the drawing) with respect to the conveyance direction (arrow direction in the drawing) of the flexible belt-like substrate 201.

Reference numeral 405 denotes a supply tank for supplying a knurling portion forming liquid to the inkjet head 401 (401A, 401B). Reference numeral 406 denotes a control unit for driving the piezoelectric substrate of the inkjet head 401 (401A, 401B), which is connected to each inkjet head 401 (401A, 401B) via a connector. The control unit 406 selects the operation strength and frequency of the piezoelectric substrate when the coating liquid is ejected.

The arrangement of the inkjet heads 401A (401B) is not particularly limited. For example, the inkjet heads 401A (401B) are arranged and tilted so that the direction in which the nozzle rows are arranged is orthogonal to the conveyance direction (arrow direction in the drawing) of the flexible belt-like substrate 201. You may arrange in the state. A plurality of inkjet heads may be arranged in accordance with the width of the knurling portion and the pattern of convex objects constituting the knurling portion.

The knurling part 201a and the knurling part 201b shown in this figure may be on the application surface side or the back surface side of the flexible belt-like substrate 201, or on both surfaces of the application surface side and the back surface side. It is possible to select. In addition, the knurling part 201a and the knurling part 201b shown in this drawing may be simultaneously formed on both side edge parts, or may be alternately provided on one side edge part.

In addition, one inkjet head 401 is arranged at the center of the flexible belt-like base material 201 so that the conveying direction of the flexible belt-like base material 201 and the direction in which the nozzle rows are arranged are orthogonal to each other. You may form a knurling part in the center part of the strip | belt-shaped base material 201. FIG. Even when the knurling part is formed in the center part, it may be the application surface side or the back surface side of the flexible belt-like substrate 201, or both surfaces of the application surface side and the back surface side. Is possible.

FIG. 4 is a schematic enlarged view of a portion indicated by K in FIG. FIG. 4A is a schematic enlarged plan view of a portion indicated by K in FIG. FIG. 4B is an enlarged schematic sectional view taken along line EE ′ of FIG.

In the figure, 201a 'indicates a convex object constituting the knurling portion 201a. The shape of the convex object 201a ′ is a dome shape. The knurling portion 201a is formed of an aggregate of dome-shaped convex objects 201a ′.

There is no particular limitation on the arrangement of the dome-shaped convex objects 201a '. For example, a staggered arrangement in the conveyance direction (arrow direction in the figure) of the flexible belt-like substrate 201, a uniform arrangement in the conveyance direction and the horizontal direction, and a random arrangement. Etc.

The dome-shaped convex object 201a ′ is formed by accumulating one or more drops of the knurling part forming liquid ejected from the ink jet head 401A (401B) (see FIG. 3).

The contact angle between the knurling part forming liquid and the substrate is preferably 10 ° to 30 ° in consideration of the shape of the convex, the height of the convex, and the like. The contact angle is a value measured with a contact angle meter manufactured by Kyowa Interface Science Co., Ltd.

W indicates the distance from the side edge of the flexible belt-like substrate 201 to the formation of the knurling portion 201a in the direction orthogonal to the conveying direction of the flexible belt-like substrate 201 (the arrow direction in the figure). The distance W is preferably 50 mm or less in consideration of the effective width of the substrate.

In addition, the total width of the knurling portions 201a provided on both side edges of the flexible belt-like substrate 201 is flexible in consideration of conveyance stability, winding property, unwinding property, effective area of the substrate, and the like. It is preferably 0.5% to 40% with respect to the entire width of the belt-like substrate 201.

X indicates the height of the dome-shaped convex object 201a ′ constituting the knurling part 201a of the flexible belt-like base material 201 from the formation surface of the flexible belt-like base material 201. The height X is preferably 20 μm to 500 μm in consideration of conveyance stability, winding property, unwinding property, effective area of the substrate, contact property between the substrates, and the like. The height X indicates a value measured using a thickness measuring machine (Sickness Gauge manufactured by Mitutoyo Corporation).

The density of the dome-shaped convex object 201a ′ constituting the knurling part 201a of the flexible belt-like base material 201 is in consideration of the conveyance stability, the winding property, the unwinding property, the effective area of the base material, etc. The number is preferably 10 / cm ² to 200 / cm ² . The density is a value measured by observing 1 cm ² with a magnifying glass.

The volume of the dome-shaped convex object 201a ′ is 3 × 10 ⁻⁴ mm ³ to 2 × 10 ⁻² mm ³ in consideration of the conveyance stability, the winding property, the unwinding property and the effective area of the base material. It is preferable. The volume of the dome-shaped convex 201a ′ was determined by the following method.

1) Take out a certain area of the knurling part where the dome-shaped convex object is formed, measure the mass, and set it as A. Also, the number of dome-shaped convex objects is measured.

2) The mass of only the base material having the same area as 1) is measured and designated as B.

3) Obtain the mass of the dome-shaped convex object cut in AB, and set it as C.

4) The mass per one point-like convex part is calculated from (C / number of dome-shaped convex objects).

5) Obtain the volume of the dome-shaped convex object from the following formula.

Volume of dome-shaped convex object = mass per dome-shaped convex object obtained by (4) / density of substance forming dome-shaped convex object)
It is preferable that the knurling portion 201b (see FIG. 3) has the same configuration as the knurling portion 201a.

It should be noted that the knurling portion shown in this figure is arranged on both the application surface side or the back surface side and the central portion or both the application surface side and the back surface side of the flexible belt-like base material 201. It is preferable that they have the same configuration.

In the present invention, the dome-shaped convex object means a shape body in which the top of the head is formed by a curved surface, and preferably the surface is formed of a curved surface not including a flat surface. More preferably, a spheroid obtained by rotating an ellipse with its major axis or minor axis as a rotation axis, and a part of a spheroid (sphere) obtained by rotating a circle are cut out and the cross section side thereof is cut. Refers to a shape in which is contacted with a flexible belt-like substrate.

Moreover, the cross-sectional shape parallel to the substrate may be any of a rectangle, a triangle, a circle, an ellipse and the like, and a circle is preferable among them.

FIG. 5 is a schematic perspective view including a partially broken surface showing an example of the ink jet head shown in FIG. This figure shows the case of a shear mode type (piezo type) ink jet head.

In the figure, 401 indicates an inkjet head. A controller 406 (see FIG. 3) for driving the piezoelectric substrate is connected to the inkjet head 401 via a connector. The control unit 406 (see FIG. 3) selects the operation strength and frequency of the piezoelectric substrate when the coating liquid is ejected.

The inkjet head 401 has a piezoelectric substrate 401a, a top plate 401b, and a nozzle plate 401c. The piezoelectric substrate 401a is formed by joining an upper piezoelectric substrate 401a1 and a lower piezoelectric substrate 401a2.

The piezoelectric substrate 401a includes a plurality of nozzles (ink pressure chambers) 401a3 having predetermined lengths parallel to each other, which are opened on the nozzle plate 401c side and closed on the opposite side by grinding, and nozzles (ink pressure chambers). ) A flat surface 401a4 connected to the closed side of 401a3 and side walls 401a5 on both sides of the nozzle (ink pressure chamber) 401a3. The plurality of nozzles may be alternately used as a nozzle for a coating solution pressure chamber and a nozzle for an air pressure chamber. This figure shows the case where it is used for a coating solution pressure chamber.

The top plate 401b has a first top plate 401b2 that covers the top surface of the piezoelectric substrate 401a, and a second top plate 401b1 that covers the top surface of the first top plate.

401d indicates a supply pipe for the knurling part forming liquid. The coating liquid supplied from the supply pipe 401d is discharged from the nozzle discharge port 401c1. Reference numeral 401b3 denotes a storage portion for the knurling portion forming liquid supplied from the supply pipe 401d. Each knurling portion forming liquid pressure chamber 401b4 communicates with each nozzle (ink pressure chamber) 401a3. The nozzle (ink pressure chamber) 401a3 is supplied. Each nozzle (ink pressure chamber) 401a3 is covered with a first top plate 401b2 and a nozzle plate 401c, so that a plurality of sealed channels (coating liquid pressure chambers) are formed.

Reference numeral 401c1 denotes a nozzle discharge port that discharges the knurling portion forming liquid in the form of liquid droplets due to a change in the pressure of the knurling portion forming liquid pressure chamber accompanying shear deformation of each side wall. The interval between the nozzle discharge ports is preferably 0.02 mm to 0.3 mm. Reference numeral 401e denotes a pipe used for bleeding air from the knurling portion forming liquid. 401e has a structure that is sealed by a valve or the like when the liquid for forming the knurling portion is injected.

The material of the first top plate and the second top plate is not particularly limited, and may be made of, for example, an organic material. However, alumina, aluminum nitride, zirconia, silicon, silicon nitride, silicon carbide, quartz, lead zirconate titanate ( PZT) and the like.

A metal or resin is used as a base material constituting the nozzle plate 401c. For example, stainless steel, polyimide, polysulfone, polyethersulfone and the like can be preferably used. Particularly preferred is a polyimide resin, and DuPont: Kapton or Ube Industries, Ltd .: Upilex, etc. are preferred because they are excellent in dimensional stability, ink resistance, heat resistance and the like.

The following effects can be obtained by the knurling portion forming method shown in FIGS.
1) The height of the dome-shaped convex object forming the knurling portion can be increased, and the shape, arrangement, and the like can be changed.
2) It became possible to eliminate generation of dust when forming the knurling portion.
3) It became possible to respond flexibly to the width, thickness, and type of the flexible belt-like substrate.

As a result, the following effects can be given as the product performance.
1) It has become possible to suppress deterioration in quality due to contact between flexible strip-shaped substrates.
2) The conveyance stability and winding property of the flexible belt-like base material were improved, and it became possible to suppress deformation of the base material such as wrinkles and slippage due to meandering and winding deviation.
3) It is possible to reduce foreign matter failures and failures caused by foreign matters, and quality can be improved.

Next, the knurling part forming method of the present invention and the material relating to the flexible strip substrate will be described.

(Flexible strip substrate)
There is no restriction | limiting in a kind as a flexible strip | belt-shaped base material, A plastic film, a metal sheet, etc. can be used. Examples of the plastic film include polyolefin films (eg, polyethylene film, polypropylene film), polyester films (eg, polyethylene terephthalate film, polyethylene 2,6-naphthalate film), polyamide films (eg, polyether ketone film), cellulose An acetate film (for example, a cellulose triacetate film etc.) etc. are mentioned. As the metal sheet, an aluminum plate is typical. In addition, the thickness of the flexible belt-shaped substrate to be used is preferably 5 μm to 80 μm. There is no particular limitation on the width.

(Narling part forming liquid and undercoat layer forming coating liquid)
The knurling part forming liquid and the undercoat layer forming coating liquid preferably contain 0.5 mass% to 50 mass% of a resin and a polymer component. Examples of the resin and polymer component include gelatin, methyl cellulose, carboxymethyl cellulose, polyacrylic acid, polyvinyl ether, polyvinyl alcohol, polyvinyl pyrrolidone, and natural rubber. There are no particular restrictions on the knurling part forming liquid and the undercoat layer forming coating liquid containing these resins and polymer components. For example, resin materials, liquids in which polymer materials are dissolved in organic solvents, water, etc., pigment dispersion Liquid, colloidal dispersion, and the like. Furthermore, examples of other resins include thermoplastic resins, thermosetting resins, and active energy ray curable resins.

Thermoplastic resins include methylcellulose, carboxymethylcellulose, polyacrylic acid, polyvinyl ether, polyvinyl alcohol, polyvinylpyrrolidone, polyethylene, polypropylene, polybutene, polystyrene, polybutadiene, polyvinyl chloride, polyvinyl acetate, polymethyl methacrylate, polyamide, polyethylene terephthalate And polyimide.

As the thermosetting resin, curing proceeds with heating, and the cured molecule generally becomes a three-dimensional network. For example, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin , Polyurethane resin, epoxy resin, aminoalkyd resin, melamine-urea co-condensation resin, silicone resin, polysiloxane resin, and the like. Further, these resins can be used by adding a curing agent such as a crosslinking agent and a polymerization initiator, a polymerization accelerator, a solvent, a viscosity modifier and the like, if necessary.

The active energy ray-curable resin is a resin obtained by curing a prepolymer, an oligomer and / or a monomer having a polymerizable unsaturated bond or an epoxy group in a molecule by irradiation with energy rays. Active energy rays refer to those having an energy quantum capable of polymerizing or cross-linking molecules among electromagnetic waves or charged particle beams, and usually ultraviolet rays or electron beams are used.

The ultraviolet ray and electron beam curable resin is not particularly limited, and can be appropriately selected from those conventionally used. This ultraviolet curable resin contains a photopolymerizable prepolymer, a photopolymerizable monomer, a photopolymerization initiator or a photosensitizer. The electron beam curable resin contains a photopolymerizable prepolymer or a photopolymerizable monomer.

Examples of the photopolymerizable prepolymer include polyester acrylate, epoxy acrylate, urethane acrylate, and polyol acrylate. These photopolymerizable prepolymers may be used alone or in combination of two or more. Examples of the photopolymerizable monomer include polymethylolpropane tri (meth) acrylate, hexanediol (meth) acrylate, tripropylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, pentaerythritol tri (meth) acrylate, Examples include dipentaerythritol hexa (meth) acrylate, 1,6-hexanediol di (meth) acrylate, and neopentyl glycol di (meth) acrylate.

Examples of the photopolymerization initiator include acetophenones, benzophenones, α-amyloxime esters, tetramethylchuram monosulfide, thioxanthones, and the like. In addition, n-butylamine, triethylamine, poly-n-butylphosphine and the like can be mixed and used as a photosensitizer.

The coating solution containing these resin / polymer components is not particularly limited, and examples thereof include a solution obtained by dissolving a resin material / polymer material in an organic solvent, water, a pigment dispersion, a colloidal dispersion, and the like. I can do it. The viscosity of the coating solution is preferably 20 mPa · sec or less.

Hereinafter, although an example is given and the concrete effect of the present invention is shown, the mode of the present invention is not limited to this.

Example 1
(Preparation of strip-shaped flexible substrate No. 1-A)
A polyethylene terephthalate (PET) film having a thickness of 80 μm, a width of 1000 mm, and a length of 1000 m was prepared as a belt-like flexible substrate. 1-A.

(Preparation of strip-shaped flexible substrate No. 1-B)
A polyethylene terephthalate (PET) film having a thickness of 5 μm, a width of 1000 mm, and a length of 1000 m was prepared as a belt-like flexible substrate. 1-B.

(Preparation of strip-shaped flexible substrate No. 1-C having an undercoat layer)
A PET film having a thickness of 80 μm, a width of 1000 mm and a length of 1000 m was used as the belt-like flexible base material, and a base material provided with an undercoat layer was prepared. 1-C.

(Preparation of strip-shaped flexible substrate No. 1-D having an undercoat layer)
A PET film having a thickness of 5 μm, a width of 1000 mm and a length of 1000 m was used as the belt-like flexible base material, and a base material provided with an undercoat layer was prepared. 1-D.

(Preparation of coating solution for undercoat layer formation)
Dipentaerythritol hexaacrylate monomer 60 parts by mass Dipentaerythritol hexaacrylate 2 monomer 20 parts by mass Dipentaerythritol hexaacrylate 3 monomer or more component 20 parts by mass Dimethoxybenzophenone photoinitiator 4 parts by mass Propylene glycol monomethyl 75 parts by mass of ether 75 parts by mass of methyl ethyl ketone (formation of undercoat layer)
Apply the prepared coating solution for forming the undercoat layer with a slit die, gradually increase the temperature and speed of the drying air and finally dry at 85 ° C., and then the irradiation intensity of 115 mJ / cm ² from the active energy ray irradiation part And an undercoat layer having a dry film thickness of 5 μm was provided.

(Forming the knurling part)
Sample No. 101 was prepared using the manufacturing process of the flexible strip substrate shown in FIG. 1 using the shear mode type (piezo type) ink jet head shown in FIG. The knurling part forming solution is applied to both side edges on the coating surface side of 1-A under the conditions shown below, dried at a temperature of 100 ° C., and composed of a dome-shaped convex as shown in FIG. A knurling part having a width of 20 mm was formed, and 1000 m was wound around the winding core. 101. The knurling part is a strip-shaped flexible base No. From the side edge of 1-A, the belt-like flexible substrate No. The distance until the knurling portion in the direction perpendicular to the 1-A conveyance direction is formed is 5 mm.

(Preparation of the knurling part forming solution)
Dipentaerystol hexaacrylate (including dimer and trimer component) 100 parts by mass Photoinitiator (dimethoxybenzophenone) 4 parts by mass Propylene glycol monomethyl ether 30 parts by mass Methyl ethyl ketone 100 parts by mass Strip-like flexible group Material No. The contact angle with respect to 1-A and 1-B was 21 °. In addition, the belt-like flexible base material No. The contact angle with respect to 1-C and 1-D was 25 °. The contact angle indicates a value measured with a contact angle meter manufactured by Kyowa Interface Science Co., Ltd.

(Application of knurling part forming liquid)
The strip-shaped flexible substrate No. which prepared the prepared knurling part formation liquid. On the 1-A, 1000 droplets were landed at one place by a shear mode type (piezo type) ink jet head shown in FIG. 5, dried at a temperature of 100 ° C. after 20 seconds, and then 150 mJ / cm from a curing processing apparatus. ^An ultraviolet ray was irradiated with an irradiation intensity of ² , and a knurling part was formed by an assembly of dome-shaped convex objects arranged as shown in FIG.

Shear mode type (piezo type) ink jet head Nozzle outlet interval: 0.05 mm
Number of nozzle outlets: 500, Average ejection volume per drop: 50 pl (picoliter)
Arrangement of shear mode type (piezo type) ink jet head: the direction in which the nozzle discharge ports are arranged is a belt-like flexible substrate No. 1-A arranged so as to be orthogonal to the conveying direction of the nozzle surface and the strip-shaped flexible substrate No. 1 1-A distance from the surface: 1 mm
Band-shaped flexible substrate No. 1-A transport speed: 10 m / min
The belt-like flexible substrate No. of the knurling part. Ratio of 1-A to the total width: 4%
Shape of dome-shaped convex object constituting knurling part One volume of dome-shaped convex object: 1.2 × 10 ⁻³ mm ³
Dome-shaped convex object height: 100 μm
Density of dome-shaped convex objects: 50 / cm ²
The height of the dome-shaped convex object is a value measured using a thickness measuring instrument (Sickness Gauge manufactured by Mitutoyo Corporation).

One volume of the dome-shaped convex object indicates a value measured by the method described in the text.

The density of the dome-shaped convex object is a value obtained by visually observing a 1 cm × 1 cm sample with a loupe, counting the number of dome-shaped convex objects, and converting it to the number per 1 cm ² .

Sample No. Fabrication of band-like flexible substrate No. 102 1-A is changed to a strip-like flexible substrate No. Sample No. 1 except that 1-B was used. Sample no. A knurling portion having a width of 20 mm composed of a dome-shaped convex material is formed as in the case of No. 101. 102.

Sample No. No. 103 Production of strip-shaped flexible substrate No. 1-A is changed to a strip-like flexible substrate No. Sample No. 1 was used except that 1-C was used. Sample no. A knurling portion having a width of 20 mm composed of a dome-shaped convex material is formed as in the case of No. 101. 103.

Sample No. No. 104 Fabrication of strip-shaped flexible substrate No. 104 1-A is changed to a strip-like flexible substrate No. Sample No. 1 was used except that 1-D was used. Sample no. A knurling portion having a width of 20 mm composed of a dome-shaped convex material is formed as in the case of No. 101. 104.

Comparative sample No. No. 105 Preparation of prepared strip-like flexible substrate No. 105 A knurling portion composed of a plate-like convex material is formed on both side edges of 1-A, and the sample of Comparative Sample No. 105. The plate-like convex material means a convex material having a flat surface that comes into contact with the belt-like flexible substrate when the belt-like flexible substrate is wound up, and is formed by a coating method.

Comparative sample No. Fabrication of band-like flexible substrate No. 106 Instead of 1-A, the strip-shaped flexible substrate No. Sample No. 1 except that 1-B was used. In the same manner as in No. 105, a knurling part composed of a plate-like convex material is formed on both side edges, and 1000 m is wound around the winding core and comparative sample No. 106.

Comparative sample No. No. 107 Fabrication of strip-shaped flexible substrate No. 107 Instead of 1-A, the strip-shaped flexible substrate No. Sample No. 1 was used except that 1-C was used. In the same manner as in No. 105, a knurling part composed of a plate-like convex material is formed on both side edges, and 1000 m is wound around the winding core and comparative sample No. 107.

Comparative sample No. No. 108 Production of strip-shaped flexible substrate No. 108 Instead of 1-A, the strip-shaped flexible substrate No. Sample No. 1 was used except that 1-D was used. In the same manner as in No. 105, a knurling part composed of a plate-like convex material is formed on both side edges, and 1000 m is wound around the winding core and comparative sample No. 108.

Comparative sample No. No. 109 Preparation of the prepared strip-like flexible substrate No. Sample No. 1 on both side edges of 1-A. The knurling part composed of the same dome-shaped convex object as that of No. 101 was formed using a knurl, and 1000 m was wound around the winding core and the comparative sample No. 109.

Comparative sample No. 110 Preparation of the prepared strip-like flexible substrate No. 110 Sample No. 1 on both side edges of 1-B. The knurling part composed of the same dome-shaped convex object as that of No. 101 was formed using a knurl, and 1000 m was wound around the winding core and the comparative sample No. 110.

Comparative sample No. 111 Preparation of the prepared strip-like flexible substrate No. 111 Sample No. 1 on both side edges of 1-C. The knurling part composed of the same dome-shaped convex object as that of No. 101 was formed using a knurl, and 1000 m was wound around the winding core and the comparative sample No. 111.

Comparative sample No. Preparation of No. 112 Prepared strip-shaped flexible substrate No. 112 Sample No. 1 on both side edges of 1-D. The knurling part composed of the same dome-shaped convex object as that of No. 101 was formed using a knurl, and 1000 m was wound around the winding core and the comparative sample No. 112.

Evaluation Each sample No. Nos. 101 to 112 are confirmed by the method shown below for winding deviation and foreign matter adhesion, and the results of evaluation according to the evaluation rank shown below are shown in Table 1.

Method for evaluating winding deviation The amount of deviation from the winding core of the end face was measured with a caliper.

Evaluation rank of winding deviation ◎: Winding deviation is less than 1 mm ○: Winding deviation is 1 mm or more and less than 5 mm △: Winding deviation is 5 mm or more and less than 10 mm ×: Winding deviation is 10 mm or more The number of foreign matters adhered was measured by visual observation and converted per m ² .

Evaluation rank of foreign matter adhesion ◎: The number of foreign matter adhered is less than 0.1 / m ² ○: The number of foreign matter adhered is 0.1 / m ² or more and less than 1 / m ² △: Foreign matter adhered The number is 1 / m ² or more and less than 5 / m ² ×: The number of adhered foreign matters is 5 / m ² or more

Specimen No. 1 in which a knurling part composed of a dome-shaped convex object was produced by the knurling formation method of the present invention. Nos. 101 to 104 were confirmed to have excellent performance with no winding deviation or adhesion of foreign matter.

Sample No. which produced a knurling part composed of a plate-like convex object. Nos. 105 to 108 have no foreign matter attached, and sample Nos. Although it has the same performance as 101 to 104, the winding misalignment is the sample No. of the present invention. It was confirmed that the performance was inferior to 101 to 104.

Specimen No. in which a knurling part was produced using a conventional knurl. From No. 109 to No. 112, it was confirmed that foreign matters were attached due to breakage of the belt-like flexible base material when a knurling portion was produced using a knurl. Sample No. 5 was prepared using a strip-shaped flexible substrate having a thickness of 5 μm. Samples 110 and 112 of the present invention were prepared using a belt-like flexible substrate having a winding deviation of 5 μm in thickness. It was confirmed that it was inferior to 102 and 104. The effectiveness of the present invention was confirmed.

DESCRIPTION OF SYMBOLS 1 Knurling formation process 2 Supply process 201, 9 Flexible strip | belt-shaped base material 201a, 201b Knurling part 201a 'Dome-shaped convex object 3 Undercoating process 302 Undercoating machine 303, 403 Drying apparatus 304, 404 Curing processing apparatus 4, 7 Knurling portion forming step 401, 401A, 401B Inkjet head 401a Piezoelectric substrate 401a1 Upper layer piezoelectric substrate 401a2 Lower layer piezoelectric substrate 401c Nozzle plate 401c1 Nozzle discharge port 401a3 Nozzle (ink pressure chamber)
405 Supply tank 5 Winding process 6 Pre-processing process 8 Various processing processes W Distance X Height

Claims (5)

1. In the knurling part forming method of providing the knurling part along at least the side edge part in the width direction orthogonal to the longitudinal direction of the flexible belt-shaped substrate,
   A knurling part forming method, wherein a knurling part forming liquid is ejected from an ink jet head to form a dome-shaped convex object.
2. The method for forming a knurling portion according to claim 1, wherein the thickness of the flexible belt-like substrate is 5 to 80 µm.
3. 3. The knurling part forming method according to claim 1, wherein the density of the protrusions is 10 pieces / cm ² to 200 pieces / cm ^{2. 4} .
4. The knurling part forming method according to any one of claims 1 to 3, wherein the height of the convex object is 20 m to 500 m.
5. The flexible belt-like base material having a knurling portion continuously along at least both side edges in the width direction orthogonal to the longitudinal direction of the flexible belt-like base material, wherein the knurling portion is defined in claim 1. A flexible belt-like base material formed by the knurling part forming method according to any one of the above items.

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