JPH091660A - Manufacturing method of embossing roll - Google Patents

Abstract

(57) [Summary] [Purpose] To provide a method for manufacturing an embossing roll that does not require a high degree of skill and a long number of days and is easy to manufacture even with a complicated uneven pattern. A protective coating layer (for example, a photocurable resin layer) 21 forming a pattern is partially provided on the surface of the metal roll 10, and sandblasting or shot blasting 40 is performed on the protective coating layer 21.
The protective coating layer 21 is removed (in the case of a photocurable resin layer,
By being scraped off and removed by the blasting), and further by sandblasting or shot blasting 40,
An uneven pattern is formed on the surface of the metal roll 10 in which the fine irregularities 11 are the concave portions 13 and the fine irregularities 12 are the convex portions 14 as a whole. In this way, the embossing roll A is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an embossing roll used for manufacturing an embossing sheet.

[0002]

2. Description of the Related Art Embossed sheets in which a surface of a thermoplastic resin sheet is provided with an uneven pattern are widely used for interlayer films for laminated glass and other applications.

For example, on the surface of the interlayer film for laminated glass, in order to improve the adhesion between the films during storage, the workability when stacking the glass plate and the interlayer film, and the degassing property during the bonding process, A special concavo-convex pattern (projection) is formed (for example, JP-A-60-204643 and JP-A 5-2).
94679 gazette).

An embossed sheet of this type is generally manufactured by embossing an embossing roll on the surface of a thermoplastic resin sheet such as plasticized polyvinyl butyral. The embossing roll is manufactured by the method of engraving on the surface of the metal roll by a skilled worker, but engraving requires a high degree of skill and long days as the uneven pattern becomes complicated like the interlayer film for laminated glass. .

The above-mentioned Japanese Patent Laid-Open No. 5-294679 discloses that
As a method of manufacturing embossing rolls, press an engraving mill (mother mill) having protrusions of a certain arrangement on the surface of the metal roll,
By rotating both of them, the engraving mill was slightly shifted in the axial direction of the metal roll in units of the array of projections, and the projections of a fixed array were transferred onto the surface of the metal roll, and shot blasting was applied to this, whereby the transfer was performed. A method of adding fine irregularities to the protrusions or recesses is disclosed.

[0006]

However, since the engraving mill is also manufactured by engraving, there is still a problem that it requires a high degree of skill and a long number of days although the degree is different. Further, the concave portion on the surface of the metal roll formed by the engraving mill (the concave portion forms a protrusion on the embossed sheet) is generally a hemispherical rounded concave portion, which is difficult to form at an acute angle.

Further, when sandblasting or shot blasting is applied to such a hemispherical rounded recess,
Since the recess has a round hemispherical shape, it is difficult for sand grains and steel grains to act effectively, and it is difficult to form sufficiently effective fine irregularities on the inner surface of the recess.

The present invention is intended to solve the above problems, and an object of the present invention is to produce an embossing roll which does not require a high degree of skill and a long number of days and is easy to produce even with a complicated uneven pattern. To provide a method.

[0009]

The method for producing an embossing roll according to the present invention comprises partially providing a protective coating layer forming a pattern on the surface of a metal roll, and subjecting it to sandblasting or shot blasting to form the protective coating layer. By removing and further subjecting it to sand blasting or shot blasting, a concavo-convex pattern is formed on the surface of the metal roll, whereby the above object can be achieved.

In the present invention, the protective coating layer provided on the surface of the metal roll is for temporarily protecting the surface of the metal roll from sandblasting or shot blasting, and a photocurable resin layer or a thin wire mesh is used. The photocurable resin layer is preferable because it has the following advantages.

The photocurable resin layer is formed by photocuring a coating film of a photocurable resin liquid, and such a photocurable resin liquid forms a continuous coating film which is easy to apply and has no seams. Since the thickness of the coating film can be freely changed and only the portion irradiated with light is cured, it is suitable for forming a protective coating layer having a complicated pattern. Further, the photocurable resin layer is convenient because it can be removed by sandblasting or shot blasting and can be easily removed.

A preferred example of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a schematic view of a partially cut longitudinal section showing an example of the process of the present invention. First, as shown in FIG. 1A, a photocurable resin liquid is applied to the entire surface of the metal roll 10 and dried to form an uncured coating film 20 of the photocurable resin liquid.

As the photocurable resin solution, for example, a solution prepared by mixing a prepolymer such as unsaturated polyester, epoxy acrylate or urethane acrylate with a photopolymerization initiator and dissolving it in a solvent is used.

Then, the coating film 20 of the photocurable resin liquid
Then, the desired pattern obtained by the design workstation is laser-exposed, for example, by using the laser beam 30 having good directivity. By this laser exposure, the coating film 20 in the exposed portion is photo-cured, and the hard photo-curable resin layer 21 is partially provided in a desired pattern.

A method of applying a photocurable resin liquid to a desired pattern on the surface of a metal roll by a printing method such as offset gravure printing, drying the solution, and irradiating the solution with ultraviolet rays to photocure the coating film, Alternatively, an uncured coating film of a photocurable resin liquid having a desired pattern is previously formed on a peelable support sheet, the uncured coating film is transferred to the surface of a metal roll, and this is irradiated with ultraviolet rays. Therefore, a method of photo-curing the coating film can also be adopted.

Here, since the pattern formed by the photocurable resin layer 21 usually forms a large number of regular concave portions as a whole on the surface of the metal roll 10, the non-exposed portion has a large number of regular concave portions as a whole. The pattern is a small circle or polygon.

Next, the surface of the metal roll 10 on which the photocurable resin layer 21 is formed is blasted by a sand blast (sand grain blast) or shot blast (steel grain blast) device 40. The blast device 40 moves in the axial direction of the metal roll 10. By such a blast treatment, the uncured coating film 20 on the non-exposed portion is peeled off, and
As shown in (b), many fine irregularities 11 'are formed on the surface of the metal roll 10 excluding the photocurable resin layer 21.

These fine irregularities 11 'generally correspond to the pattern of the photocurable resin layer 21, and usually have a large number of regular small circles or polygons on the surface of the metal roll 10. Is formed.

When the blasting process is further continued, as shown in FIG. 1C, the fine unevenness 11 'is further deeply blasted to form a large number of deep fine unevennesses 11 having a sharper angle. To be done. At the same time, the photocurable resin layer 21
Is also blasted to scrape and remove the photo-curable resin layer 21, and the surface of the metal roll 10 in this portion is also shallowly blasted to produce a large number of shallow fine irregularities 12.
Is formed.

In this way, a concavo-convex pattern consisting of fine concavities and convexities 11 and 12 is formed on the surface of the metal roll 10. In this uneven pattern, the fine unevenness 11 as a whole is the recess 1
3, and the fine irregularities 12 constitute the protrusions 14 as a whole. In this way, the embossing roll A is obtained.

In order to produce an embossed sheet using the embossing roll A, the embossing roll A is embossed by a conventional method on the surface of a thermoplastic resin sheet such as plasticized polyvinyl butyral to transfer an uneven pattern. The embossed sheet thus obtained includes the recess 13 of the embossing roll A.
A large number of sharp and regular projections corresponding to the above are formed, resulting in an uneven pattern as a whole.

[0022]

When a protective coating layer forming a pattern is partially provided on the surface of the metal roll and sand blasting or shot blasting is performed on the surface, the surface of the metal roll in the protective coating layer is
You will be temporarily protected from this blast and not blasted,
The surface of the metal roll other than the protective coating layer is directly blasted.

Here, when the protective coating layer is removed and further sand blasting or shot blasting is performed, the entire surface of the metal roll is blasted, but the portion of the protective coating layer is shallowly blasted, and the portion other than the protective coating layer is blasted. Is already blasted, then blasted more and more, so it is deeply blasted.

Therefore, finally, the shallow blasted portion becomes a convex portion as a whole, and the deep blasted portion becomes a concave portion as a whole to form an uneven pattern, and the surface of the uneven pattern is finely divided by blasting. Unevenness will be added.

[0025]

EXAMPLES Examples and comparative examples of the present invention will be shown below.

Example 1 The steps shown in FIG. 1 were carried out. First, an unsaturated polyester-based photocurable resin liquid was applied to the entire surface of the metal roll 10 and dried to form a coating film 20 of the photocurable resin liquid.

A pattern obtained by a design workstation using a laser beam 30 on the coating film 20 of the above-mentioned photocurable resin liquid (a regular diameter of 200 μm having a large number of non-exposed portions)
The pattern that makes a circle of m) is exposed by laser, leaving the coating film in the non-exposed area and photo-curing the coating film in other areas.
A photocurable resin layer 21 having a thickness of about 100 μm was partially provided.

Next, the entire surface of the metal roll 10 provided with the photocurable resin layer 21 was sandblasted by a sandblasting device 40. For sandblasting, sand grains # 120 were used, air pressure was 3 kg / cm ² and jetting was carried out from a distance of 30 cm from the metal roll, and the jetting port was moved in the axial direction of the metal roll 10 at 15 cm / min. The speed was 10 m / min.

The coating film 20 in the non-exposed portion was peeled off by the first sandblasting treatment, and the fine irregularities 11 'were formed on the surface of the metal roll 10 in the non-exposed portion, and the photocurable resin layer 21 remained as it was.

Then, when the second sand blasting process is performed under the same conditions as above, the fine irregularities 11 'are further blasted to form deep fine concave portions 11, and at the same time, the photocurable resin layer 21 is scraped off and removed. While being blasted, it was shallowly blasted to form shallow fine irregularities 12 on the surface of the metal roll 10 in this portion.

Using the embossing roll A thus obtained, an interlayer film for laminated glass was manufactured by a conventional method, and further a laminated glass was manufactured by a conventional method. The surface roughness of the obtained intermediate film as a whole was 28.0 μm. Also,
The self-adhesive force of this film is 250 g / 15 cm, and the film slip resistance is 35.
It was 0 g / (10 cm × 10 cm), and the workability of the interlayer film and the workability during the alignment process were good. Further, the degassing property during the laminating process was also good.

The surface roughness of the intermediate film is shown as a 10-point average roughness measured by a stylus surface roughness meter. The self-adhesive force of the membrane is such that the intermediate membrane is cut into a size of 15 cm × 15 cm, two sheets are stacked and a load of 13 kg is placed on it, and the membrane is kept at room temperature for 2 minutes.
After being left for 4 hours, a 180 ° peel test was performed with a tensile tester at a speed of 500 mm / min, and the average peel force at that time (repeated number 5) was shown. The smaller this value, the better the workability of handling the interlayer film.

The film sliding resistance is 50 cm × 5 for the intermediate film.
Cut it to a size of 0 cm and cut it into a glass plate with a smooth surface (5
0 cm x 50 cm x thickness 2.5 mm), place a glass plate with a smooth surface (10 cm x 10 cm x thickness 2.5 mm) on it, and after 30 seconds, place the upper glass plate through a spring balance. It was pulled horizontally, and the average value of the maximum static friction coefficient (repetition number 5) obtained from the reading of the spring balance at that time was shown. The measurement was performed at a temperature of 20 ° and a humidity of 4% RH. The smaller this value, the better the workability of aligning the glass plate and the interlayer film.

COMPARATIVE EXAMPLE 1 The steps shown in FIG. 2 were carried out. As shown in FIG. 2 (a), an engraving mill (mother mill) 2 is pressed against the surface of the metal roll 1, both are rotated, and the engraving mill 2 is slightly shifted in the axial direction of the metal roll 1 in an array unit of uneven patterns. Meanwhile, an uneven pattern was transferred onto the surface of the metal roll 1.

As shown in FIG. 2 (a), the concave and convex portion 3 was a hemispherical rounded concave portion having a diameter of 200 μm. The portions other than the concave portions 3 become the convex portions 4. This was subjected to sandblasting with the sandblasting device 5 under the same conditions as in Example 1. Fine irregularities 6 were formed on the convex portions 4 by blasting, but almost no fine irregularities were formed on the inner surface of the round hemispherical concave portions 3.

Using the embossing roll A thus obtained, an interlayer film for laminated glass was manufactured by a conventional method, and further a laminated glass was manufactured by a conventional method. The surface roughness of the obtained intermediate film as a whole was 27.0 μm. Also,
The self-adhesive force of this film is 500g / 15cm, and the film slip is 900g.
/ (10 cm × 10 cm), the workability of the interlayer film and the workability during the alignment process were insufficient. The degassing property during the laminating process was good.

[0037]

As described above, according to the method for manufacturing an embossing roll of the present invention, a protective coating layer forming a pattern is partially provided on the surface of a metal roll, and the protective coating layer is sandblasted or shot blasted to form the protective coating layer. By removing and further sandblasting or shot blasting,
Since it forms an uneven pattern on the surface of the metal roll, it does not require a high level of skill and long days as compared with the conventional engraving method or a method using an engraving mill, and even a complicated uneven pattern is extremely easy. An embossing roll can be manufactured.

Further, since the above-mentioned concavo-convex pattern is formed by sand blasting or shot blasting, the concave portion is formed at an acute angle as compared with the method of forming the concave-convex pattern by using an engraving mill. Sharp projections can be formed on the embossed sheet.

Therefore, the embossing roll obtained by the method of the present invention is intended to improve the adhesion between the films during storage, the workability when stacking the glass plate and the intermediate film, and the degassing property during the laminating process. Particularly, it is preferably used for manufacturing an interlayer film for laminated glass, which requires a projection with an acute angle.

[Brief description of the drawings]

FIG. 1 is a schematic view of a partially cut longitudinal section showing a process of the method of the present invention.

FIG. 2 is a schematic view of a partially cutaway vertical section showing a step of a conventional method.

[Explanation of symbols]

 10 metal roll 11 deep fine unevenness 12 shallow fine unevenness 13 concave portion 14 convex portion 20 coating film of photocurable resin liquid 21 photocurable resin layer (protective coating layer) 30 laser light 40 sandblasting device

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area // B29L 31:32

Claims (1)

[Claims] 1. A metal roll surface is partially provided with a protective coating layer forming a pattern, and sandblasting or shot blasting is applied to this, the protective coating layer is removed, and further sandblasting or shot blasting is performed,
A method for manufacturing an embossing roll, comprising forming an uneven pattern on the surface of the metal roll.