JP2009248431A - Manufacturing process and manufacturing apparatus of molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process for molding a molding which is ultra finely machined, has a high dimensional accuracy, low residual stress, low birefringence, high light transmittance, and high mechanical strength in a shape of a thin wall thickness and a large area even by a super low pressure molding process and an apparatus for the method. <P>SOLUTION: A finely patterned surface to be coated is coated by a molten thermoplastic resin discharged from a discharge port being the lip of a T die. The coating is made by moving the surface to be coated relatively to the discharge port in a way that the distance between the lip of the T die and the surface defines the thickness of the coated molten resin. Immediately after the coating, a pressure is applied by a press roller to facilitate the filling of the coating resin into the fine pattern on the coated surface, to flatten the thickness of the coated resin, and to transfer the pattern from the mirror-finished surface to the top surface, while the contact force of the press roller is kept lower than the adhesion force between the resin and the mold. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a molded body and a manufacturing apparatus, and more specifically, a molded body having ultrafine processing, high dimensional accuracy, low residual stress, low birefringence, high light transmittance, and excellent mechanical strength. The present invention relates to a method and an apparatus for manufacturing a molded body that can be provided in a thin and large-area shape while being an ultra-low pressure molding process. More specifically, by adding a pressure roller to the method and apparatus for producing a molded article disclosed in JP-A-2006-056107, there is almost no temperature drop immediately after application (small deformation resistance and short relaxation time). The present invention provides a manufacturing method and apparatus having a lower pressure and higher productivity than conventional methods by pressurizing the resin with a roller, filling the fine pattern with the resin, making the coating thickness uniform, eliminating the die line, and the like. .

  Currently, molded products with ultra-fine pattern shapes on the surface of the order of sub-μm, and three-dimensional, thin, and large-area shapes are used for microfluidics such as optical components for electronic displays such as microlens arrays and blood test chips. It is required as a life science part with a processed road.

Conventionally, the manufacturing method of the molded article which has a fine pattern on the surface is known by the following patent document 1, for example. In this technology, a molten thermoplastic resin is applied to a shape and thickness almost close to the final product by a coating device on a mold having a fine pattern heated to a temperature at which the molten thermoplastic resin adheres. After completing the application operation, the resin applied by the press was pressed (pressed against the fine pattern).
JP 2006-056107 A

  The technique described in Patent Document 1 (hereinafter referred to as the conventional method) is characterized in that a resin having a temperature higher than the mold temperature (≈the temperature of the stamper on which the fine pattern is processed) is discharged from the T die lip and directly supplied to the fine pattern. It is.

  The deformation resistance and relaxation time of the resin are temperature dependent. The higher the temperature, the smaller the deformation resistance and the shorter the relaxation time. That is, since the resin having a small deformation resistance and a short relaxation time is filled with a fine pattern by the discharge pressure from the T-die, the filling is almost completed at the time of application, and the press process after application is completed. Since the amount of resin flow is small, sufficient strain relaxation occurs before the solidification of the molded body, and a molded body having high dimensional accuracy, low residual stress, and low birefringence is obtained. In fact, with this conventional method, it has been confirmed that the resin filling up to the bottom of the pattern concave portion is obtained at the stage of the coating process for a fine pattern having an aspect ratio of 0.5.

  However, when a shortage occurs in the resin filling at the time of application, the conventional method corrects this shortage in the pressing step. In the pressing process after the completion of the coating process, since the temperature of the applied resin is lowered to the mold temperature (see FIG. 10), the deformation resistance is large and the relaxation time is long. The pressure required for the press increases, the press time becomes longer, and the productivity decreases. Further, since the amount of deformation applied to the resin having a long relaxation time becomes large, there is a concern that the low residual stress and low birefringence of the molded article, which are the features of this method, cannot be obtained sufficiently.

  For this reason, in the conventional method, when filling is difficult because the aspect ratio of the fine pattern is high, it is necessary to promote filling of the resin in the coating process. Methods for promoting the filling of the resin in the coating process can be broadly classified as follows: (1) make the resin easy to enter the fine pattern (reduce the deformation resistance of the resin and shorten the relaxation time); There is a method of pressing a fine pattern with a strong force.

  However, in the method (1), it is necessary to increase the temperature of the resin in the vicinity of the interface with the fine pattern. For this purpose, it is necessary to increase the mold temperature, and the time required to raise the mold is long. Therefore, productivity is reduced. Further, the higher the temperature of the molten resin when it is in contact with the stamper surface (metal surface), the more energy required for peeling increases (FIG. 11), and secondary problems such that it becomes difficult to release.

  As a method of (2), it is conceivable to increase the discharge pressure of the resin from the T-die lip, but the discharge pressure is closely related to the shape of the apparatus and the product shape such as the shape of the resin flow path of the lip and the flow rate of the resin. Therefore, it cannot be freely changed, and the parameter is substantially free of adjustment. As a result, it is difficult to fill the fine pattern with resin in the coating process.

  Die lines (scratched scratches) may remain on the top surface of the applied resin (the side in contact with the lip of the T die) (FIG. 12). At present, the die line is erased by press-pressing (scratches (unevenness) are smoothed by press-pressing), but during press-pressing, the resin temperature decreases, the deformation resistance increases, and the relaxation time also increases. It is necessary to increase the press pressure and lengthen the press time. In addition, since the depth of the die line is usually deeper than the fine shape to be transferred, it is necessary to pressurize for a long time at a pressure higher than the pressure and pressurization time necessary for the original fine shape transfer. As a result, productivity is hampered (cycle time is shortened).

  When press-pressing is performed in a state where the thickness distribution of the applied resin is large, the thick portion is first pressed and the resin flows toward the thin portion (FIG. 13). At this time, as described above, since the temperature of the resin is lowered and the relaxation time is lengthened, if the mold is cooled and solidified after press pressurization (or during press pressurization), the resin flows. The orientation of the resulting resin is frozen soon after relaxation. As a result, defects such as optical distortion and residual stress occur in the final product. Further, when the resin is deformed so as to flow macroscopically, the necessary press pressure becomes high and the press time becomes long, so that productivity is also lowered.

  In order to obtain good products, strict flatness is required for the lower metal mold (the surface on which the stamper having a fine pattern is mounted) and the upper metal mold (the surface that contacts the resin during pressurization). And parallelism is required. If the product has a large area, it becomes difficult to ensure the accuracy of the mirror surface by machining, which is an impediment to increasing the product area. In addition, if a pressure similar to that of a product with a small area is applied, the pressing force increases in proportion to the area, and a high-thrust press is required, leading to an increase in the size of the device, an increase in energy consumption, and an increase in device cost. .

  The present invention has been made to solve the above-described problems, and an object thereof is to provide a manufacturing method and apparatus having a lower pressure and higher productivity than conventional methods.

This time, we measured the temperature change of the resin during application by the conventional method, and it depends on the type of resin and the application conditions, but at the time of application, the resin temperature generally decreases to the mold temperature. It has been found that it takes time around seconds. That is, as in the conventional method, when pressing the T-die after application away from the upper space of the pattern, the resin is lowered to the mold temperature, but if the pressure can be applied immediately after the resin is applied, the resin is small. The molten resin can be filled into the fine pattern in a short time with force, and the shape can be fixed (strain can be reduced).
Therefore, in order to solve the above-mentioned problem, the manufacturing method of the molded body of the present invention is the distance between the coated surface having a fine pattern and the lip of the T die, which is a thermoplastic resin discharge port, and the coated surface. After the resin is applied while the coated surface and the discharge port move relatively so that the thickness of the applied molten thermoplastic resin is regulated, the resin and pressure are applied rather than the adhesive force between the resin and the mold. While maintaining the low adhesive force with the pressure roller, it immediately presses with the pressure roller to facilitate filling the fine pattern of the resin applied to the coated surface and smooth the thickness of the applied resin. And transferring the mirror surface to the top surface.

  Further, the method for producing a molded body of the present invention includes a temperature raising step for raising the surface to be coated having a fine pattern to a temperature at which the molten thermoplastic resin adheres, a discharge port of the thermoplastic resin, and the surface to be coated. A coating step of applying the resin while relatively moving the surface to be applied and the discharge port, and the applied thermoplastic resin, While maintaining the adhesive force between the resin and the pressure roller lower than the adhesive force with the mold, immediately press the pressure roller sequentially to fill the fine pattern of the resin applied to the coated surface. Roller pressurizing process that promotes smoothing of applied resin thickness and mirror surface transfer to the top surface, and press pressurization and solidification that cools and solidifies the thermoplastic resin while further pressing Process and solidified resin And a releasing step of peeling.

Moreover, the manufacturing method of the molded body of the present invention includes (a) the temperature of at least the fine pattern of the mold having the fine pattern, the temperature at which the thermoplastic resin discharged from the discharge portion in the subsequent coating step adheres, Is deformed to the extent that a solidified layer is not formed at the contact interface of the thermoplastic resin that has been applied and is in contact with the mold surface (including the fine pattern), and the fine pattern is filled with the resin by the pressing force of the pressure roller. A temperature increasing step of the surface to be coated that is heated to a temperature that can maintain a softened state to a degree that can be performed, and (b) a discharge portion or a discharge portion or a fine pattern filled from the discharge port of the coating apparatus. The thickness of the final product depends on the distance between the tip of the discharge port and the coated surface while moving the mold and relatively moving the dispensing portion and the coated surface including the fine pattern in the coating direction. Melt as specified (C) Resin to fine pattern by applying a pressing force to the applied resin with a pressure roller. A roller pressurizing step for smoothing the thickness of the applied resin and transferring the mirror surface to the top surface,
(D) press-pressing the applied resin to completely fill the fine pattern with the resin, cooling the mold, and cooling and solidifying the resin; and (e) solidification. And a mold release step for peeling the molded product from the mold.

  Further, the method for producing a molded body of the present invention includes (a) the temperature of the fine pattern on which the molten resin is applied at least in the subsequent stage of the endless belt having the fine pattern, and the heat discharged from the discharge unit in the subsequent application process. The temperature at which the plastic resin adheres, and further, the solidified layer is not formed at the contact interface of the thermoplastic resin that has been applied and is in contact with the fine pattern, and the fine pattern is filled with the resin by the pressing force of the pressure roller. And (b) the thermoplastic resin is filled into the entire fine pattern portion from the discharge port of the coating apparatus, and the temperature of the coating surface is increased to a temperature at which the softened state capable of being deformed can be maintained. The end product is moved depending on the distance between the tip of the discharge port and the surface to be coated while moving the endless belt to relatively move the discharge portion and the surface to be coated including the fine pattern in the coating direction. A coating process in which the molten resin is discharged so that the thickness is regulated to perform a precise coating to a state almost close to the final thickness and width of the molded body, and (c) the applied resin is pressed by a pressure roller. The resin is completely filled into the fine pattern by applying pressure, and the pressure forming step for shaping the thickness and width as the final product, and (d) cooling the fine pattern portion on which the resin is placed, A solidifying step of cooling and solidifying the resin pressed by the pressure roller; and (e) a releasing step of peeling the solidified molded product from the fine pattern.

  In addition, the molded product manufacturing apparatus of the present invention is applied to a coated surface having a fine pattern at a distance between a lip of a T die, which is a discharge port of a thermoplastic resin, and the coated surface. After the resin is applied while the surface to be coated and the discharge port move relatively so that the thickness of the resin is regulated, the adhesion force between the resin and the pressure roller is greater than the adhesion force between the resin and the mold. While maintaining a low state, it is immediately pressed with a pressure roller to promote filling of the resin applied to the fine pattern into a fine pattern, smoothing the thickness of the applied resin, and mirroring the top surface Transcription.

  Further, the molded body manufacturing apparatus of the present invention includes a temperature raising means for raising the surface to be coated having a fine pattern to a temperature at which the molten thermoplastic resin adheres, a discharge port of the thermoplastic resin, and the surface to be coated. The coating means for applying the resin while relatively moving the surface to be applied and the discharge port, and the applied thermoplastic resin, While maintaining the adhesive force between the resin and the pressure roller lower than the adhesive force with the mold, immediately press the pressure roller sequentially to fill the fine pattern of the resin applied to the coated surface. Roller pressurizing means for smoothing the thickness of the applied resin and transferring the mirror surface to the top surface, and press pressurizing / solidifying means for cooling and solidifying the thermoplastic resin while pressing And the solidified resin is peeled off from the coated surface To include a releasing means.

According to the present invention, one or more pressure rollers are installed in the vicinity of the T die lip, and the molten resin applied to the fine pattern is lowered to the mold temperature (at a higher temperature than the mold, the resin Since the deformation resistance is small and the relaxation time is short), the resin is pressed against the fine pattern by the pressure roller (FIG. 1). The resin having a small deformation resistance and a short relaxation time can be pressed against the fine pattern, and the filling of the resin into the fine pattern in the coating process is promoted. For example, as shown in FIG. 2 (b), even if the resin cannot be completely filled in the coating process, the amount that must be filled in the pressing process to obtain a completely filled final product is reduced. The press time can be shortened and the press pressure can be reduced, leading directly to improved productivity and energy saving.

  Further, even when the applied resin becomes concave or convex, it can be smoothed by pressurizing with a roller, and the resin thickness distribution can be reduced (smoothed). FIG. 3 is a conceptual diagram in which a resin whose center has a convex shape by application (as an example) is smoothed by roller pressure. The resin flows in the same manner as in FIG. 13 to pressurize the resin of the convex portion, but the deformation caused by the flow is relieved in a short time due to deformation under high resin temperature, and the product remains strained. Absent.

  Furthermore, the die line of the applied resin can be erased without leaving any distortion by the same action as described above. By eliminating the die line in addition to reducing the coating thickness distribution (smoothing), there is almost no need to flow the resin during press pressurization, so the press time can be shortened and productivity is improved. Furthermore, by eliminating the flow of the resin during pressing, it is possible to suppress the occurrence of distortion associated with the flow, and it is possible to make the product non-stretched and non-oriented. Therefore, it is possible to obtain a product having low distortion (no residual stress, no change in product shape over time, etc.) and excellent optical characteristics (eg no birefringence).

  In the conventional method, one of the roles of press-pressing is to transfer a mirror surface shape to a resin by pressing a mirror-finished mold against the resin. Also in the method of the present invention, if the surface of the roller is mirror-finished, the mirror surface can be transferred to the resin with a smaller force and in a shorter time by pressing the roller. Similarly, if a concavo-convex pattern is processed on the roller surface, the shape of the concavo-convex pattern can be transferred to the resin by pressing the roller.

Furthermore, as described above, as a means for promoting the filling of the resin into the fine pattern in the coating process, there is a method of increasing the resin temperature, but the temperature at which the resin contacts the stamper. When it becomes high, it becomes difficult to remove. Therefore, considering the product release, it is preferable to fill the resin by pressing the resin strongly against the fine pattern rather than increasing the temperature. However, it was difficult to increase the pressing force independently of the coating conditions in the conventional method.
In the present invention in which pressing can be applied immediately after coating regardless of the coating conditions, even if the filling in the coating process seems to be insufficient, this can be compensated. Therefore, unlike the conventional method, it is not necessary to increase the mold temperature in order to make the resin easy to fill the fine pattern (the deformation resistance is small and the relaxation time is short). That is,
Even if the mold temperature is low enough to fill the fine pattern in the coating process, pressurization is performed immediately after coating so that the resin temperature does not fall down to the mold temperature. Can be compatible. If the mold temperature can be lowered, the energy required for peeling the resin from the wall of the stamper also becomes low, and the product can be released at a higher mold temperature than before in the release process. As a result, the mold temperature at the time of application is low, the temperature at the time of product release can be increased, and the temperature difference between the temperature when the temperature is raised and the time when it is cooled can be reduced compared to the conventional method. it can. That is, the time required for the temperature rise and cooling of the mold can be shortened, which directly leads to an improvement in productivity.

  When the product has a large area (wide width and long length), it can be achieved by increasing the length of the roller. In the conventional method, processing for achieving excellent parallelism and flatness between molds becomes difficult, and it has been described that it becomes a restriction on the enlargement of the area. It is only necessary to process the straightness of the plane with high accuracy, which is easier than processing a plane with high accuracy.

  In the roller pressurization method, since the contact area between the resin and the roller is small, the pressing force is small even when a high pressure is applied. Furthermore, the apparatus is more compact than the case where a large press is used, and the cost can be reduced.

  Furthermore, if it becomes possible to fill a fine pattern with resin and impart product properties (for example, transfer a mirror surface) to the resin top surface only with a pressure roller, ideally press pressing is not necessary. Since application and roller pressurization can be performed continuously, a strip-shaped product can be continuously manufactured by using a seamless stamper.

  In addition to the above, the following are listed as features unique to the present construction method (melting and fine transfer process).

  According to this method, the thickness of the molten thermoplastic resin applied to the surface to be coated having a fine pattern on the surface is the distance between the lip of the T die that is the discharge port of the thermoplastic resin and the surface to be coated. As prescribed | regulated, resin is apply | coated, moving a to-be-coated surface and a discharge port relatively.

Therefore, the distance between the lip and the surface to be coated is changed, and only the amount of molten resin that can fill the gap (coating thickness x coating width x volume flow rate of coating speed (m ³ / s) or more) is discharged. By doing, application thickness can be changed easily.

  In general, after the pellets in circulation are melted, they are discharged as they are from the T die into a film and applied to the surface to be coated, so that a product can be obtained directly from the pellets.

  Since the product properties are imparted by coating, even a resin having a low viscosity that cannot be formed into a film by a general film forming method can be used even if the viscosity of the resin is high. That is, there is no restriction on the type and grade of the thermoplastic resin applicable to the method of the present invention, and a wide variety of resins can be used.

  When the molten thermoplastic resin is applied to the surface to be coated, it is adhered and fixed, so that the positional relationship between the resin and the fine pattern on the surface to be coated does not shift, and accurate shape transfer becomes possible.

  The molten resin is applied while sequentially sticking to the application surface. Therefore, most of the air existing between the molten resin and the surface to be coated is excluded in the coating process. As a result, a vacuum process becomes unnecessary.

  FIG. 4 is a diagram illustrating a coating process and a pressurizing process according to the embodiment of the present invention. A molten thermoplastic resin 2 is discharged from a discharge port 3a of a coating apparatus 3 on a surface to be coated 1 having a fine pattern (fine pattern) 1a on the surface. Immediately pressurizing a resin (low viscosity and short relaxation time) with a roller (pressure roller) 4 immediately after coating, thereby facilitating filling of the molten resin into the fine pattern and coating thickness Smoothing and erasing die lines, etc., and reducing the filling time of the resin in the subsequent press process shortens the press time, shortens the production cycle, saves energy by reducing the press force, and further increases the press force. By minimizing resin flow during pressing, a final product with excellent dimensional accuracy and optical properties such as low residual stress, low birefringence, and high light transmission can be obtained. The resin applied to the lower mold varies depending on the type of resin and the application conditions, but as shown in FIG. 10, it is cooled to the mold temperature in about 10 seconds, so the roller pressure is within 8 seconds after application. It is desirable to carry out within 5 seconds.

  In order to pressurize the applied resin with a roller, it is necessary to maintain “adhesive strength with a mold> adhesive strength with a roller”. When the adhesive strength with the roller is larger than that of the mold, the resin to which the roller is applied is peeled off. For this purpose, it is necessary to maintain the temperature of the pressure roller (the surface in contact with the resin) below the mold temperature.

  It is desirable to adjust the temperature of the roller by passing a heat medium (water or oil) adjusted to a desired temperature. This acts as a heating medium if the temperature of the roller is lower than the heating medium, and acts as a cooling medium if the temperature is higher than the heating medium, so that the temperature of the roller is easily maintained at a predetermined temperature. However, it is not necessary to limit to this, and heating may be performed by a heater, an infrared lamp, or the like by supplying power with a slip ring. In addition to water cooling, the Peltier element or the like may be electrically cooled. When using these, the temperature of the roller can be detected with a contact-type thermocouple or a non-contact infrared thermometer, and the heating and cooling amounts can be adjusted automatically with a temperature controller so that the temperature is set in advance. Good.

  The pressure roller 4 is configured to be capable of adjusting the pressing force against the resin or the distance between the lower surface of the roller and the fine pattern. A desired pressing force can be applied to the resin by adjusting the pressing force to the resin. In this case, the resin film thickness after applying the pressing force is not controlled. Therefore, when the film thickness of the final product is important, the film thickness after applying the pressing force can be set to a desired thickness by adjusting the distance between the roller lower surface and the fine pattern. The mechanism can change the pressing force applied in the coating width direction by independently adjusting the left and right sides of the roller as shown in FIG. When adjusting the pressing force, an air cylinder 4a or a hydraulic cylinder 4b may be installed as shown in FIG. When adjusting the position, as shown in FIG. 5B, the adjustment is facilitated by combining the motor 4d and the ball screw 4e. By these, it becomes possible to adjust the inclination of the roller, and for example, it is possible to accurately apply a uniform pressing force even to a product having a tapered thickness distribution in the coating width direction. It is also possible to obtain a final product having a thickness distribution in the width direction intentionally by position control. Instead of providing an independent actuator, the housing to which the roller is attached may be tilted.

  The coated surface, the discharge port, and the pressure roller may be moved relative to each other, the coated surface may be fixed and the discharge port and the roller may move in the coating direction, or the discharge port and the pressure roller may be fixed. The coated surface may move.

  FIG. 6 illustrates a typical series of product manufacturing steps of the present invention. The coating device and the pressure roller are moved by a moving means (not shown). In the figure, a stamper with a fine pattern mounted on a mold is used as the surface to be coated, and the coating device (discharge port) and pressure roller move to apply the molten resin and pressurize it. The process of manufacturing a body is shown. It is assumed that the mold can be heated and cooled.

  First, the coated surface is heated to a temperature at which the molten resin adheres (S1). When the temperature rise to the predetermined temperature is completed, the coating device and the pressure roller are moved to the coating start position. Next, while moving the resin discharge port along the shape of the stamper, the distance, the coating speed (surface to be coated) so that the final product thickness is defined by the distance between the tip of the discharge port and the surface to be coated. (Relative movement speed between the nozzle and the discharge port) and by applying while adjusting the discharge flow rate of the molten resin, the molten thermoplastic resin is applied in a shape and thickness almost similar to the final product (S2-1, S2-2). In the coating process, the molten resin is pressed with a pressure roller immediately after coating (coating / pressing step). Further, the resin is cooled and solidified while being pressed with a press (solidification step: S3), and the product is peeled off (S4).

  FIG. 7 shows a manufacturing method including a plurality of molds (a) to (d) and sequentially performing different processes at each place. An embodiment realized by moving (traversing) the coating apparatus and moving the surface to be coated in the coating direction will be described. The surface to be coated may be fixed, and the coating apparatus may move in the traversing direction and the coating direction. If it is this form, since heating and cooling of a metal mold | die will be performed in places other than application and pressurization shaping, it is not necessary to wait for an application and pressurization shaping process for heating and cooling. Therefore, a product can be manufactured with higher efficiency.

FIG. 8 shows a method in which the embodiment of FIG. 7 is performed on a turntable. In this embodiment, the T die and the pressure roller need only move up and down.

  Although an example using one roller is shown in the figure, a plurality of rollers may be used side by side. In particular, when the pressing time by the roller is short with respect to the relaxation time of the molten resin, after the pressure is removed (after passing through the roller), it is elastically recovered and returns to its original shape (for example, the resin pushed into the fine pattern returns. ). In this case, it is possible to secure a necessary pressing time by providing a plurality of rollers.

  FIG. 9 shows an example of an embodiment in which the coated surface is an endless belt. Although not shown in detail in the drawing, a stamper in which a fine pattern is processed may be installed on the endless belt 7, or a fine pattern may be processed directly on the surface of the endless belt 7. The endless belt 7 is provided with a mechanism capable of heating and cooling (at least) a fine pattern. In this figure, heating by the infrared lamp 8 is performed before the coating, but it is sufficient if the endless belt 7 can be heated, and induction heating, hot air blowing, passing through a room maintained at a high temperature, etc. are possible. Any means can be used.

  Usually, since the endless belt 7 is thin and easily deformed, a backup roller 8 is provided in each of the part A to which the molten resin is applied and the part to be pressure-formed by the pressure roller 4. When it is not preferable that the endless belt 7 in contact with the backup roller 8 is cooled, the temperature may be adjusted. The same applies to cooling.

  In this figure, the molten resin applied to the endless belt 7 is cooled by blowing cold air as the cooling means 9. The direction of blowing cold air may be blown from the back surface of the endless belt 7. If a problem such as bending of the endless belt 7 and the product attached to the endless belt 7 due to the wind pressure when the cold wind is blown, a backup roller may be provided to support the wind pressure.

  The backup roller described above is not necessarily a roller, and may be a plate. If the deformation (deflection) of the endless belt can be prevented, the shape may not be as shown.

  The cooled product is peeled off from the endless belt and wound up with a roller or the like. The location for releasing the mold does not necessarily have to be the position shown in FIG. 9, and it is sufficient that the peeling is completed before the belt makes one round and heating is started again.

  If it is said method, since a product can be manufactured continuously, it is applicable also to mass production.

  The surface of the pressure roller 4 may be a smooth surface, or when a product has a design surface, a roller having a desired shape may be pressed. If a fine pattern shape is provided on the roller surface, it is possible to obtain a product having the fine shape transferred on both surfaces.

  By providing a cleaning mechanism for cleaning the surface of the pressure roller 4, the roller surface can always be kept clean. For example, if a resin film adheres to the roller surface, not only the shape of the resin film is transferred to the product surface, but also the resin melts and adheres to each other, so that the applied molten resin is peeled off from the coated surface (When the adhesion between the roller and the resin film is won), the resin film adheres to the product surface (when the adhesion between the roller and the resin film is lost).

  The cleaning mechanism is a method of scraping off the dirt adhered to the roll surface with a scraper, a method of removing a thin resin film that is difficult to remove with a scraper with cleaning paper, and a resin film that is completely removed using a solvent that dissolves the resin. What is necessary is just to select suitably from a method etc. and to use. In addition to the above method, a method of removing a resin layer that remains even if a solvent is used by using ultraviolet rays or ozone can be used.

  Furthermore, it is preferable that the roller surface is subjected to a surface treatment that makes it difficult for the resin to adhere. Specifically, it is preferable to coat the surface with fluorine. In addition, plating such as chromium plating, TiC, TiCN, CrC, TiN, CrN, DLC (diamond-like coating) is also effective.

It is a figure which shows the coating method for showing the effect of this invention. It is a figure which shows the application | coating state for showing the effect of this invention. It is a figure which shows the shape of apply | coated resin for showing the effect of this invention. It is a side view which shows Embodiment 1 of this invention. It is the schematic which shows the attachment method of a pressure roller. It is explanatory drawing which shows each process of the shaping | molding method of this invention. It is a figure which shows the manufacturing method of the molded object which provides a some metal mold | die and performs a different process in each place. It is a figure which shows the case where the process shown in FIG. 7 is performed with a turntable. It is a figure which shows the method of manufacturing a molded object by making a to-be-coated surface into an endless belt. It is a figure which shows the temperature change of resin apply | coated to the metal mold | die surface. It is a figure which shows the temperature dependence of energy required in order not to peel off the acrylic resin adhered to the silicon substrate. It is a figure which shows the die line which arises on the top | upper surface of the apply | coated resin. It is a figure which shows the state press-pressed in the state with the large thickness distribution of conventionally apply | coated resin.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Surface to be coated, 1a Fine pattern, 2 Thermoplastic resin, 3 Coating apparatus, 3a Discharge port of a coating apparatus, 4 Pressure roller, 7 Endless belt, 8 Backup roller, 9 Cooling means.

Claims (20)

  The thickness of the applied molten thermoplastic resin is defined on the surface to be coated having a fine pattern by the distance between the lip of the T die, which is the thermoplastic resin discharge port, and the surface to be coated. After applying the resin while the surface and the discharge port move relatively, immediately press the pressure roller while keeping the adhesion force between the resin and the pressure roller lower than the adhesion force between the resin and the mold. The molded body is characterized by promoting the filling of the fine pattern of the resin applied to the application surface by pressing, smoothing the thickness of the applied resin, and transferring the mirror surface to the top surface. Production method. In the manufacturing method of the molded object according to claim 1,
The temperature of the coated surface having a fine pattern is increased to a temperature at which the molten thermoplastic resin adheres, and the distance between the discharge port of the thermoplastic resin and the coated surface is such that the thickness of the coated resin is As specified, the application process in which the resin is applied while the surface to be applied and the discharge port are moved relatively, and the applied thermoplastic resin is pressed against the resin rather than the adhesive force between the resin and the mold. While maintaining a low adhesive force with the roller, it immediately presses with a pressure roller immediately to facilitate filling the fine pattern of the resin applied to the application surface and smooth the thickness of the applied resin. And a roller pressurizing step for transferring the mirror surface to the top surface, a press pressurization / solidification step for cooling and solidifying the thermoplastic resin while further pressurizing, and a solidified resin from the surface to be coated A molded body including a release step for peeling Manufacturing method. In the manufacturing method of the molded object of Claim 1 or Claim 2,
A method for producing a molded body, comprising: a plurality of pressure rollers arranged in a coating direction, wherein the applied resin can be pressed a plurality of times with a pressure roller. In the manufacturing method of the molded object according to any one of claims 1 to 3,
The pressure roller moves the roller up and down and has means capable of arbitrarily adjusting the pressing force to the applied molten resin or the distance between the roller and the surface to be coated. A method for producing a molded body, wherein the pressure or the final thickness of the applied molten resin can be adjusted. In the manufacturing method of the molded object according to claim 4,
The mechanism for moving the roller up and down is provided independently at both ends of the roller, and the pressing force to the applied molten resin or the thickness after pressing of the applied molten resin can be adjusted independently at both ends. A method for producing a molded article. In the manufacturing method of the molded object in any one of Claims 1 thru | or 5,
The pressure roller has a heating and cooling function, and the temperature of the roller surface can be adjusted and maintained at a desired temperature. In the manufacturing method of the molded object according to any one of claims 1 to 6,
A method for producing a molded body, wherein the surface of the pressure roller is subjected to a surface treatment that prevents the molten resin from sticking even when the surface temperature of the roller is high. In the manufacturing method of the molded object in any one of Claim 1 thru | or 7,
A method for producing a molded body, comprising a mechanism for cleaning resin waste and dirt adhering to the surface of a pressure roller. A method for producing a molded body according to any one of claims 1 to 8,
(A) The temperature of at least the fine pattern of the mold having a fine pattern is the temperature at which the thermoplastic resin discharged from the discharge portion adheres in the subsequent coating step, and further the applied mold surface (including the fine pattern) The temperature is raised to a temperature at which the solidified layer is not formed at the contact interface of the thermoplastic resin that is in contact with (3), and can be maintained in a softened state that can be deformed to the extent that the resin is filled into the fine pattern by the pressing force of the pressure roller A temperature raising step of the coated surface to be heated;
(B) The discharge unit or the mold is moved so that the thermoplastic resin is filled into the fine pattern from the discharge port of the coating apparatus, and the discharge unit and the surface to be coated including the fine pattern are relative to each other in the coating direction. The molten resin is discharged so that the thickness of the final product is regulated by the distance between the tip of the discharge port and the surface to be coated while being moved in a continuous manner, and is almost close to the final shape and thickness of the molded body Application process for precise application,
(C) By applying a pressing force to the applied resin with a pressure roller, the filling of the resin into the fine pattern is promoted, the thickness of the applied resin is smoothed, and the mirror surface is transferred to the top surface. Roller pressurizing process,
(D) press-pressing the applied resin to completely fill the fine pattern with the resin, cooling the mold, and cooling and solidifying the resin;
And (e) a mold release step of peeling the solidified molded product from the mold. In the manufacturing method of the molded object according to any one of claims 1 to 9,
An endless belt having a coated surface that runs in the coating direction is provided, and means for heating the endless belt before coating the molten resin on the endless belt surface, and cooling the endless belt after the coating process and pressurizing process And a mold release means for separating the solidified resin from the endless belt at the subsequent stage. In the manufacturing method of the molded object according to any one of claims 1 to 10,
A backup roller is provided at least at a position facing the discharge unit with the endless belt interposed therebetween and at a position facing the pressure roller with the endless belt interposed therebetween, and the reaction force of the resin pressure generated during application and the pressure roller A method for producing a molded body, wherein a resin pressure and a pressing force can be applied to an applied molten resin by receiving a reaction force of a pressing force. A method for producing a molded body according to any one of claims 1 to 11,
(A) The temperature of the fine pattern at which the molten resin is applied at least in the subsequent stage of the endless belt having the fine pattern, the temperature at which the thermoplastic resin discharged from the discharge portion in the subsequent application process adheres, and At a temperature at which a solidified layer is not formed at the contact interface of the thermoplastic resin in contact with the fine pattern, and the softened state can be maintained so that the fine pattern can be deformed by the pressing force of the pressure roller. A temperature raising step of the coated surface to be heated;
(B) The endless belt is moved so that the entire thermoplastic resin is filled in the entire fine pattern portion from the discharge port of the coating apparatus, and the discharge portion and the coated surface including the fine pattern are relative to each other in the coating direction. The final thickness and width of the molded product by discharging the molten resin so that the thickness of the final product is regulated by the distance between the tip of the discharge port and the coated surface. An application process for precise application to a close state,
(C) a pressure forming step for completely filling the fine pattern with the resin by applying a pressing force to the applied resin with a pressure roller, and forming the final product with a thickness and a width;
(D) a solidification step of cooling the fine pattern portion on which the resin is placed, and cooling and solidifying the resin pressed by the pressure roller;
And (e) a mold release step of peeling the solidified molded product from the fine pattern. In the manufacturing method of the molded object according to claim 12,
In the step (d), the fine pattern is cooled while a plurality of pressure rollers are installed in the coating direction, and the pressing force is applied and the thickness and width are adjusted while the resin is cooled and solidified. A method for producing a molded article, characterized by continuing. In the manufacturing method of the molded object according to any one of claims 1 to 12,
While providing a plurality of molds having a surface to be coated, a resin discharge part and a pressure roller, or a moving means for the molds, The application process and roller pressurizing process are performed on the mold at the location of 2, the press-pressing and solidification process is performed on the mold at the third location, and the mold release process is performed on the mold of the fourth location. While moving the mold or discharge part and pressure roller sequentially, perform the application process and roller pressure forming process at the mold where the temperature raising process is completed, and at the place where the application process and pressure forming process are completed The manufacturing method of the molded object characterized by performing sequentially performing a solidification process. In the manufacturing method of the molded object according to claim 14,
A turntable for mounting a plurality of molds;
Means for moving the mold in the application direction in order to move the discharge port tip and the surface to be coated in the application direction, or means for moving the discharge part in the application direction;
And a moving means for moving the discharge portion or the surface to be coated up and down in order to adjust the distance between the tip of the discharge port and the surface to be coated. In the manufacturing method of the molded object according to any one of claims 1 to 12,
A traversing means for moving the discharge unit and the pressure roller to each location;
Means for moving the mold in the coating direction or means for moving the discharge part in the coating direction in order to move the discharge port tip and the pressure roller and the surface to be coated relative to each other in the coating direction;
And a moving means for moving the discharge portion or the surface to be coated up and down in order to adjust the distance between the tip of the discharge port and the surface to be coated. An apparatus for manufacturing a molded body used in the method for manufacturing a molded body according to claim 1,
The thickness of the applied molten thermoplastic resin is defined on the surface to be coated having a fine pattern by the distance between the lip of the T die, which is the thermoplastic resin discharge port, and the surface to be coated. After applying the resin while the surface and the discharge port move relatively, immediately press the pressure roller while keeping the adhesion force between the resin and the pressure roller lower than the adhesion force between the resin and the mold. The molded body is characterized by promoting the filling of the fine pattern of the resin applied to the application surface by pressing, smoothing the thickness of the applied resin, and transferring the mirror surface to the top surface. Manufacturing equipment. An apparatus for manufacturing a molded body used in the method for manufacturing a molded body according to claim 2,
A temperature raising means for raising the surface to be coated having a fine pattern to a temperature at which the molten thermoplastic resin adheres;
An application means for applying the resin while relatively moving the application surface and the discharge port so that the thickness of the applied resin is defined by the distance between the discharge port of the thermoplastic resin and the application surface;
The applied thermoplastic resin is applied to the surface to be coated by immediately pressing with the pressure roller while maintaining the adhesion force between the resin and the pressure roller lower than the adhesion force between the resin and the mold. Roller pressurizing means for facilitating filling of the fine resin pattern and smoothing the thickness of the applied resin and transferring the mirror surface to the top surface;
Press pressing and solidifying means for cooling and solidifying the thermoplastic resin while pressing,
A mold manufacturing apparatus comprising: mold release means for peeling the solidified resin from the surface to be coated. In the manufacturing apparatus of the molded object according to claim 18,
An endless belt having a coated surface that runs in the coating direction is provided, and means for heating the endless belt before coating the molten resin on the endless belt surface, and cooling the endless belt after the coating process and pressurizing process And a mold release means for separating the solidified resin from the endless belt at the subsequent stage. In the manufacturing apparatus of the molded object according to claim 19,
While providing a plurality of molds having a surface to be coated, a resin discharge part and a pressure roller, or a moving means for the molds, The application process and roller pressurizing process are performed on the mold at the location of 2, the press-pressing and solidification process is performed on the mold at the third location, and the mold release process is performed on the mold of the fourth location. While moving the mold or discharge part and pressure roller sequentially, perform the application process and roller pressure forming process at the mold where the temperature raising process is completed, and at the place where the application process and pressure forming process are completed An apparatus for manufacturing a molded body, wherein the solidifying step is sequentially performed.

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