Method of manufacturing resin film, and metal mold

Abstract

To provide a method of manufacturing a resin film capable of providing the resin film with water repellency, hydrophilicity and / or antiviral properties by providing at least a part of surface of the resin film with a roughened shape.SOLUTION: A method of manufacturing a resin film having a roughened shape at least on a part of a surface of the resin film has a transfer step of transferring a roughened shape of a roughened surface to the resin film by bringing a metal mold having the roughened surface at least on a part of the surface into contact with the resin film. The roughened surface of the metal mold has a developed area ratio (Sdr) measured in accordance with ISO 25178 of 0.094 to 0.4285, and a root mean square gradient (Sdq) of 0.14 to 0.99.SELECTED DRAWING: Figure 14

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a resin film and a metal mold.

Background Art

[0002] Resin films are required to have many characteristics depending on their applications. For example, there are various applications for resin films with high water repellency or hydrophilicity. In recent years, in order to prevent the spread of COVID-19, so-called novel coronavirus infections, and seasonal influenza, it may be required to impart antiviral properties to the surface of resin films that are touched by hand.

[0003] Patent Document 1 below describes an antiviral surface treatment method in which a shot material is projected onto the surface of a member (hereinafter also referred to as "blasting treatment") to randomly form innumerable minute irregularities having a specific uneven pitch width and the width of the depth of the recesses, thereby imparting an antiviral action to the surface of the member.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] As an evaluation criterion for antiviral properties, there is an "antiviral activity value." In the technology described in Patent Document 1, the comparison target (stainless steel plate material) does not exhibit antiviral properties, but when an antiviral surface treatment method is applied, the antiviral activity value shows 0.4 to 0.7 after 24 hours at 25°C. However, as a result of the study by the present inventors, in the case of the blasting treatment, due to the projection treatment of shot materials onto the surface of the member, only a convex shape can be imparted to the back surface of the member. Therefore, the antiviral properties obtained by the technology described in Patent Document 1 are insufficient, and it has been found that it is necessary to further improve the antiviral properties.

[0006] In addition, Patent Document 1 does not describe or suggest anything about imparting water repellency or hydrophilicity to the resin film.

[0007] In view of the above, an object of the present invention is to provide a method for manufacturing a resin film capable of imparting water repellency, hydrophilicity, and / or antiviral properties to the resin film by imparting a roughened shape to at least a part of the surface of the resin film. Further, an object of the present invention is to provide a metal mold for forming a roughened shape on at least a part of the surface of the resin film, and capable of imparting water repellency, hydrophilicity, and / or antiviral properties to the resin film by imparting a roughened shape to at least a part of the surface of the resin film.

Means for Solving the Problems

[0008] The above problems can be solved by the following configuration. The present invention is a method for manufacturing a resin film having a roughened shape on at least a part of the surface of the resin film, comprising a transfer step of bringing a metal mold having a roughened surface on at least a part of the surface into contact with the resin film to transfer the roughened shape of the roughened surface to the resin film, wherein the roughened surface of the metal mold has a developed area ratio (Sdr) measured in accordance with ISO25178 of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5, and relates to a method for manufacturing a resin film (1).

[0009] In the manufacturing method (1) of the resin film, in the transfer step, a manufacturing method (2) of the resin film for imparting water repellency to at least a part of the surface of the resin film is preferable.

[0010] In the manufacturing method (2) of the resin film, a manufacturing method (3) of the resin film in which the contact angle of the resin film with water before the transfer step is 90° or more is preferable.

[0011] In the manufacturing method (1) of the resin film, in the transfer step, a manufacturing method (4) of the resin film for imparting hydrophilicity to at least a part of the surface of the resin film is preferable.

[0012] In the manufacturing method (4) of the resin film, a manufacturing method (5) of the resin film in which the contact angle of the resin film with water before the transfer step is 90° or less is preferable.

[0013] In the manufacturing method (1) of the resin film, in the transfer step, a manufacturing method (6) of the resin film for imparting antiviral properties to at least a part of the surface of the resin film is preferable.

[0014] The present invention also relates to a metal mold for forming a roughened shape on at least a part of the surface of a resin film. The metal mold has, on at least a part of the surface, a roughened surface for transferring the roughened shape to the resin film. The roughened surface has a developed area ratio (Sdr) of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5 as measured in accordance with ISO25178. The present invention relates to a metal mold (7).

Advantages of the Invention

[0015] In the method for manufacturing a resin film according to the present invention, there is a transfer step of bringing a metal mold having a roughened surface into contact with the resin film to transfer the roughened shape of the roughened surface to the resin film. Here, in the method for manufacturing a resin film according to the present invention, the roughened surface of the metal mold is designed such that the developed area ratio (Sdr) measured in accordance with ISO25178 is 0.005 to 0.5 and the root mean square slope (Sdq) is 0.1 to 1.5. Thereby, water repellency, hydrophilicity, and / or antiviral properties can be imparted to the resin film.

Brief Description of the Drawings

[0016]

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BEST MODE FOR CARRYING OUT THE INVENTION

[0017] In the method for manufacturing a resin film according to the present invention, a resin film exhibiting water repellency, hydrophilicity and / or antiviral properties is manufactured by having a roughened shape on at least a part of the surface. The method for manufacturing a resin film according to the present invention has a transfer step of transferring the roughened shape of the roughened surface to the resin film by bringing a metal mold having a roughened surface into contact with the resin film at least on a part of the surface. The roughened surface of the metal mold used in the transfer step has a developed area ratio (Sdr) measured in accordance with ISO25178 of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5.

[0018] In the method for manufacturing a resin film according to the present invention, various resin films can be used as raw materials in order to advantageously impart desired water repellency, hydrophilicity, and / or antiviral properties. For example, when imparting water repellency to at least a part of the surface of the resin film, it is preferable to use a resin film having a contact angle with water of 90° or more as the raw material. Examples of such resin films include polypropylene (PP) films. Further, for example, when imparting hydrophilicity to at least a part of the surface of the resin film, it is preferable to use a resin film having a contact angle with water of 90° or less as the raw material. Examples of such resin films include poly(meth)acrylic films.

[0019] Also, for example, when imparting antiviral properties to at least a part of the surface of the resin film, examples of resin films that can be used as raw materials include thermoplastic resins, thermosetting resins, or UV curable resins. Examples of thermoplastic resins include general-purpose plastics such as polypropylene, polyacrylic resins, and ABS resins; engineering plastics such as 6 nylon, 66 nylon, polyacetal, polycarbonate, polybutylene terephthalate, and modified polyphenylene ether; and super engineering plastics such as polyphenylene ether, liquid crystal polymer, and polyetherimide. Examples of thermosetting resins include phenol resins, urea resins, melamine resins, epoxy resins, unsaturated polyester resins, polyurethane resins, diallyl phthalate resins, silicone resins, and alkyd resins. Examples of UV curable resins include acrylic resins and epoxy resins.

[0020] Next, the metal mold used in the transfer process will be described.

[0021] In the transfer step of the method for manufacturing a resin film according to the present invention, the metal mold used has a roughened surface on at least a part of the surface. The specific properties of the roughened surface will be described separately. Examples of the metal member constituting the metal mold include aluminum, aluminum alloy, copper, copper alloy, nickel, nickel alloy, stainless steel, titanium, titanium alloy, iron, or iron alloy. Among these, in the present invention, it is preferable to use aluminum, aluminum alloy, copper, or copper alloy as the metal member, and it is more preferable to use copper or copper alloy. The shape and size of the metal mold can be appropriately designed according to the use of the resin film to which water repellency, hydrophilicity, and / or antiviral properties are imparted.

[0022] Examples of the step of forming a roughened surface on at least a part or all of the surface of the metal mold include a roughening treatment step of bringing a micro-etching agent into contact with the surface of the metal member to form a roughened surface on the surface of the metal member.

[0023] As the micro-etching agent used in the roughening treatment step, for example, an organic acid-based micro-etching agent, an inorganic acid-based micro-etching agent, an alkali-based micro-etching agent, or a hydrogen peroxide-based micro-etching agent can be used.

[0024] Examples of the organic acid-based micro-etching agent include a micro-etching agent composed of an aqueous solution containing an organic acid, a metal ion source, a halide ion source, and the like.

[0025] Examples of the inorganic acid-based micro-etching agent include a micro-etching agent composed of an acidic aqueous solution containing an inorganic acid, a metal ion source, a halide ion source, and the like.

[0026] Examples of the alkali-based micro-etching agent include a micro-etching agent composed of an aqueous solution containing an alkali source, an amphoteric metal ion source, nitrate ions, a thio compound, and the like.

[0027] Examples of the hydrogen peroxide-based microetching agent include a microetching agent composed of an aqueous solution containing hydrogen peroxide and sulfuric acid as main components.

[0028] The roughening treatment step may be carried out in one step. However, in order to make the properties of the roughened surface of the metal mold to be manufactured more preferable, it is preferably carried out in two steps, and particularly preferably carried out in three steps including a pretreatment step, a main treatment step, and a post-treatment step. Hereinafter, an embodiment of carrying out the roughening treatment step in three steps will be described.

[0029] In the pretreatment step, for example, a step of immersing at least the treatment surface of the metal member in an alkaline soft etching agent such as a hydrogen peroxide-based soft etching agent composed of an aqueous solution containing dilute nitric acid, hydrogen peroxide, and sulfuric acid as main components, the above-mentioned alkali source, an amphoteric metal ion source, nitrate ions, a thio compound, etc. can be exemplified. As the treatment temperature, for example, 15 to 40°C, and as the treatment time, about 3 seconds to 10 minutes can be exemplified.

[0030] In the main treatment step, a step of immersing at least the treatment surface of the metal member in the above-mentioned organic acid-based microetching agent, inorganic acid-based microetching agent, alkaline microetching agent, or hydrogen peroxide-based microetching agent, etc. can be exemplified. As the treatment temperature, for example, 10 to 40°C, and as the treatment time, about 5 seconds to 10 minutes can be exemplified.

[0031] In the post-treatment step, a step of immersing at least the treatment surface of the metal member in, for example, dilute nitric acid, etc. can be exemplified. As the treatment temperature, for example, 15 to 40°C, and as the treatment time, about 3 to 40 seconds can be exemplified.

[0032] After the roughening treatment step, a roughened surface with a developed area ratio (Sdr) measured in accordance with ISO 25178 of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5 can be formed on the surface of the metal member. The developed area ratio (Sdr) and the root mean square slope (Sdq) of the roughened surface formed on the surface of the metal member can be adjusted by changing the type of micro-etching agent in the above-mentioned roughening treatment step and the treatment time and / or temperature of the roughening treatment step (1 step, 2 steps and / or 3 steps) to arbitrary conditions. In order to impart higher levels of water repellency, hydrophilicity and / or antiviral properties to the resin film, it is more preferable that the roughened surface provided on the metal mold has a developed area ratio (Sdr) measured in accordance with ISO 25178 of 0.0094 to 0.4285 and a root mean square slope (Sdq) of 0.14 to 0.99.

[0033] Next, the transfer step of the method for manufacturing a resin film according to the present invention will be described. In the transfer step, the roughened shape of the roughened surface is transferred to the resin film by bringing a metal mold having a roughened surface on at least a part of its surface into contact with the resin film.

[0034] As a method of transferring the roughened shape of the roughened surface provided on the metal mold to the resin film by bringing the metal mold into contact with the resin film, for example, a method of overlapping the roughened surface of the metal mold and the surface of the resin film to which water repellent treatment, hydrophilic treatment and / or antiviral treatment is applied and performing hot pressing using a press machine can be mentioned. On the other hand, as a method of transferring the roughened shape of the roughened surface provided on the surface of the metal mold to the surface of a thermosetting resin or a UV curable resin, for example, a mold including at least the roughened surface of the metal mold is formed, and the raw material components of the thermosetting resin or the UV curable resin are poured into this, and after curing, the resin film is demolded, so that the roughened shape formed on the surface of the metal member is transferred to the surface of the thermosetting resin or the UV curable resin.

[0035] After the transfer process, a complex roughened shape is formed on the surface of the resin film. Specific examples of the complex roughened shape formed on the surface of the resin member after the transfer process will be described later.

[0036] In the method for manufacturing a resin film according to the present invention, water repellency, hydrophilicity, and / or antiviral properties can be imparted to the resin film. In the present invention, the water repellency of the resin film is evaluated by the contact angle with water. Specifically, in the present invention, when the contact angle is 10° or more higher than the contact angle of the untreated resin film before the transfer process, it is considered that water repellency has been imparted. In the present invention, particularly when a resin film having a contact angle with water exceeding 110° is manufactured, such a resin film is preferable because it has particularly excellent water repellency. Also, in the present invention, the water repellency of the resin film is also evaluated by the contact angle with water. When the contact angle is 10° or more lower than the contact angle of the untreated resin film before the transfer process, it is considered that water repellency has been imparted. In the present invention, particularly when a resin film having a contact angle with water of 70° or less is manufactured, such a resin film is preferable because it has particularly excellent hydrophilicity.

[0037] Further, by the method for manufacturing a resin film according to the present invention, a resin film having excellent antiviral properties can be manufactured. The antiviral activity value indicating the degree of antiviral properties can be calculated from the following calculation formula with reference to JIS R1756:2020 (Visible light-responsive photocatalyst, antiviral, film adhesion method). V D =Log(B D ) - Log(C D ) (1) In the above formula (1), V D represents the antiviral activity value, D represents the dark place, B represents the infection titer of the non-processed product, and C represents the infection titer of the processed product.

[0038] As described above, a resin film excellent in antiviral properties can be produced by the method for producing a resin film according to the present invention. Therefore, the method for producing a resin film according to the present invention is also useful as a treatment method for imparting antiviral properties to resin films used in home appliances, housing building materials / equipment, toilet-related facilities / supplies, kitchen-related facilities / supplies, bathroom-related facilities / supplies, office equipment / office supplies, printing (printed matter, laminated processed products, paper), transportation equipment, industrial equipment / industrial supplies (packaging materials / films for films, foods, etc., packaging materials), medical care / health, communication-related accessories, pet supplies, daily necessities (shoes, cleaning supplies, cosmetics, etc.).

Example

[0039] An example of an embodiment according to the present invention will be described below, but the present invention is not limited to such description.

[0040] [[ID=ll]]<Method for Measuring Developed Area Ratio (Sdr) and Root Mean Square Slope (Sdq) of Roughened Surface of Metal Mold> Using a confocal microscope (Hybrid Laser Microscope OPTELICS HYBRID+) manufactured by Lasertec, the developed area ratio (Sdr) and root mean square slope (Sdq) of the roughened surface of the metal mold were measured in accordance with ISO 25178. In the measurement, a cut-off value was set using an S filter (0.0025 mm) and an L filter (0.08 mm) for measurement.

[0041] [Manufacturing Example of Metal Mold (Example of Formation of Roughened Surface)] First, a copper plate without a roughened shape (untreated) was prepared. Figure 1 shows a scanning electron micrograph (magnification 1500 times) of the surface of the copper plate without a roughened shape (untreated), and Figure 2 shows a scanning electron micrograph (magnification 5000 times) of the surface of the copper plate without a roughened shape (untreated). By subjecting the untreated copper plate to a roughening treatment process, at least a part of the surface has a metal mold A with a roughened surface having a roughened shape A, a metal mold B with a roughened surface having a roughened shape B, a metal mold C with a roughened surface having a roughened shape C, and a metal mold D with a roughened surface having a roughened shape D. Figure 3 shows a scanning electron micrograph (magnification 1500 times) of the surface of the copper plate (metal mold A) having a roughened shape A, Figure 4 shows a scanning electron micrograph (magnification 5000 times) of the surface of the copper plate (metal mold A) having a roughened shape A, Figure 5 shows a scanning electron micrograph (magnification 1500 times) of the surface of the copper plate (metal mold B) having a roughened shape B, Figure 6 shows a scanning electron micrograph (magnification 5000 times) of the surface of the copper plate (metal mold B) having a roughened shape B, Figure 7 shows a scanning electron micrograph (magnification 1500 times) of the surface of the copper plate (metal mold C) having a roughened shape C, Figure 8 shows a scanning electron micrograph (magnification 5000 times) of the surface of the copper plate (metal mold C) having a roughened shape C, Figure 9 shows a scanning electron micrograph (magnification 1500 times) of the surface of the copper plate (metal mold D) having a roughened shape D, and Figure 10 shows a scanning electron micrograph (magnification 5000 times) of the surface of the copper plate (metal mold D) having a roughened shape D. The details of the roughening treatment process applied to the metal mold A, metal mold B, metal mold C, and metal mold D are shown below.

[0042] [Roughening Treatment Process of Metal Mold A] For an unused copper plate (100 mm × 100 mm × t1.3 mm), a roughening treatment process (three steps: a pretreatment step, a main treatment step, and a post-treatment step) was carried out under the following conditions. The conditions for each step are shown below. (Pretreatment Step) Using a sulfuric acid / hydrogen peroxide-based soft etching agent, the surface of the copper plate to be treated was spray-treated. Treatment temperature: 25°C. Treatment time: 20 seconds. (Main Treatment Step) Following the pretreatment, the surface of the copper plate to be treated is spray-treated with an inorganic acid-based micro-etching agent (a micro-etching agent composed of an aqueous solution containing an inorganic acid, a metal ion source, a halide ion source, etc.). Treatment temperature: 30 °C. Treatment time: 50 seconds. (Post-treatment step) Following this treatment, the surface of the copper plate to be treated is spray-treated with dilute hydrochloric acid. Treatment temperature: 25 °C. Treatment time: 15 seconds. Table 1 shows the developed area ratio (Sdr) and the root mean square slope (Sdq) of the roughened surface of the metal mold A obtained after the roughening treatment step.

[0043] [Roughening treatment process of metal mold B] For an unused copper plate (100 mm × 100 mm × t 1.3 mm), a roughening treatment process (three steps: pretreatment step, main treatment step, and post-treatment step) was carried out under the following conditions. The conditions for each step are shown below. (Pretreatment step) The surface of the copper plate to be treated is spray-treated with a sulfuric acid / hydrogen peroxide-based soft etching agent. Treatment temperature: 25 °C. Treatment time: 20 seconds. (Main treatment step) Following the pretreatment, the surface of the copper plate to be treated is spray-treated with an inorganic acid-based micro-etching agent (a micro-etching agent composed of an aqueous solution containing an inorganic acid, a metal ion source, a halide ion source, etc.). Treatment temperature: 30 °C. Treatment time: 50 seconds. (Post-treatment step) Following this treatment, the surface of the copper plate to be treated is spray-treated with dilute hydrochloric acid. Treatment temperature: 25 °C. Treatment time: 15 seconds. Table 1 shows the developed area ratio (Sdr) and the root mean square slope (Sdq) of the roughened surface of the metal mold B obtained after the roughening treatment step.

[0044] [Roughening treatment process of metal mold C] For an unused copper plate (100 mm × 100 mm × t 1.3 mm), a roughening treatment process (three steps: pretreatment step, main treatment step, and post-treatment step) was carried out under the following conditions. The conditions for each step are shown below. (This processing step) Following the pretreatment, the surface of the copper plate to be processed is spray-treated using a sulfuric acid / hydrogen peroxide-based micro-etching agent. Processing temperature: 30 °C. Processing time: 50 seconds. Table 1 shows the developed area ratio (Sdr) and the root mean square slope (Sdq) of the roughened surface of the metal mold C obtained after the roughening treatment step.

[0045] [Roughening treatment step of metal mold D] For an unused copper plate (100 mm × 100 mm × t 1.3 mm), a roughening treatment step (three steps: pretreatment step, this processing step, and post-treatment step) was carried out under the following conditions. The conditions for each step are shown below. (Pretreatment step) The surface of the copper plate to be processed is spray-treated using a sulfuric acid peroxide-based soft etching agent. Processing temperature: 25 °C. Processing time: 20 seconds. (This processing step) Following the pretreatment, the surface of the copper plate to be processed is spray-treated using an organic acid-based micro-etching agent (a micro-etching agent composed of an aqueous solution containing an organic acid, a metal ion source, a halide ion source, etc.). Processing temperature: 30 °C. Processing time: 50 seconds. (Post-treatment step) Following this processing, the surface of the copper plate to be processed is spray-treated using dilute hydrochloric acid. Processing temperature: 25 °C. Processing time: 15 seconds. Table 1 shows the developed area ratio (Sdr) and the root mean square slope (Sdq) of the roughened surface of the metal mold D obtained after the roughening treatment step.

[0046]

Table 1

[0047] [Method for measuring the contact angle of the resin film with water] The contact angle of the resin film with water was measured under the following conditions. Measuring instrument; Automatic contact angle meter (DM-501) manufactured by Kyowa Interface Science Measuring conditions; Measuring solvent DI water Measurement method: Contact angle immediately after droplet placement Liquid volume: 2.0 μL Analysis method: Droplet method, θ / 2 method

[0048] [Transfer process of resin film (hydrophobicity imparting)] A polypropylene film (PP film) was prepared as the resin film. The contact angle of the untreated PP film before the transfer process was 96°. The transfer process was carried out on the untreated PP film by the following method. The roughened surfaces of metal molds A, B, C, and D were overlapped with the surface of the untreated polypropylene film (PP film) before the transfer process to be subjected to the water-repellent treatment, and heat pressing was performed using a press machine, whereby the roughened shapes of metal molds A, B, C, and D were transferred to the untreated polypropylene film (PP film). Table 4 shows the heat pressing conditions.

[0049] Example 1 By carrying out the above transfer process using metal mold A, a resin film (PP film) according to Example 1 was produced. FIG. 11 shows a scanning electron micrograph (magnification 1500 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold A) having the roughened shape A, and FIG. 12 shows a scanning electron micrograph (magnification 5000 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold A) having the roughened shape A. The contact angle of the resin film (PP film) obtained after the transfer process was 116°, indicating high water repellency.

[0050] Example 2 By carrying out the above transfer process using the metal mold B, a resin film (PP film) according to Example 2 was manufactured. Fig. 13 shows a scanning electron micrograph (magnification 1500 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold B) having the roughened shape B, and Fig. 14 shows a scanning electron micrograph (magnification 5000 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold B) having the roughened shape B. The contact angle of the resin film (PP film) obtained after the transfer process was 118°, indicating high water repellency.

[0051] Example 3 By carrying out the above transfer process using the metal mold C, a resin film (PP film) according to Example 3 was manufactured. Fig. 15 shows a scanning electron micrograph (magnification 1500 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold C) having the roughened shape C, and Fig. 16 shows a scanning electron micrograph (magnification 5000 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold C) having the roughened shape C. The contact angle of the resin film (PP film) obtained after the transfer process was 124°, indicating high water repellency.

[0052] Example 4 By carrying out the above transfer process using the metal mold D, a resin film (PP film) according to Example 4 was manufactured. Fig. 17 shows a scanning electron micrograph (magnification 1500 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold D) having the roughened shape D, and Fig. 18 shows a scanning electron micrograph (magnification 5000 times) of the surface of the resin film (PP film) on which the transfer process was carried out using a copper plate (metal mold A) having the roughened shape D. The contact angle of the resin film (PP film) obtained after the transfer process exceeded 140°, indicating high water repellency.

[0053] Table 2 shows the contact angles of the untreated PP film before the transfer process (Comparative Example 1) and the contact angles of the PP films on which the transfer process was carried out in Examples 1 to 4. It can be seen that in any of Examples 1 to 4, the contact angle of the PP film is 10° or more higher, indicating that excellent water repellency can be imparted.

[0054]

Table 2

[0055] [Transfer process of resin film (imparting hydrophilicity)] A poly(meth)acrylic film (Acryl film) was prepared as the resin film. The contact angle of the untreated Acryl film before the transfer process was 84°. The transfer process was carried out on the untreated Acryl film by the following method. The Acryl raw material component was poured onto the roughened surfaces of metal molds A, B, C, and D, and after UV curing, the resin film was demolded to produce films on which the roughened shapes of metal molds A, B, C, and D were transferred. Table 4 shows the hot pressing conditions.

[0056] Example 5 By carrying out the above transfer process using metal mold A, a resin film (Acryl film) according to Example 5 was manufactured. Fig. 19 shows a scanning electron micrograph (magnification 1500 times) of the surface of the resin film (Acryl film) on which the transfer process was carried out using a copper plate (metal mold A) having roughened shape A, and Fig. 20 shows a scanning electron micrograph (magnification 5000 times) of the surface of the resin film (Acryl film) on which the transfer process was carried out using a copper plate (metal mold A) having roughened shape A. The contact angle of the resin film (Acryl film) obtained after the transfer process was 65°, indicating high hydrophilicity.

[0057] Example 6 By performing the above transfer process using the metal mold B, a resin film (Acryl film) according to Example 6 was manufactured. FIG. 21 shows a scanning electron micrograph (magnification 1500 times) of the surface of a resin film (Acryl film) obtained by performing the transfer process using a copper plate (metal mold B) having a roughened shape B, and FIG. 22 shows a scanning electron micrograph (magnification 5000 times) of the surface of a resin film (Acryl film) obtained by performing the transfer process using a copper plate (metal mold B) having a roughened shape B. The contact angle of the resin film (Acryl film) obtained after the transfer process was 46°, indicating high hydrophilicity.

[0058] Table 3 shows the contact angles of the untreated Acryl film before the transfer process (Comparative Example 2) and the Acryl films on which the transfer process was performed in Examples 5 to 6. It can be seen that in any of Examples 5 to 6, the contact angle of the Acryl film was lowered by 10° or more, indicating that excellent hydrophilicity could be imparted.

[0059]

Table 3

[0060] [Transfer Process of Resin Film (Virus Resistance Imparting)] The roughened surfaces of metal molds A, B, C, and D were overlapped with the surfaces of the untreated resin films (polypropylene film (PP film) and poly(meth)acrylic film (Acryl film)) to be subjected to antiviral treatment before the transfer process, and heat pressing was performed using a press machine. Thus, a transfer process was carried out to transfer the roughened shapes of metal molds A, B, C, and D to the untreated resin films (polypropylene film (PP film) and poly(meth)acrylic film (Acryl film)). Table 4 shows the heat pressing conditions.

[0061]

Table 4

[0062] Examples 7 - 8 By carrying out the above transfer process using the metal mold B, the resin films (PP films) according to Examples 7 to 8 were manufactured. Example 9 By carrying out the above transfer process using the metal mold C, the resin film (PP film) according to Example 9 was manufactured. Examples 10 to 11 By carrying out the above transfer process using the metal mold D, the resin films (PP films) according to Examples 10 to 11 were manufactured.

[0063] Examples 12 to 13 By carrying out the above transfer process using the metal mold A, the resin films (Acryl films) according to Examples 12 to 13 were manufactured. Examples 14 to 15 By carrying out the above transfer process using the metal mold B, the resin films (Acryl films) according to Examples 14 to 15 were manufactured. Examples 16 to 17 By carrying out the above transfer process using the metal mold C, the resin films (Acryl films) according to Examples 16 to 17 were manufactured. Example 18 By carrying out the above transfer process using the metal mold D, the resin film (Acryl film) according to Example 18 was manufactured.

[0064] <Antiviral property evaluation> Using Ref.(-)(glass plate) as the unprocessed product, the antiviral properties of the resin films (polypropylene films (PP films) and poly(meth)acrylic films (Acryl films)) manufactured in Examples 7 to 18 were evaluated under the following conditions. [Test standard] Refer to JIS R1756:2020 (Visible light-responsive photocatalyst, antiviral, film adhesion method). [Name of unprocessed product] Ref.(-)(glass plate) [Name of test product] Resin films produced in Examples 7 to 18 (polypropylene film (PP film) and poly(meth)acrylic film (Acryl film)) [Size of test samples (PP film and Acryl film)] 50 mm × 50 mm × t ≤ 1 mm [Number of n] n = 1 [Test phage] · Bacteriophage Qβ (NBRC 20012) [host Escherichia coli (NBRC 106373)]; The results are shown in Tables 5 and 7. · Bacteriophage φ6 (NBRC 105899, outside JIS standard) [host Pseudomonas syringae (NBRC 14084)]; The results are shown in Tables 6 and 8. [Diluent of test phage] 1 / 500 NB [Sterilization of test samples] Sterilization with UV 254 nm (15 minutes each for front and back) [Action conditions] Temperature 25°C, dark place, action time 0 hours, 8 hours [Adhesive film] Polypropylene film (VF-10, KOKUYO), 40 mm × 40 mm

[0065]

Table 5

[0066] As shown in Table 5, the PP films obtained in Example 7, Example 9, and Example 10 showed a significant decrease in the infectious titer against bacteriophage Qβ (norovirus substitute) after 8 hours at 25°C in the dark. Along with this, the antiviral activity value also increased after 8 hours at 25°C in the dark. From these results, it can be understood that the PP films subjected to the transfer process using metal molds B, metal molds C, and metal molds D exhibit a remarkable effect on antiviral properties due to the formation of a very complex roughened shape on the surface of the PP film.

[0067]

Table 6

[0068] As shown in Table 6, the PP films obtained in Example 8 and Example 11 showed a significantly reduced infectivity titer against bacteriophage φ6 (influenza virus, surrogate for COVID-19) after 8 hours at 25°C in the dark. Accordingly, the antiviral activity value also increased after 8 hours at 25°C in the dark. From these results, it can be understood that the PP films subjected to the transfer process using metal molds B and D exhibit a remarkable effect on antiviral properties due to the formation of a very complex roughened shape on the surface of the PP film.

[0069]

Table 7

[0070] As shown in Table 7, the Acryl films obtained in Example 12, Example 14 and Example 16 showed a significantly reduced infectivity titer against bacteriophage Qβ (surrogate for norovirus) after 8 hours at 25°C in the dark. Accordingly, the antiviral activity value also increased after 8 hours at 25°C in the dark. From these results, it can be understood that the Acryl films subjected to the transfer process using metal molds A, B and C exhibit a remarkable effect on antiviral properties due to the formation of a very complex roughened shape on the surface of the Acryl film.

[0071]

Table 8

[0072] As shown in Table 8, the Acryl films obtained in Example 13, Example 15, Example 17, and Example 18 also showed a significantly reduced infectious titer against bacteriophage φ6 (influenza virus, COVID-19 substitute) after 8 hours at 25°C in the dark. Accordingly, the antiviral activity value also increased similarly after 8 hours at 25°C in the dark. From these results, it can be understood that the Acryl films subjected to the transfer process using Metal Mold A, Metal Mold B, Metal Mold C, and Metal Mold D exhibit a remarkable effect on antiviral properties due to the formation of a very complex roughened shape on the surface of the Acryl film.

Claims

1. A method for manufacturing a resin film having a roughened shape on at least a part of the surface of the resin film, comprising: a transfer step of bringing a metal mold having a roughened surface on at least a part of the surface into contact with the resin film to transfer the roughened shape of the roughened surface to the resin film; wherein the roughened surface of the metal mold has a developed area ratio (Sdr) of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5 as measured in accordance with ISO 25178. A method for manufacturing a resin film, characterized in that.

2. The method for manufacturing a resin film according to claim 1, wherein in the transfer step, water repellency is imparted to at least a part of the surface of the resin film.

3. The method for manufacturing a resin film according to claim 2, wherein the contact angle of the resin film with water before the transfer step is 90° or more.

4. The method for manufacturing a resin film according to claim 1, wherein in the transfer step, hydrophilicity is imparted to at least a part of the surface of the resin film.

5. The method for manufacturing a resin film according to claim 4, wherein the contact angle of the resin film with water before the transfer step is 90° or less.

6. The method for manufacturing a resin film according to claim 1, wherein in the transfer step, antiviral properties are imparted to at least a part of the surface of the resin film.

7. A metal mold for forming a roughened shape on at least a part of the surface of a resin film, comprising: the metal mold has a roughened surface on at least a part of the surface for transferring the roughened shape to the resin film; wherein the roughened surface has a developed area ratio (Sdr) of 0.005 to 0.5 and a root mean square slope (Sdq) of 0.1 to 1.5 as measured in accordance with ISO 25178. A metal mold, characterized in that.

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