Preparation device and method of heterogeneous micro-costal membrane

Abstract

The invention discloses a preparation device and method of a heterogeneous micro-costal membrane. The device is sequentially provided with an unwinding module, a coating module, an imprint curing module, a winding module and a central controller in the advancing direction of a base film, wherein the imprint curing module comprises a first silica gel compression roller, a second silica gel compression roller, a tunable microstructure plate roller, a pre-curing area, a main curing area, a post curing area and a real-time detection feedback system. The tunable microstructure plate roller is composed of a female template roller and a flexible intelligent liner, an array type shape memory alloy driving unit is embedded in the liner, and the geometrical parameters of the millimeter-level micro vortex generator can be adjusted; each curing area is provided with an independent UV light source, and a gradient curing process is adopted. The method comprises the continuous steps of unwinding, corona treatment, precise coating, imprinting gradient curing and winding. The full-process automatic continuous production is realized, the curing internal stress is reduced, the microstructure forming precision, the adhesive strength and the mechanical property of the film are improved, and an efficient preparation scheme is provided for engineering application of the multi-scale heterogeneous micro-costal film.

Description

Technical Field

[0001] This invention relates to the field of thin film preparation technology, and in particular to an apparatus and method for preparing heterogeneous microribbed films. Background Technology

[0002] Microstructured thin films, with their unique surface fluid control capabilities, have broad application prospects in drag reduction, antifouling, anti-icing, and fluid transport. Among them, heterostructured microribbed films, which combine millimeter-scale eddy current generators and micrometer-scale rib structures, can significantly broaden the effective Reynolds number range for flow control through multi-scale coupling, demonstrating great application potential in high-end fields such as natural gas pipelines, aerospace, and marine engineering.

[0003] However, existing microstructure thin film fabrication technologies have many shortcomings. While commonly used methods such as photolithography, laser etching, electroforming, and hot pressing can achieve high-precision microstructures, they generally suffer from complex processes, long production cycles, high manufacturing costs, and limited mold life, and are difficult to implement for large-area continuous production. For products like heterogeneous microfiber films, which exhibit large structural size variations and numerous layer changes, traditional methods face even greater bottlenecks in terms of processing difficulty and precision assurance.

[0004] While existing UV embossing technology offers continuous production capabilities, it is primarily used in low-precision applications such as decorative films and packaging films. Its single-batch, high-intensity exposure curing method is prone to causing rapid polymerization and shrinkage of the UV resin in complex, heterogeneous microfiber films, generating significant internal stress. This leads to microstructural deformation, collapse, or microcracks, severely impacting molding accuracy and structural integrity. Furthermore, the excessively rapid curing rate results in insufficient bonding between the UV oil layer and the base film interface, leading to poor film mechanical strength, abrasion resistance, and service stability, failing to meet the long-term performance requirements of complex fluid environments.

[0005] In summary, current technologies lack a preparation method that can balance the molding precision of complex microstructures, the mechanical properties of materials, and the efficiency of continuous production. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a novel integrated preparation device and method to achieve continuous and stable preparation of high-strength, high-precision, and designable heterogeneous microfiber membranes.

[0007] This invention was made in view of the aforementioned existing conditions, and its purpose is to provide a device for preparing heterogeneous microfiber films, comprising an unwinding module, a coating module, an imprinting and curing module, a rewinding module, and a central controller arranged sequentially along the base film travel direction. The imprinting and curing module includes a first silicone roller, a tunable microstructure roller, a second silicone roller, a pre-curing zone, a main curing zone, a post-curing zone, and a real-time detection and feedback system. The tunable microstructure roller includes a master mold roller and a flexible intelligent pad. The surface of the master mold roller is engraved with a negative mold pattern of the microstructure base outline. The flexible intelligent pad covers the surface of the master mold roller. An array of shape memory alloy driving units is embedded in the flexible intelligent pad in the region corresponding to the target millimeter-level micro eddy current generator structure. The pre-curing zone, main curing zone, and post-curing zone are each equipped with an independent UV light source and a light intensity adjustment device. Each UV light source can emit ultraviolet light of different wavelengths. The pre-curing zone is located below the tunable microstructure roller, and its UV light source is directed towards the UV coating applied by the coating module. After oiling, the oil enters the rolling area between the first silicone roller and the tunable microstructure plate roller, and the oil base film is set after rolling. The first silicone roller and the second silicone roller are both in contact with the tunable microstructure plate roller and rotate in opposite directions at the same speed. The second silicone roller is located on the right side of the tunable microstructure plate roller.

[0008] Therefore, by integrating five core modules—unwinding, coating, imprinting and curing, rewinding, and central control—a fully integrated design for the preparation of heterogeneous microfiber films was achieved. The special structure of the tunable microstructure roller solves the problem of traditional molds being unable to flexibly adjust the geometric parameters of heterogeneous microstructures, adapting to the molding requirements of millimeter-level micro eddy current generators of different specifications. The independent UV light source design for the pre-curing zone, main curing zone, and post-curing zone provides hardware support for the gradient curing process, effectively avoiding the internal stress problem caused by single curing. The reverse rotation of the first and second silicone rollers at the same speed ensures both uniform transmission of imprinting pressure and smooth demolding of the pre-cured base film, guaranteeing the integrity of the microstructure molding.

[0009] The flexible smart pad is made of high-temperature resistant and high-hardness silicone. The shape memory alloy driving unit is electrically connected to the central controller, which can control the shape memory alloy driving unit to undergo controllable deformation through local heating.

[0010] Therefore, the flexible smart pad is made of high-temperature resistant and high-hardness silicone to ensure its structural stability in the high-temperature environment of the UV curing process, while also having sufficient elasticity to adapt to the pressure transmission of the imprinting. The electrical connection design between the shape memory alloy drive unit and the central controller enables precise electrical control adjustment of the geometric parameters of the micro eddy current generator. By activating the controllable deformation of the drive unit through local heating, the pad surface can be flexibly pushed up or pulled down to meet the personalized needs of microstructure size under different working conditions, thereby improving the versatility and adaptability of the device.

[0011] The surfaces of the first and second silicone rollers are made of elastic silicone material, and the UV light intensity of the pre-curing zone, main curing zone, and post-curing zone is independently controlled by the light intensity adjustment device.

[0012] Therefore, the elastic silicone material on the surfaces of the first and second silicone rollers can compensate for the contact deviation between the base film and the printing roller through its own deformation, ensuring that the printing pressure is evenly distributed on the surface of the base film and avoiding the problem of insufficient microstructure filling caused by insufficient local pressure. The independent adjustment function of UV light intensity in the three curing zones can accurately match the gradient curing process requirements of "pre-curing - main curing - post-curing". The low-intensity light in the pre-curing zone realizes the initial shaping of the microstructure, the high-intensity light in the main curing zone completes the core polymerization reaction, and the medium-intensity light in the post-curing zone eliminates internal stress. The light intensity of each stage can be adjusted as needed, which significantly improves the curing quality and structural stability.

[0013] The coating module includes an integrated coating chamber, a first UV scraper, a laser thickness gauge, a zoned coating chamber, a second UV scraper, and a substrate support plate arranged sequentially. The integrated coating chamber is connected to a pressure regulating device, and the first and second UV scrapers are both connected to an automatic lifting mechanism composed of a servo motor and a rack and pinion. The laser thickness gauge is electrically connected to a central controller, and the central controller is electrically connected to the zoned coating chamber. The substrate support plate has a smooth surface and supports the base film during movement.

[0014] Therefore, the "integrated coating + zoned touch-up coating + secondary leveling" structural design of the coating module achieves precise control of the UV oil coating thickness. The integrated coating chamber completes the initial coating through pressure regulation, the first UV scraper performs initial leveling, and the laser thickness gauge detects the thickness distribution in real time and feeds it back to the central controller. The zoned coating chamber precisely touches up areas with insufficient thickness, and the second UV scraper performs secondary leveling to ensure that the UV oil thickness on the base film surface is uniform. The smooth surface of the substrate support plate provides stable support for the coating and leveling process, avoiding base film deformation that affects coating accuracy. This structure effectively solves the problem of uneven thickness in traditional coating processes and lays the foundation for subsequent precise microstructure forming.

[0015] The unwinding module includes a base film output roller, a base film spreading roller, a first tension adjusting roller, and a corona discharge device. The first tension adjusting roller has an arc-shaped layout structure with tension sensors evenly distributed on its surface. The tension sensors and a servo motor control system form a tension adjustment system, and the servo motor control system adjusts the tilt angle of the first tension adjusting roller. The base film spreading roller is located to the lower right of the base film output roller, and the first tension adjusting roller is located to the upper right of the base film spreading roller. The corona discharge device is positioned towards the base film conveyed by the first tension adjusting roller.

[0016] Therefore, the multi-roller collaborative design of the unwinding module ensures the smooth movement of the base film: the positional layout of the base film spreading roller and the first tension adjustment roller forms a large wrap angle, improving the spreading and tension adjustment efficiency; the arc-shaped spreading structure and the evenly distributed tension sensors on the surface of the first tension adjustment roller can detect the tension of the base film in real time and adjust the tilt angle through the servo motor control system to achieve complete spreading of the base film and effectively prevent edge curling; the corona device treats the surface of the base film, significantly improving its surface energy and enhancing the interfacial bonding force between the UV oil and the base film, providing a preliminary guarantee for improving the film adhesion strength.

[0017] The winding module includes a second tension adjusting roller and a paired flexible pressure roller and a base film take-up roller. The flexible pressure roller and the base film take-up roller are in contact and rotate in opposite directions at the same speed.

[0018] Therefore, the second tension adjustment roller can adjust the tension of the base film in real time during the winding process, avoiding stretching or wrinkling of the base film caused by tension fluctuations; the design of the flexible pressure roller and the base film take-up roller rotating in opposite directions at the same speed not only ensures the stability of the winding process, but also plays a slight compaction role on the formed heterogeneous micro-ribbed film, avoiding damage to the microstructure during the winding process, and ensuring the structural integrity and winding quality of the finished film.

[0019] The real-time detection feedback system includes a linear CCD camera and a fiber optic spectrometer, which are respectively positioned in front of the main curing zone and the post-curing zone. The linear CCD camera and the fiber optic spectrometer are electrically connected to the central controller, which is electrically connected to the pressure adjustment components of the first silicone roller and the second silicone roller, as well as the production line speed control component.

[0020] Therefore, the real-time detection and feedback system, through the collaborative operation of a linear CCD camera and a fiber optic spectrometer, achieves dual real-time monitoring of microstructure molding quality and UV curing degree. The linear CCD camera accurately captures the microstructure contour precision, while the fiber optic spectrometer provides real-time feedback on the curing degree. After the detection signal is uploaded to the central controller, it can be used to adjust the pressure of the pressure rollers, UV light intensity, and production speed, forming a closed-loop control system. This ensures that deviations occurring during the production process can be corrected in a timely manner, significantly improving product consistency and yield.

[0021] This invention also provides a method for preparing heterogeneous microribbed membranes, comprising the following steps: S1. The base film is discharged via the base film discharge roller; S2. The base film is initially spread by a base film spreading roller, further spread by a first tension adjusting roller, and then subjected to surface corona treatment by a corona device; S3. The base film is conveyed on the substrate support plate, UV oil is applied to the integrated coating chamber, and the first UV scraper initially smooths it out; S4. The laser thickness gauge measures the thickness of the UV oil and uploads it to the central controller. The central controller feeds back correction information to the partition coating chamber, which then applies additional coating. The second UV scraper smooths the coating a second time. S5. The base film contacts the flexible smart pad, and the first silicone roller applies pressure to fill the microcavity of the flexible smart pad with the UV oil on the surface of the base film. The UV oil forms a microstructure in the microcavity that is complementary to the pattern of the negative mold. S6. The microstructure is pre-cured by UV light irradiation in the pre-curing zone, and demolding is assisted by a second silicone roller; S7. After the real-time detection feedback system detects the microstructure, it adjusts the parameters of the main curing zone, and the main curing zone is irradiated with UV light to basically cure the microstructure; S8. After the real-time detection feedback system detects the microstructure, it adjusts the parameters of the post-curing zone. The post-curing zone is then irradiated with UV light and supplemented with heating to completely cure the microstructure. S9. After passing through the second tension adjusting roller, the base film is wound up by a flexible pressure roller in conjunction with a base film take-up roller.

[0022] Therefore, this preparation method follows a continuous process of "unwinding – precise coating – imprinting – gradient curing – smooth winding," with each step interconnected, achieving automated mass production of heterogeneous microfiber films. The corona treatment in step S2 enhances the surface energy of the base film; the two-stage coating and thickness detection in steps S3-S4 ensure uniform UV oil coating; the imprinting filling in step S5 guarantees complete replication of the microstructure; the gradient curing in steps S6-S8 effectively reduces internal stress; and the smooth winding in step S9 ensures finished product quality. The entire process is seamlessly connected, significantly improving production efficiency while solving the problems of dispersed processes and difficulty in controlling precision in traditional methods.

[0023] The pre-curing zone uses low-intensity, long-wavelength UV light, the main curing zone uses high-intensity, optimal absorption wavelength UV light, and the post-curing zone uses medium-intensity UV light.

[0024] Therefore, the gradient UV light parameter design is adapted to the polymerization reaction characteristics of UV oil: the low-intensity, long-wavelength UV light in the pre-curing zone causes slight cross-linking of the UV oil surface, achieving preliminary microstructure shaping and avoiding structural damage during demolding; the high-intensity, optimal absorption wavelength UV light in the main curing zone rapidly completes the polymerization of most monomers, building a stable microstructure framework; the medium-intensity UV light in the post-curing zone promotes the complete polymerization of unreacted monomers and eliminates the internal stress generated by the previous curing. The three work synergistically to ensure the molding accuracy of the microstructure and significantly improve the mechanical strength and service stability of the film.

[0025] The UV oil comprises polyurethane acrylate, a ternary reactive diluent system, a dual photoinitiator combination, and nano-reinforcing materials.

[0026] Therefore, the specific formulation of UV oil provides a material basis for the high performance of the film: polyurethane acrylate serves as the polymer matrix, providing hardness and structural support; the ternary reactive diluent system constructs a rigid network with high cross-linking density, while also taking into account leveling and flexibility; the dual photoinitiator combination is appropriately matched with the gradient curing process to precisely activate the polymerization reaction under different light intensities and wavelengths; nano-reinforcing materials further enhance the mechanical strength and wear resistance of the film. The synergistic effect of each component enables the prepared heterogeneous microribbed film to have excellent structural integrity, mechanical properties and service stability. Attached Figure Description

[0027] Figure 1 shows a schematic diagram of the heterogeneous microribbed membrane preparation device according to an embodiment of the present invention; Figure 2 shows an isometric side view of the tunable microstructure roller of the heterogeneous microrib film preparation apparatus according to an embodiment of the present invention. Figure 3 shows a cross-sectional view of the tunable microstructure roller of the heterogeneous microribbed film preparation apparatus according to an embodiment of the present invention. Figure 4 shows a flowchart of the method for preparing heterogeneous microribbed membranes according to an embodiment of the present invention. Detailed Implementation

[0028] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description, the same reference numerals are used for the same parts, and repeated descriptions are omitted. Furthermore, the drawings are merely schematic diagrams, and the proportions of the parts or the shapes of the parts may differ from the actual figures.

[0029] As shown in Figures 1 to 3, this invention provides a device 1 for preparing heterogeneous microribbed films, used to achieve continuous roll-to-roll preparation of high-strength heterogeneous microribbed films. The device includes an unwinding module, a coating module, an imprinting and curing module, a winding module, and a central controller 51 arranged sequentially along the base film's travel direction. Each module works collaboratively under the unified control of the central controller 51 to complete the fully automated production process from base film processing to finished product winding.

[0030] (a) Unwinding module The unwinding module includes a base film discharge roller 11, a base film spreading roller 12, a first tension adjusting roller 13, and a corona device 14 arranged in sequence. The base film is made of polyethylene terephthalate (PET) material with a thickness of 100μm, and is discharged from the base film discharge roller 11 by rotating counterclockwise.

[0031] The base film spreading roller 12 is positioned to the lower right of the base film discharge roller 11, and the first tension adjusting roller 13 is positioned to the upper right of the base film spreading roller 12. The two rollers form a large wrap angle design, which respectively improves the initial spreading efficiency and further spreading effect of the base film. The first tension adjusting roller 13 has an arc-shaped layout structure, with tension sensors evenly distributed on its surface. The tension sensors and the servo motor control system constitute a tension adjustment system. The tension sensors collect base film tension data in real time and feed it back to the servo motor control system. The system automatically adjusts the tilt angle of the first tension adjusting roller 13 based on the data to ensure complete spreading of the base film and effectively prevent edge curling.

[0032] The corona device 14 is positioned toward the base film conveyed by the first tension adjusting roller 13 to perform corona treatment on the upper surface of the base film. By increasing the surface energy of the base film, the interfacial bonding force between the subsequent UV oil and the base film is enhanced, laying the foundation for improving the film adhesion strength.

[0033] (ii) Coating module The coating module includes an integrated coating chamber 21, a first UV doctor blade 22, a laser thickness gauge 23, a zoned coating chamber 24, a second UV doctor blade 25, and a substrate support plate 26 arranged sequentially. The substrate support plate 26 has a smooth surface, and the base film moves along its surface throughout the entire coating module, providing stable support for UV oil coating and doctor blade smoothing, and preventing base film deformation from affecting coating accuracy.

[0034] The integrated coating chamber 21 is connected to a pressure regulating device, which adjusts the initial coating thickness of the UV oil by controlling the pressure inside the chamber; the first UV scraper 22 and the second UV scraper 25 are both connected to an automatic lifting mechanism composed of a servo motor and a gear rack, which precisely controls the final thickness of the UV oil on the base film surface by adjusting the height.

[0035] The laser thickness gauge 23 is electrically connected to the central controller 51 to measure the thickness distribution information of the UV oil on the base film after it has been smoothed by the first UV scraper 22 in real time, and uploads the data to the central controller 51. After analyzing and processing the thickness data, the central controller 51 sends correction information to the partition coating chamber 24. The partition coating chamber 24 performs precise supplementary coating on areas with low UV oil thickness. Then, the second UV scraper 25 smooths the UV oil on the base film surface a second time to ensure that the UV oil thickness on the base film surface is uniform.

[0036] (III) Imprinting and Curing Module The imprinting and curing module includes a first silicone roller 31, an adjustable microstructure plate roller 32, a second silicone roller 33, a pre-curing zone 34, a main curing zone 35, a post-curing zone 36, and a real-time detection and feedback system 37, arranged in sequence.

[0037] Both the first silicone roller 31 and the second silicone roller 33 are in contact with the tunable microstructure printing roller 32, and all three rotate in opposite directions at the same speed. The rotation speed matches the base film transfer speed, ensuring that printing and transfer are synchronized. The surfaces of the first silicone roller 31 and the second silicone roller 33 are made of elastic silicone material, which can compensate for contact deviations through its own elastic deformation, ensuring that the printing pressure of the tunable microstructure printing roller 32 on the base film is evenly distributed.

[0038] The tunable microstructure printing roller 32 consists of a master mold roller 322 and a flexible intelligent pad 321. The surface of the master mold roller 322 is engraved with a negative mold pattern of the microstructure base outline. The flexible intelligent pad 321 covers the surface of the master mold roller 322. The flexible intelligent pad 321 is made of high-temperature resistant and high-hardness silicone. An array-type shape memory alloy driving unit is embedded in the area of ​​the negative mold structure of the millimeter-level micro eddy current generator on the master mold roller 322. This driving unit is electrically connected to the central controller 51. The central controller 51 activates the driving unit through local heating, causing it to undergo controllable deformation, thereby pushing up or pulling down the surface of the flexible intelligent pad 321, realizing precise adjustment of the geometric parameters of the micro eddy current generator.

[0039] In some examples, millimeter-scale micro-eddy current generators can be sloped. They can have triangular or trapezoidal cross-sections.

[0040] The pre-curing zone 34, main curing zone 35, and post-curing zone 36 are each equipped with independent UV light sources and intensity adjustment devices. Each UV light source can emit ultraviolet light of different wavelengths, and the light intensity can be independently adjusted through the intensity adjustment device. The pre-curing zone 34 is located below the tunable microstructure roller 32. Its UV light source directly irradiates the oil-coated base film after it has been rolled by the first silicone roller 31 and the tunable microstructure roller 32. Low-intensity, long-wavelength (main peak 365nm) UV light is used to cause slight cross-linking of the UV oil surface layer, initially shaping the microstructure outline. The second silicone roller 33 is located to the right of the tunable microstructure roller 32 and is mainly used for the smooth demolding of the base film after microstructure pre-curing.

[0041] The main curing zone 35 uses high-intensity UV light with the optimal absorption wavelength. Under the control of the real-time detection and feedback system 37, the polymerization reaction of most monomers is completed, resulting in the basic curing of the microstructure. The post-curing zone 36 uses medium-intensity UV light, supplemented by moderate heating (heating temperature controlled at 80~100℃), to promote the complete polymerization of unreacted monomers and eliminate the internal stress generated during the previous curing process, achieving uniform and thorough curing of the microstructure from the surface to the bottom.

[0042] In this embodiment, the optimal absorption wavelength of UV light refers to the wavelength that precisely matches the absorption characteristics of the dual photoinitiator combination (phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide 819 / BAPO and 2-hydroxy-2-methyl-1-phenyl-1-propanone 1173) in the UV oil. This wavelength efficiently excites the dual photoinitiators to synergistically generate active free radicals, promoting the rapid polymerization of most monomers in the UV oil, thereby achieving basic microstructure solidification. The irradiation mode is strong full-spectrum UV or UVV irradiation.

[0043] The real-time detection feedback system 37 includes a linear CCD camera and a fiber optic spectrometer, both of which are respectively set in front of the main curing zone 35 and the post-curing zone 36 (one set in front of each curing zone). The linear CCD camera monitors the microstructure molding quality in real time, and the fiber optic spectrometer monitors the UV oil curing degree in real time. Both are electrically connected to the central controller 51 and upload the detection signals to the central controller 51. Based on the detection signals, the central controller 51 adjusts the pressure between the first silicone roller 31, the second silicone roller 33 and the tunable microstructure roller 32, as well as the UV light intensity and production line speed in the pre-curing zone 34, the main curing zone 35 and the post-curing zone 36, forming a closed-loop control to ensure stable product quality.

[0044] In this embodiment, the production line control component is used to control the speed of the servo motors of the unwinding module and the rewinding module to achieve production line speed control. The central controller 51 may include the production line control component.

[0045] (iv) Rewinding Module In this embodiment, the winding module includes a second tension adjusting roller 41 and a paired flexible pressure roller 42 and a base film take-up roller 43. The flexible pressure roller 42 and the base film take-up roller 43 are in contact and rotate in opposite directions at the same speed, with the rotation speed being the same as the base film transmission speed (0.1m / s), and the rotation speed is controlled by a servo motor.

[0046] After the base film is thoroughly cured in the post-curing zone 36, the winding tension is adjusted by the second tension adjusting roller 41 to avoid tension fluctuations causing the base film to stretch or wrinkle. Then, under the slight compaction of the flexible pressure roller 42, the base film take-up roller 43 smoothly winds it up to complete the preparation of the finished heterogeneous microribbed film.

[0047] In this embodiment, the UV oil formulation is as follows: Polymer matrix: High-functionality polyurethane acrylate (provides skeletal rigidity); The ternary reactive diluent system consists of propoxylated trimethylolpropane triacrylate (TPO3TA, 58 wt%), 1,6-hexanediol diacrylate (HDDA), and isobornyl acrylate (IBOA). These three components work together to construct a rigid network with high cross-linking density, while also ensuring leveling and flexibility. Fluorine-containing low surface energy monomer: reactive fluorinated acrylate (2~3 wt%, reducing surface energy and facilitating demolding); A dual photoinitiator combination: phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (819 / BAPO) and 2-hydroxy-2-methyl-1-phenyl-1-propanone (1173), adapted for gradient curing processes; Nano-reinforcing material: Nano-silica (3 wt%, treated with silane coupling agent to improve mechanical strength and wear resistance); Additives: silicone leveling agent, defoamer, and adhesion promoter (appropriate amount, to optimize coating and curing effects).

[0048] As shown in Figure 4, this embodiment of the invention also provides a method for preparing heterogeneous microribbed membranes, which is implemented using the above-mentioned preparation apparatus, and the specific steps are as follows: S1. The base film is placed on the base film discharge roller 11, and the base film discharge roller 11 rotates counterclockwise to feed the base film out; S2. The base film is first initially spread by the base film spreading roller 12, and then further spread by the first tension adjusting roller 13 to ensure that the base film has no curling edges; then the corona device 14 performs corona treatment on the upper surface of the base film to improve the surface energy of the base film; S3. The base film is smoothly conveyed above the base support plate 26, and the integrated coating chamber 21 applies a UV oil with a specific formula to the entire surface of the base film. The first UV doctor blade 22 performs preliminary smoothing of the UV oil. S4. The laser thickness gauge 23 measures the UV oil thickness distribution information on the base film surface and uploads the data to the central controller 51. After analysis, the central controller 51 sends correction information to the partition coating chamber 24. The partition coating chamber 24 performs secondary coating on the UV oil depression area, and the second UV scraper 25 performs secondary scraping of the UV oil to ensure uniform UV oil thickness. S5. The uniformly coated base film comes into contact with the flexible smart pad 321. Under the pressure of the first silicone roller 31, the UV oil fills the microcavities of the flexible smart pad 321, forming a microstructure that complements the pattern of the negative mold. S6. The microstructure on the surface of the base film is irradiated with low-intensity, long-wavelength UV light in the pre-curing zone 34, causing slight cross-linking of the UV oil surface layer and initially shaping the microstructure outline; then the second silicone roller 33 assists in demolding the base film to avoid damage to the microstructure. S7. Real-time detection feedback system 37 detects the molding quality and curing degree of the microstructure after pre-curing and uploads signals to the central controller 51; the central controller 51 adjusts the UV curing parameters of the main curing zone 35. The main curing zone 35 is irradiated with high-intensity UV light with the best absorption wavelength to complete the polymerization reaction of most monomers and make the microstructure basically cured. S8. The real-time detection feedback system 37 re-detects the microstructure after main curing, and the central controller 51 adjusts the parameters of the post-curing zone 36. The post-curing zone 36 is irradiated with medium-intensity UV light and supplemented with moderate heating to promote the complete polymerization of unreacted monomers, eliminate internal stress, and achieve complete curing of the microstructure. S9. After the base film has been completely cured, the tension is adjusted by the second tension adjusting roller 41, and with the cooperation of the flexible pressure roller 42, the base film take-up roller 43 smoothly winds it up to obtain the finished heterogeneous microribbed film.

[0049] The embodiments described above do not constitute a limitation on the scope of protection of this technical solution. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the above embodiments should be included within the scope of protection of this technical solution.

Claims

1. An apparatus for preparing a heterogeneous micro-ribbed film, characterized by: The application relates to a base film coating and curing device, which comprises unwinding modules, coating modules, impression curing modules, winding modules and a central controller arranged in sequence along the running direction of the base film, wherein the impression curing module comprises a first silica gel compression roller, a tunable microstructure plate roller, a second silica gel compression roller, a pre-curing area, a main curing area, a post-curing area and a real-time detection feedback system; the tunable microstructure plate roller comprises a master template roller and a flexible intelligent pad, the roller surface of the master template roller is engraved with a negative pattern of a microstructure base profile, the flexible intelligent pad is wrapped on the surface of the master template roller, arrayed shape memory alloy driving units are embedded in the area corresponding to target millimeter-level micro vortex generator structures in the flexible intelligent pad, the pre-curing area, the main curing area and the post-curing area are all provided with independent UV light sources and light intensity adjusting devices, each UV light source can emit ultraviolet rays with different wavelengths, the pre-curing area is located below the tunable microstructure plate roller, the UV light source of the pre-curing area is arranged towards the base film entering the roller pressing area of the first silica gel compression roller and the tunable microstructure plate roller after being coated with UV oil by the coating module, and the base film after roller pressing is arranged; the first silica gel compression roller and the second silica gel compression roller are attached to the tunable microstructure plate roller and rotate at the same speed in opposite directions, and the second silica gel compression roller is located on the right side of the tunable microstructure plate roller.

2. The apparatus for preparing a heterogeneous micro-ribbed film according to claim 1, characterized in that: The flexible intelligent pad is made of high-temperature-resistant and high-hardness silica gel, the shape memory alloy driving units are electrically connected with the central controller, and the central controller can control the shape memory alloy driving units to occur controllable deformation through local heating.

3. The apparatus for preparing a heterogeneous micro-ribbed film according to claim 1, wherein: The surfaces of the first silica gel compression roller and the second silica gel compression roller are made of elastic silica gel material, and the UV light intensity of the pre-curing area, the main curing area and the post-curing area is independently adjusted by the light intensity adjusting devices.

4. The apparatus for preparing a heterogeneous micro-ribbed film according to claim 1, wherein: The coating module comprises integrated coating bins, first UV scrapers, laser thickness gauges, partitioned coating bins, second UV scrapers and base support plates arranged in sequence; the integrated coating bins are connected with pressure adjusting devices, the first UV scrapers and the second UV scrapers are connected with automatic lifting mechanisms composed of servo motors and gear racks; the laser thickness gauges are electrically connected with the central controller, the central controller is electrically connected with the partitioned coating bins, and the surface of the base support plate is smooth and supports the running base film.

5. The apparatus for preparing a heterogeneous micro-ribbed film according to claim 1, wherein: The unwinding module comprises a base film discharge roller, a base film spreading roller, a first tension adjusting roller and a corona device; the first tension adjusting roller is an arc lofting structure, and the surface of the first tension adjusting roller is uniformly distributed with tension sensors; the tension sensors and a servo motor control system constitute a tension adjusting system, and the servo motor control system adjusts the inclination angle of the first tension adjusting roller; the base film spreading roller is located below and right of the base film discharge roller, the first tension adjusting roller is located above and right of the base film spreading roller, and the corona device is arranged towards the base film conveyed by the first tension adjusting roller.

6. The apparatus for preparing a heterogeneous micro-ribbed film of claim 1, wherein: The winding module comprises a second tension adjusting roller and a pair of flexible compression rollers and base film collecting rollers arranged oppositely, and the flexible compression rollers and the base film collecting rollers are attached and rotate at the same speed in opposite directions.

7. The apparatus for preparing a heterogeneous micro-ribbed film of claim 1, wherein: The real-time detection feedback system comprises a linear array CCD camera and a fiber spectrometer, both of which are arranged in front of the main curing area and the post-curing area; the linear array CCD camera and the fiber spectrometer are electrically connected with the central controller, and the central controller is electrically connected with the pressure adjusting assembly of the first silica gel compression roller and the second silica gel compression roller and the production line speed regulating assembly.

8. A method of making a heterogeneous micro-ribbed film, the method comprising: The application of the device according to claim 1 comprises the following steps: S1. The base film is discharged through a base film discharge roller; S2. The base film is sequentially preliminarily spread through a base film spreading roller, further spread through a first tension adjusting roller, and then subjected to surface corona treatment through a corona device; S3. The base film is conveyed on a base support plate, a UV oil is coated by an integrated coating bin, and a first UV scraper is used for preliminary leveling; S4. A laser thickness gauge measures the thickness of the UV oil and uploads the central controller, and the central controller feeds back correction information to a partitioned coating bin, which is supplemented with coating, and a second UV scraper is used for secondary leveling; S5. The base film contacts the flexible intelligent pad, the first silica gel compression roller applies pressure, so that the UV oil on the surface of the base film fills into the microcavity outside the flexible intelligent pad, and the UV oil forms a microstructure complementary to the negative mold pattern in the microcavity; S6. The microstructure is pre-cured by UV irradiation in the pre-curing area, and the second silica gel compression roller assists in demolding; S7. The real-time detection feedback system detects the microstructure and adjusts the parameters of the main curing area, and the microstructure is substantially cured by UV irradiation in the main curing area; S8. The real-time detection feedback system detects the microstructure and adjusts the parameters of the post-curing area, and the microstructure is completely cured by UV irradiation and heating in the post-curing area; S9. The base film is wound by a flexible compression roller after passing through a second tension adjusting roller and a base film take-up roller.

9. The method of claim 8, wherein: The pre-curing area uses low-intensity and long-wavelength UV light, the main curing area uses high-intensity and best-absorbing-wavelength UV light, and the post-curing area uses medium-intensity UV light.

10. The method of claim 8, wherein: The UV oil comprises polyurethane acrylate, a ternary active diluent system, a combination of dual photoinitiators, and nano-enhancing materials.

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