WO2012088921A1 - Method of manufacturing reflective film having micro prism array structure - Google Patents

Abstract

Disclosed is a method of manufacturing a reflective film having a micro prism array structure, wherein an annular mould performing reciprocating motion along a closed loop is adopted. The annular mould has a recessed successive micro prism array structure on an outer surface thereof. The manufacturing steps comprise: coating a layer of hot melt resin on a side surface of a resin film; performing mould pressing on the resin film, the hot melt resin and the annular mould synchronously; and cooling the resin film coated with the hot melt resin and the annular mould synchronously, so that the resin film coated with the hot melt resin and the micro prism array structure on the hot melt resin layer form a lamination film together. The method of manufacturing the reflective film using the hot melt resin enables the material of molding micro prisms to have a wide selection, the manufacturing cost is low, and it is more beneficial to subsequent processing and use of the reflective film, so that the reflective film has a wider application range.

Description

Method for producing reflective film with microprism array structure  Technical field

 The invention relates to a method for producing a reflective film, in particular to a method for producing a reflective film having a microprism array structure.

 Background technique

Reflective materials with microprism array structure are more and more widely used in various road traffic safety facilities, vehicle passive safety devices, signs and personal safety protection products due to their excellent retroreflective properties. And other fields.

The invention patent application entitled "Production Method of Reflective Film Having Microprism Array Structure" on October 21, 2009, application number CN200910098915.X discloses a reflective film using a photosensitive resin to form a microprism The production method comprises the following steps: coating a photosensitive resin on a resin film, drying, heating the film pressure, and rapidly curing by UV light irradiation to form a resin film coated with a photosensitive resin and a photosensitive resin layer. The upper microprism array structure collectively constitutes a laminate film, and finally the laminate film is cooled, and the laminate film is a reflective film having a microprism array structure.

The reflective film obtained by the method needs to be vapor deposited with a metal reflective layer, or sealed by a conventional welding technique such as ultrasonic wave, high frequency or hot melt on the surface of one side of the microprism, and then in the metal. The reflective layer or the base film side is combined with a pressure sensitive adhesive to form a microprism type reflective film for use in road traffic safety signs or personal safety protection articles. Moreover, the micro-prism type reflective film which is vapor-deposited with a metal reflective layer and sealed with a base film has different application ranges and fields .

The microprism structure formed by the above method has excellent hardness and scratch resistance, heat resistance and solvent resistance, and has good product consistency. However, since the type of photosensitive resin is relatively small, the performance is special, and the general price is very good. High; and after curing, the photosensitive resin ester crosslinks into a network, the surface is dense, and the polarity is very low. Although a metal reflective layer can be evaporated on one side of the microprism, it is difficult to use ultrasonic waves. The existing welding technique such as high frequency or hot melt seals a base film on the surface of one side of the microlens of the laminated film, which is disadvantageous for subsequent processing and use of the reflective film, and the application range of the reflective film is also limited.

 Utility model content

 The technical problem to be solved by the present invention is to overcome the above prior art. The use of photosensitive resin as a microprism forming material has a narrow selection surface, high production cost, poor subsequent processing performance of the reflective film and narrow application range, and provides a new type of defect. The production method of the reflective film, the molding material of the microprism is widely selected, and the production cost is low, which is more favorable for the subsequent processing and use of the reflective film, and the reflective film has a wider application range.

 In order to solve the above technical solution, the present invention is implemented by the following technical solutions:

 A method of producing a retroreflective film having a microprism array structure, the method comprising an annular die that reciprocates along a closed loop, The mold has an inner surface and an outer surface, the outer surface of which has a continuous microprism array structure in a concave shape, the method comprising the steps of:

 (1) coating a layer of a hot melt resin on one side of the resin film;

 (2) The side surface of the resin film coated with the hot melt resin is in close contact with the annular mold The outer surface, and then the resin film, the hot melt resin and the annular mold are simultaneously molded, so that the molten molten metal ester fills the gap of the concave microprism display structure under pressure;

(3) in the engaged state, the hot-melt resin-coated resin film treated by the step (2) and the annular mold are simultaneously cooled, and the cooled hot-melt resin has a side surface and a resin film. Forming a strong bond, the microprism array structure on the other side surface is simultaneously molded, and the resin film coated with the hot melt resin and the microprism array structure on the hot melt resin layer are formed. The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

 The invention provides a production of a microprism using a hot melt resin to produce a reflective film Methods. Since the molecules of the hot-melt resin have a linear structure, high activity and high polarity, it is easy to evaporate a metal reflective layer on one side of the microprism or use existing welding techniques such as ultrasonic, high-frequency or hot melt in the microprism. One side surface is sealed with a base film, so the microprism type reflective film formed by hot melt resin has better subsequent processing performance and A wider range of applications; in addition, the choice of hot melt resin is wider and the production cost is lower.

 A method of producing a retroreflective film having a microprism array structure, the method comprising an annular die that reciprocates along a closed loop, The mold has an inner surface and an outer surface, the outer surface of which has a continuous microprism array structure in a concave shape, the method comprising the steps of:

 (1) coating a layer of a hot melt resin on one side of the resin film;

 (2) The side surface of the resin film coated with the hot melt resin is in close contact with the outer surface of the annular mold, and a layer is attached to the other side surface of the resin film. a backing film, and then simultaneously molding the resin film, the hot melt resin and the ring mold to which the backing film is attached, so that the molten molten metal ester fills the concave microprism display structure under pressure gap;

(3) in the engaged state, the backing film, the resin film coated with the hot-melt resin, and the annular mold, which are treated by the step (2), are simultaneously cooled and cooled, and the cooled hot-melt resin is One side surface and the resin film form a strong bond, and the microprism array structure on the other side surface is simultaneously molded, and the backing film is attached and coated with the resin film of the hot melt resin and the hot melt resin layer. Microprism array structure The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

 The use of the backing film can effectively prevent the resin film from being heated during the heating process. The deformation is made, and the surface of the side of the resin film which is not coated with the hot melt resin is prevented from being scratched.

 a method for producing a retroreflective film having a microprism array structure, in the step (1), Before one side surface of the resin film is coated with the hot melt resin, a coupling agent is applied to the side surface of the resin film, and the coupling agent and the resin film form a strong bond, and then coated with On one side of the mixture A layer of hot melt resin is applied to bond the hot melt resin to the coupler. The use of a coupling agent can increase the bonding properties and bond strength between the resin film and the hot melt resin.

 In the above method for producing a retroreflective film having a microprism array structure, the annular die is an endless belt die.

 The above-mentioned production method of a reflective film having a microprism array structure, the endless belt mold is a flexible metal strip . Since the endless belt-shaped mold must reciprocate along the closed loop, better flexibility is required; in addition, in order to ensure uniformity of cooling, the microprism array structure It is precisely copied and peeled off from the mold after the completion of the production of the laminated film. The mold should have dimensional stability and good anti-stick properties, so the metal material should be selected to make the mold.

 Method for producing reflective film having microprism array structure described above The endless belt mold is made of a nickel metal material. Nickel has excellent dimensional stability, and when the endless belt mold is cooled, the change in mold size can be effectively reduced, thereby ensuring accurate reproduction of the microprism structure on the resin layer.

 In the above method for producing a retroreflective film having a microprism array structure, the loop mold is a cylindrical mold.

 A method for producing a retroreflective film having a microprism array structure, wherein the cylindrical mold is a hollow rigid roller, Made of steel or copper. A hollow cylindrical mold with a cooling medium inside.

 A method for producing a retroreflective film having a microprism array structure, the outer surface of the cylindrical mold The continuous microprism array structure in a concave shape is formed by chemical etching, laser engraving or cutting with a diamond cutter.

 A method for producing a retroreflective film having a microprism array structure, the outer surface of the cylindrical mold It is assembled from a nickel sheet having a continuous microprism array structure having a concave surface on one side.

 A method for producing a retroreflective film having a microprism array structure, the resin film Using acrylate materials, polycarbonate materials, polyester materials, polyvinyl chloride materials, polyurethane materials, polyvinyl alcohol materials, polypropylene materials, polyethylene materials, polyamide materials, polystyrene materials, two or more of the above Composite material of the above materials. In order to maximize the probability of incident light energy passing through the surface resin film to the microprism for total internal reflection, thereby ensuring excellent retroreflective properties of the reflective film, the selected resin film needs to have excellent light transmittance, so the invention is preferred The above materials serve as carriers for the attachment of the hot melt resin.

 A method for producing a retroreflective film having a microprism array structure, the hot-melt resin Acrylate resin, polycarbonate resin, polyester resin, polyvinyl chloride resin, polyurethane resin, polyvinyl alcohol resin, polypropylene resin, polyethylene resin, polyamide resin, polyphenylene A vinyl resin, a vinyl chloride vinyl acetate co-ester, an ethylene vinyl acetate copolymer resin, a mixture of two or more of the above resins.

 A method for producing a retroreflective film having a microprism array structure, coated with a hot melt resin The method of hot melt coating or hot melt extrusion is adopted.

 In the above method for producing a retroreflective film having a microprism array structure, the melt index of the hot-melt resin is from 3 to 40 g/10 min. Since the hot melt resin having a melt index in the range of 3 to 40 g/10 min is relatively easy to coat by hot melt coating or hot melt extrusion.

 a method for producing a retroreflective film having a microprism array structure, The backing film is made of a polyester material, a polypropylene material, a polyamide material, a polyethylene material or a fluorine-containing material. Due to the excellent temperature resistance and dimensional stability of the above materials, these materials are used as The backing film can better prevent the deformation of the resin film during film pressing and cooling, and prevent the side surface of the resin film from being coated with the hot melt resin from being scratched.

 The invention has the following beneficial effects:

1. The selection surface of the microprism molding material is more extensive: in the prior art, the photosensitive resin is used as the molding material of the microprism, but the photosensitive resin has strict requirements on construction and storage, so relatively speaking There are not many types to choose from; and the hot melt resin can be used as the microprism molding material in the method of the present invention as long as it is suitable for hot melt coating or hot melt extrusion operation, so the selection surface is wide.

2, lower production costs: due to the small variety of photo-sensitive resin, special performance, the price is very high, usually more than 100 yuan / kg, and the price of hot-melt resin is relatively cheap, generally not more than 50 yuan / kg.

3. It is more conducive to the subsequent processing and use of the reflective film: on the side of the reflective film with the microprism array structure, if there is no protective metal reflective layer or base film, it will be affected by the accumulation of dust or any other foreign matter. Its reflective properties, so After the reflective film is peeled off from the ring mold, it is required A layer of metal reflective layer is deposited on the surface of the microprism by vapor deposition or a layer of base film, a base film and a microprism array are sealed on one surface of the microprism by an existing welding technique such as ultrasonic wave, high frequency or hot melt. Honeycomb seal between structures The airbag structure is such that the microprism type reflective film can be used in the fields of road traffic safety signs or personal safety protection articles. After the photosensitive resin is cured, the molecules crosslink into a network, the surface is dense, and the polarity is very low, which is difficult to use on it. Existing welding techniques such as ultrasonic, high frequency or hot melt form a honeycomb sealed airbag structure. The microprism structure formed by the hot melt resin has a linear structure, a high degree of activity and a strong polarity, so it is easy to A honeycomb sealed balloon structure is formed between the microprism array structure and the base film, so that the retroreflective film having the microprism array structure produced by the method of the present invention has more excellent subsequent processing properties.

4, has a wider range of applications: vapor-deposited metal reflective layer and microprism reflective film sealed with a base film have different applications and fields. In the prior art, a photosensitive resin is used as a molding material of a microprism. Although a metal reflective layer can be deposited on one surface of the microprism, it is difficult to use an existing welding technique such as ultrasonic wave, high frequency or hot melt. The surface of one side of the laminated film microprism is sealed with a base film, so that the retroreflective film having the microprism array structure produced by the method of the present invention has a wider range of applications and fields.

 detailed description

 The present invention is further described in detail below with reference to specific embodiments, but they are not intended to limit the invention:

 Example 1

 A method for producing a reflective film having a microprism array structure, the method comprising a closed loop Reciprocating annular strip mold, the endless strip mold is preferably a flexible metal strip made of nickel metal material, the mold has an inner surface and an outer surface, and the outer surface has a concave microprism array structure on the outer surface , The method includes the following steps:

 (1) coating a layer of hot-melt resin on one side of the resin film by hot melt coating, the resin film is preferably acrylate material, and the hot melt resin is used. a polycarbonate resin, the hot melt resin has a melt index of 3 g/10 min;

 (2) The side surface of the resin film coated with the hot melt resin is in close contact with the outer surface of the endless belt mold, and then the resin film, the hot melt resin and The annular strip mold is simultaneously molded to fill the gap of the concave microprism array structure under pressure by the hot melt resin in a molten state;

(3) in the engaged state, the hot-melt resin-coated resin film treated by the step (2) and the endless belt-shaped mold are simultaneously cooled, the cooled hot-melt resin, one side surface and the tree The ester film is firmly bonded, and the microprism array structure on the other side surface is simultaneously molded, and the resin film coated with the hot melt resin and the microprism array structure on the hot melt resin layer are formed. The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

 Example 2

 A method for producing a reflective film having a microprism array structure, the method comprising a closed loop a reciprocating cylindrical mold which is preferably a hollow rigid roll made of a steel material having an inner surface and an outer surface. The outer surface has a continuous microprism array structure with a concave shape, and the concave microprism array structure is formed by chemical etching, and the method comprises the following steps:

 (1) coating a layer of hot-melt resin on one side of the resin film by hot melt extrusion, the resin film is preferably a polycarbonate material, and the hot melt resin is used. Acrylate resin, the hot melt resin has a melt index of 40 g/10 min;

 (2) The side surface of the resin film coated with the hot melt resin is in close contact with the outer surface of the annular mold, and a layer is attached to the other side surface of the resin film. a backing film, and then simultaneously molding the resin film, the hot melt resin and the ring mold to which the backing film is attached, so that The hot-melt resin in a molten state fills the gap of the concave microprism display structure under pressure, and the backing film is preferably made of a polyester material;

(3) in the engaged state, the backing film, the resin film coated with the hot-melt resin, and the annular mold, which are treated by the step (2), are simultaneously cooled and cooled, and the cooled hot-melt resin is One side surface and the resin film form a strong bond, and the microprism array structure on the other side surface is simultaneously molded, and the backing film is attached and coated with the resin film of the hot melt resin and the hot melt resin layer. Microprism array structure The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

 Example 3

 A method for producing a reflective film having a microprism array structure, the method comprising a closed loop a reciprocating cylindrical mold, preferably a hollow rigid roll made of a copper material, the mold having an inner surface and an outer surface, The outer surface is provided with a continuous microprism array structure having a concave shape, and the continuous microprism array structure having a concave shape is formed by laser engraving or cutting by a diamond cutter, and the method comprises the following steps:

 ( 1 ) Applying a layer of coupling agent on one side of the resin film to form a strong bond between the coupling agent and the resin film, and then using a hot melt extrusion method on the surface of the resin film coated with the coupling agent. A layer of hot melt resin is applied to bond the hot melt resin to the coupler. The resin film is preferably a composite material of an acrylate material and a polycarbonate material, and the hot melt resin is a mixture of an acrylate resin and a polycarbonate resin. The hot melt resin has a melt index of 10 g/10 min;

 (2) The side surface of the resin film coated with the coupling agent and the hot melt resin is in close contact with the annular mold The outer surface is then simultaneously molded with the resin film, the hot melt resin and the annular mold, so that the molten molten metal ester fills the gap of the concave microprism array structure under pressure;

(3) in the engaged state, the hot-melt resin-coated resin film treated by the step (2) and the annular mold are simultaneously cooled, and the cooled hot-melt resin has a side surface and a resin film. Forming a strong bond, the microprism array structure on the other side surface is simultaneously molded, and the resin film coated with the hot melt resin and the microprism array structure on the hot melt resin layer are formed. The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

 Example 4

 A method for producing a reflective film having a microprism array structure, the method comprising a closed loop a reciprocating cylindrical mold, preferably a hollow rigid roll made of a copper material, the mold having an inner surface and an outer surface, the outer surface of which has a continuous microprism array structure having a concave shape. Description The recessed continuous microprism array structure is assembled from a nickel sheet having a continuous microprism array structure having a concave shape on one side, the method comprising the steps of:

 ( 1 ) Applying a coupling agent on one side of the resin film to form a strong bond between the coupling agent and the resin film, and then hot-melt coating on the surface of the resin film coated with the coupling agent. A layer of hot melt resin is applied to bond the hot melt resin to the coupler. The resin film is preferred Polyester material, polyvinyl chloride material, polyurethane material, polyvinyl alcohol material, polypropylene material, polyethylene material, polyamide material, polystyrene material, composite material of two or more kinds of the above materials, hot melt resin Optional Polyester resin, polyvinyl chloride resin, polyurethane resin, polyvinyl alcohol resin, polypropylene resin, polyethylene resin, polyamide resin, polystyrene resin, vinyl chloride vinyl acetate co-ester, Ethylene vinyl acetate copolymer resin, a mixture of two or more of the above resins, The hot melt resin has a melt index of 20 g/10 min;

 (2) The side surface of the resin film coated with the coupling agent and the hot melt resin is in close contact with the outer surface of the annular mold, in the resin film a backing film is attached to the other side surface, and then the resin film to which the backing film is attached, the hot melt resin and the ring mold are simultaneously molded. The hot-melt resin in a molten state fills the gap of the concave microprism display structure under pressure, and the backing film may be a polypropylene material, a polyamide material, a polyethylene material or a fluorine-containing material;

(3) in the engaged state, the backing film, the resin film coated with the hot-melt resin, and the annular mold, which are treated by the step (2), are simultaneously cooled and cooled, and the cooled hot-melt resin is One side surface and the resin film form a strong bond, and the microprism array structure on the other side surface is simultaneously molded, and the backing film is attached and coated with the resin film of the hot melt resin and the hot melt resin layer. Microprism array structure The laminated film is collectively formed, and the laminated film is a reflective film having a microprism array structure.

In the above, the above description is only the preferred embodiment of the present invention, and all changes and modifications made to the scope of the present invention should be within the scope of the present invention.

Claims (15)

 A method of producing a retroreflective film having a microprism array structure, the method comprising an annular die that reciprocates along a closed loop, The mold has an inner surface and an outer surface, the outer surface of which has a continuous microprism array structure in a concave shape, the method comprising the steps of: (1) coating a layer of a hot melt resin on one side of the resin film; (2) The side surface of the resin film coated with the hot melt resin is in close contact with the outer surface of the annular mold, and then the resin film, the hot melt resin and the annular mold are simultaneously molded. The molten molten metal ester fills the gap of the recessed microprism array structure under pressure; (3) in the engaged state, the hot-melt resin-coated resin film treated by the step (2) and the annular mold are simultaneously cooled, and the cooled hot-melt resin has a side surface and a resin film. Forming a firm bond, the microprism array structure on the other side surface is simultaneously formed, and the resin film coated with the hot melt resin and the microprism array structure on the hot melt resin layer together form a laminate film, the laminate The film is a reflective film having a microprism array structure.  A method of producing a retroreflective film having a microprism array structure according to claim 1, wherein: in addition to the step (2) The side surface of the resin film coated with the hot melt resin is adhered to the outer surface of the annular mold, and a backing film is attached to the other side surface of the resin film. Then, the resin film to which the backing film is attached, the hot melt resin and the annular mold are simultaneously molded, so that the molten molten metal ester fills the gap of the concave microprism display structure under pressure. In the step (3), in the engaged state, the backing film, the resin film coated with the hot melt resin, and the annular mold are simultaneously cooled and cooled. The cooled hot-melt resin has a side surface and a resin film formed firmly bonded, and the microprism array structure on the other side surface is simultaneously molded, and a tree coated with a backing film and coated with a hot melt resin Microprism array structure on ester film and hot melt resin layer The laminate film is collectively formed, and the laminate film is a light-reflecting film having a microprism array structure.  The method for producing a retroreflective film having a microprism array structure according to claim 1 or 2, wherein in the step (1), Before one side surface of the resin film is coated with the hot melt resin, a coupling agent is applied to the side surface of the resin film, and the coupling agent and the resin film form a strong bond, and then coated with On one side of the mixture A layer of hot melt resin is applied to bond the hot melt resin to the coupler.  A method of producing a retroreflective film having a microprism array structure according to claim 1 or 2, wherein the annular die is an endless belt die.  The method for producing a retroreflective film having a microprism array structure according to claim 4, wherein the endless belt mold is a flexible metal strip.  The method for producing a retroreflective film having a microprism array structure according to claim 5, wherein the annular strip mold is made of a nickel metal material.  A method of producing a retroreflective film having a microprism array structure according to claim 1 or 2, wherein the annular die is a cylindrical die. The method for producing a retroreflective film having a microprism array structure according to claim 7, wherein the cylindrical mold is a hollow rigid roller made of a steel or a copper material. The method for producing a reflective film having a microprism array structure according to claim 8, wherein the outer surface of the cylindrical mold has a concave continuous microprism array structure which is chemically etched, laser engraved or Cut with a diamond cutter. The method for producing a retroreflective film having a microprism array structure according to claim 8, wherein the outer surface of the cylindrical mold has a nickel piece having a concave continuous prism array structure on one side surface Assembled. The method for producing a retroreflective film having a microprism array structure according to claim 1, wherein the resin film is made of an acrylate material, a polycarbonate material, a polyester material, a polyvinyl chloride material, Polyurethane material, polyvinyl alcohol material, polypropylene material, polyethylene material, polyamide material, polystyrene material, composite material of two or more kinds of the above materials. The method for producing a retroreflective film having a microprism array structure according to claim 1, wherein the hot-melt resin is made of acrylate resin, polycarbonate resin, polyester resin, and poly Vinyl chloride resin, urethane resin, polyvinyl alcohol resin, polypropylene resin, polyethylene resin, polyamide resin, polystyrene resin, vinyl chloride vinyl acetate copolyester, ethylene vinyl acetate copolymer resin, a mixture of two or more of the above resins. The method for producing a retroreflective film having a microprism array structure according to claim 1, wherein the hot melt resin is coated by hot melt coating or hot melt extrusion. The method for producing a retroreflective film having a microprism array structure according to claim 1 or 2, wherein the hot melt resin has a melt index of from 3 to 40 g/10 min. The method for producing a retroreflective film having a microprism array structure according to claim 2, wherein the backing film is made of a polyester material, a polypropylene material, a polyamide material, a polyethylene material or a fluorine-containing material. material.