JP2010082943A - Method and apparatus for manufacturing roll mold, roll mold, and method for manufacturing sheetlike optical element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To form a sheetlike optical element superior in optical performance and to facilitate the manufacturing of a roll mold. <P>SOLUTION: An apparatus 1 for manufacturing the roll mold for transferring the shape of a circumferential surface to the sheetlike optical element has a cutting means 2 for forming a mold intermediate 7 on the circumferential surface of a cylindrical mold base material 6 by cutting a plurality of pyramidal or truncated-pyramidal unevenness, a cylindrical bathtub 30 which stores a polishing liquid K in which an abrasive is dispersed and can hold the mold intermediate 7 in the inside, and a rotation apparatus 31 for polishing a projection 501 by relatively rotating the bathtub 30 and the mold intermediate 7 while the mold intermediate 7 with the pyramidal projection 501 formed on the circumferential surface is immersed in the bathtub 30. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a roll mold manufacturing method, a manufacturing apparatus, a roll mold, and a sheet-shaped optical element manufacturing method.

  Conventionally, in a display device such as a liquid crystal display or an organic EL panel, cone-shaped or frustum-shaped irregularities such as a cone, a quadrangular pyramid, a truncated cone, and a quadrangular pyramid are formed on a sheet-like optical element. Used as an anti-reflection film to prevent reflection of external light and surrounding objects, used as a light diffusing plate for distributing and distributing light with a wide directivity in a wide angle range, and from light emitting elements It is used as a light control sheet for preventing light reflection and improving front luminance (for example, see Patent Document 1). And as a manufacturing method of the sheet | seat which formed such fine unevenness | corrugation on such a surface, the mold roller by which unevenness | corrugation was formed in the surface in a roller shape was rotated on a sheet | seat, and the fine uneven | corrugated shape of the mold surface was made. A method of transferring to the sheet surface is known (for example, see Patent Document 2).

Here, among the sheet-like optical elements as described above, an optical element used as a light control sheet is particularly preferably a cone-shaped or frustum-shaped convex portion 100 as shown in FIGS. 5 and 6A. Is arranged toward the emission surface 102 side of the surface light emitting element 101 such as an organic EL element, and as a result, as shown in FIG. It is intended to prevent the element 101 from being trapped inside.
JP 2008-123694 A JP 2003-25431 A

  However, in order to form negative-shaped irregularities with respect to the conical or frusto-conical irregularities on the peripheral surface of the die base material of the roll mold, in general, each of the truncated cones must be formed in an arbitrary order. There is no method, however, it takes an enormous time to form such fine irregularities over almost the entire mold surface. In addition, there is a risk that the tool used for processing will deteriorate due to wear or the like within the enormous amount of time, and the quality of the product may be adversely affected due to degradation of the processing quality.

  On the other hand, when negative irregularities with respect to the pyramid or truncated pyramid irregularities are simply formed on the peripheral surface of the mold base material by cutting or engraving, the irregularities transferred to the optical element are distributed by the ridge lines. Since unevenness is caused in the optical characteristics, the optical performance is inferior as compared with the conical or truncated cone-shaped irregularities.

  An object of the present invention is to provide a roll mold manufacturing method, a manufacturing apparatus, and a manufacturing method capable of forming a sheet-like optical element having excellent optical performance and facilitating the manufacture of the roll mold. It is providing the manufacturing method of the roll metal mold | die manufactured by (1), and a sheet-like optical element.

According to the first aspect of the present invention, in the method of manufacturing a roll mold for transferring the shape of the peripheral surface to the sheet-like optical element,
A cutting step of cutting a plurality of irregularities in the shape of a pyramid or a truncated pyramid on a cylindrical mold base material peripheral surface;
A preparation step of storing a polishing liquid in which an abrasive is dispersed and preparing a cylindrical bathtub capable of accommodating the mold base material therein;
A polishing step of polishing the unevenness by immersing the mold base material in which the unevenness is formed by the cutting step in the bathtub and relatively rotating the bathtub and the mold base material,
It is characterized by having.

  In the roll mold manufacturing method of the present invention, the height h of the irregularities formed by the cutting step is preferably 0 <h ≦ 30 (μm).

In the method for producing a roll mold of the present invention,
In the polishing step, the mold base material is preferably rotated with respect to the bathtub.

In this case,
In the polishing step, it is preferable to reciprocate the mold base material in the circumferential direction of the mold base material.

In the method for producing a roll mold of the present invention,
In the polishing step, it is preferable to relatively rotate the mold base material and the bathtub while changing one direction of the central axis of the mold base material and the central axis of the bathtub.

According to the second aspect of the present invention, in the roll mold,
It was manufactured by the manufacturing method of the roll metal mold | die of this invention, It is characterized by the above-mentioned.

In the roll mold of the present invention,
The height h of the unevenness is preferably 0 <h ≦ 30 (μm).

According to the third aspect of the present invention, in the method for manufacturing a sheet-like optical element having a plurality of concave and convex shapes on the surface using the roll mold formed by the roll mold manufacturing method of the present invention,
A first step of placing a sheet-like optical element member, and a step of transferring irregularities on the peripheral surface of the roll die by rotating the roll die on the sheet-like optical element placed in the first step. And two steps.

According to the fourth aspect of the present invention, in the roll mold manufacturing apparatus for transferring the shape of the peripheral surface to the sheet-like optical element,
A cutting means for cutting a plurality of concavities and convexities in the shape of a pyramid or a truncated pyramid on a cylindrical mold base material peripheral surface;
A cylindrical bathtub for storing a polishing liquid in which an abrasive is dispersed and accommodating the mold base material therein;
The concavo-convex shape is obtained by relatively rotating the tub and the mold base material in a state where the mold base material in which a plurality of concavo-convex shapes of a pyramid shape or a truncated pyramid shape are formed on the peripheral surface is immersed in the bathtub. And rotating means for polishing.

In the roll mold manufacturing apparatus of the present invention,
The rotating means preferably rotates the mold base material with respect to the bathtub.

In this case,
The rotating means preferably rotates the mold base material back and forth in the circumferential direction of the mold base material.

In the roll mold manufacturing apparatus of the present invention,
It is preferable that the rotating means rotate the mold base material and the bathtub relative to each other while changing one direction of the central axis of the mold base material and the central axis of the bathtub.

  According to the present invention, in order to provide an optical sheet having a conical or frustoconical fine irregularity with excellent optical performance, the conical or frustoconical processing step, which is laborious, is performed by dispersing an abrasive. By performing polishing using a cylindrical bathtub that stores liquid, it is easier to manufacture roll dies and shortens manufacturing time compared to the case where conical and frustoconical irregularities are formed by cutting. In addition, it is possible to provide a roll mold with less variation in the shape of fine irregularities. As a result, compared to an optical sheet having fine irregularities formed using a conventional die by cutting, an excellent effect is provided that an optical sheet superior in optical performance can be provided. .

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
First, the roll metal mold | die manufactured by the manufacturing method of the roll metal mold | die which concerns on this invention is demonstrated.

FIG. 1 is a schematic view showing a roll mold 5 in the present embodiment.
As shown in this figure, the roll mold 5 has a cylindrical mold body 50 and a rotating shaft 51.

  Among them, the peripheral surface of the mold body 50 is provided with a fine concavo-convex shape having a rounded pyramid shape or a truncated pyramid shape. Here, being provided with a pyramid-shaped (pyramidal frustum-shaped) irregularity means that at least one of a pyramid-shaped (pyramidal frustum-shaped) concave portion and convex portion is provided. In the present embodiment, as shown in FIG. 2 (a), a plurality of substantially quadrangular pyramid-shaped convex portions 500 having rounded ridge portions are arranged on the circumferential surface of the mold body 50 in the axial direction and the circumferential direction. Has been. Here, as a magnitude | size of the convex part 500, for example, height (height difference) is 100 micrometers or less, Preferably 30 micrometers or less are preferable. In addition, as a material of such a mold main body 50, a conventionally known material can be used, and more specifically, a homogeneous metal capable of obtaining an appropriate surface roughness, for example, copper or aluminum, electroless Ni-P plating or the like can be preferably used.

  Further, as shown in FIG. 1, the rotating shaft 51 is provided coaxially with the mold body 50 in a state of penetrating the mold body 50. In addition, as such a rotating shaft 51, a conventionally well-known thing can be used.

  In the roll mold 5 as described above, a sheet-like optical element member is placed on a flat plate or the like, and rotated on the optical element member to transfer the irregular shape of the peripheral surface to the optical element. It has become. As a method for manufacturing an optical element using the roll mold 5 as described above, a conventionally known method such as a method disclosed in Japanese Patent Application Laid-Open No. 2007-83447 can be used.

Then, the manufacturing apparatus which manufactures said roll metal mold | die 5 is demonstrated.
FIG. 3 is a conceptual diagram showing a schematic configuration of a roll mold manufacturing apparatus 1 (hereinafter referred to as a mold manufacturing apparatus 1) according to the present invention.

  As shown in this figure, the mold manufacturing apparatus 1 includes a cutting device 2 and a polishing device 3.

Among these, the cutting device 2 cuts the peripheral surface of the roll die 5 (hereinafter referred to as a die base material 6) before the convex portion 500 is formed, as shown in FIG. 2 (b). A quadrangular pyramid-shaped convex portion 501 is formed. In addition, unlike the above-mentioned convex part 500, this convex part 501 is in the state where the ridgeline was not rounded but was square. As such a cutting device 2, a conventionally known cutting device such as an end mill can be used.
As the cutting process, a line-shaped concave groove is formed in the circumferential direction by relatively moving the cutting tool and the mold base material 6 in the contact and separation direction while rotating the mold base material 6 about the axis. A machining method for forming a grid-shaped pyramid shape or a truncated pyramid shape by moving the cutting tool and the mold base material 6 relative to each other in the axial direction of the mold base material 6 in the next processing is a cutting process. This is preferable in that the time can be shortened.

Moreover, the polisher 3 has the bathtub 30 and the rotation apparatus 31, as shown in FIG. 3, FIG.
The bathtub 30 is a bottomed cylindrical container that can accommodate a mold base material (hereinafter referred to as a mold intermediate body 7) in which convex portions 501 are formed in a vertical orientation, and has an abrasive dispersed therein. The polishing liquid K is stored inside. Here, the amount of the polishing liquid K in the bathtub 30 is an amount in which the entire mold body 50 of the mold intermediate body 7 is immersed. As the polishing liquid K, a dispersion liquid in which an abrasive such as alumina is dispersed in a liquid such as water can be used.

  The rotating device 31 relatively rotates the bathtub 30 and the mold intermediate body 7 in a state where the mold intermediate body 7 is immersed in the polishing liquid K in the bathtub 30. In the present embodiment, The rotating shaft 51 of the mold intermediate body 7 is held and the mold intermediate body 7 is rotated relative to the bathtub 30.

Then, the manufacturing method of the roll metal mold | die 5 using said metal mold | die manufacturing apparatus 1 is demonstrated.
First, the cutting device 2 cuts the peripheral surface of the mold base 6 and forms a plurality of convex portions 501 on the peripheral surface (cutting process). Thereby, the mold intermediate body 7 is formed. In addition, the height of the convex part 501 formed here is 100 micrometers or less, Preferably it is 30 micrometers or less.

  Next, the mold intermediate body 7 is immersed in the polishing liquid K in the bath 30 in the polishing apparatus 3, and the rotating device 31 rotates the mold intermediate body 7 relative to the bath 30 (polishing step). More specifically, the rotating device 31 reciprocates the mold intermediate body 7 in the circumferential direction of the mold intermediate body 7. Thereby, the convex part 501 of the surrounding surface of the metal mold | die intermediate body 7 is grind | polished, a ridgeline part is rounded, the convex part 500 is formed, As a result, the roll metal mold | die 5 is manufactured.

  According to Preston's formula, the amount of polishing removal by the polishing process is expressed by (polishing removal amount) = (proportional constant) × (processing pressure) × (processing speed) × (processing time). Alternatively, the processing time of the polishing process can be set by setting the abrasive used, the outer diameter of the mold intermediate 7 to be polished, the relative rotational speed, the processing time, and the like. Further, when the mold intermediate 7 is reciprocally rotated, it is preferable that the processing time in each direction is approximately the same.

  According to the manufacturing method of the roll mold 5 described above, the convex portion is obtained by immersing the mold intermediate 7 in the polishing liquid K in the bathtub 30 and rotating the mold intermediate 7 relative to the bathtub 30. Since 501 is polished, the ridge line portion of the convex portion 501 can be rounded and the shape can be made close to a cone. Therefore, it is possible to manufacture a roll mold with less unevenness of the uneven shape, and it is possible to prevent unevenness transferred and formed on the optical element from causing unevenness in the light distribution characteristics of the emitted light due to the ridge line portion. . In addition, since the improvement of the surface roughness expected for the polishing process is expected as compared with the conical shape or the truncated cone shape by cutting, it is possible to obtain an effect of preventing problems such as partial unevenness in the amount of light. Moreover, since a conical shape or a truncated cone shape can be collectively formed by a polishing process, the manufacture of the roll mold 5 is facilitated and manufactured as compared with the case where the conical shape or the truncated cone shape is formed by cutting. The manufacturing time as the whole process can be shortened.

  Moreover, since the mold intermediate body 7 is reciprocally rotated in the bathtub 30, the ridge line portion of the convex portion 501 can be surely rounded and brought close to a conical shape. Therefore, a sheet-like optical element having excellent optical performance can be reliably formed.

  It should be noted that the present invention should not be construed as being limited to the above-described embodiment, and of course can be modified or improved as appropriate.

  For example, in the above embodiment, the rotating device 31 has been described as rotating the mold intermediate body 7 relative to the bathtub 30, but the rotating device 31 may be rotated relative to the mold intermediate body 7. good. Furthermore, in this case, the bathtub 30 may be reciprocated in the circumferential direction.

  In addition, the rotating device 31 has been described as reciprocatingly rotating the mold intermediate body 7, but the direction of one of the center axis of the mold intermediate body 7 and the center axis of the bathtub 30 is changed to the other axis. It is good also as rotating these mold intermediate bodies 7 and the bathtub 30 relatively, shifting. By adopting such a configuration, the volume of the polishing liquid K between the bathtub 30 and the mold intermediate 7 becomes non-uniform and turbulent flow occurs, and the polishing amount is locally increased or decreased. It becomes possible. Of course, also in this case, since the ridge line portion of the convex portion 501 can be reliably rounded and brought close to a conical shape, a sheet-like optical element having excellent optical performance can be reliably formed.

  In addition, the description has been given on the case where the pyramid-shaped convex portion 500 is provided on the peripheral surface of the roll mold 5. It may be provided.

It is a conceptual diagram which shows schematic structure of a roll metal mold | die (metal mold | die base material). (A) is a figure which shows the convex part 500 of a roll metal mold | die, (b) is a figure which shows the convex part 501 of a metal mold | die intermediate body. It is a conceptual diagram which shows schematic structure of the manufacturing apparatus of the roll metal mold | die which concerns on this invention. It is a schematic diagram which shows schematic structure of the manufacturing apparatus of the roll metal mold | die which concerns on this invention. It is a figure which shows the sheet-like optical element in which the unevenness | corrugation was formed. It is a figure which shows the state by which the sheet-like optical element in which the unevenness | corrugation was formed was arrange | positioned by the output surface of the surface emitting element.

Explanation of symbols

1 Mold manufacturing equipment (roll mold manufacturing equipment)
2 Cutting device (cutting means)
5 Roll mold 30 Bath 31 Rotating device (Rotating means)
500,501 Convex part (concave / convex)
K polishing liquid

Claims (12)

In the manufacturing method of the roll mold for transferring the shape of the peripheral surface to the sheet-like optical element,
A cutting step of cutting a plurality of irregularities in the shape of a pyramid or a truncated pyramid on a cylindrical mold base material peripheral surface;
A preparation step of storing a polishing liquid in which an abrasive is dispersed and preparing a cylindrical bathtub capable of accommodating the mold base material therein;
A polishing step of polishing the unevenness by immersing the mold base material in which the unevenness is formed by the cutting step in the bathtub and relatively rotating the bathtub and the mold base material,
A process for producing a roll mold characterized by comprising: In the manufacturing method of the roll metal mold | die of Claim 1,
The method for manufacturing a roll mold, wherein the height h of the unevenness formed by the cutting step is 0 <h ≦ 30 (μm). In the manufacturing method of the roll metal mold | die of Claim 1 or 2,
In the polishing step, the mold base material is rotated with respect to the bathtub. In the manufacturing method of the roll metal mold | die of Claim 3,
In the polishing step, the mold base material is rotated back and forth in the circumferential direction of the mold base material. In the manufacturing method of the roll metal mold | die as described in any one of Claims 1-4,
In the polishing step, a roll mold characterized by relatively rotating the mold base material and the bathtub while changing one direction of the center axis of the mold base material and the central axis of the bathtub. Manufacturing method.   A roll mold manufactured by the method for manufacturing a roll mold according to any one of claims 1 to 5. The roll mold according to claim 6,
The height of the unevenness is 0 <h ≦ 30 (μm). In the manufacturing method of the sheet-like optical element which has the several uneven | corrugated shape on the surface using the roll metal mold | die formed by the manufacturing method of the roll metal mold | die as described in any one of Claims 1-5,
A first step of placing a sheet-like optical element member, and a step of transferring irregularities on the peripheral surface of the roll die by rotating the roll die on the sheet-like optical element placed in the first step. The manufacturing method of the sheet-like optical element characterized by having 2 processes. In a roll mold manufacturing apparatus for transferring the shape of the peripheral surface to a sheet-like optical element,
A cutting means for cutting a plurality of concavities and convexities in the shape of a pyramid or a truncated pyramid on a cylindrical mold base material peripheral surface;
A cylindrical bathtub for storing a polishing liquid in which an abrasive is dispersed and accommodating the mold base material therein;
The concavo-convex shape is obtained by relatively rotating the tub and the mold base material in a state where the mold base material in which a plurality of concavo-convex shapes of a pyramid shape or a truncated pyramid shape are formed on the peripheral surface is immersed in the bathtub. A roll mold manufacturing apparatus comprising: a rotating means for polishing the surface. In the manufacturing apparatus of the roll metal mold | die of Claim 9,
The said rotation means rotates the said metal mold | die base material with respect to the said bathtub, The manufacturing apparatus of the roll metal mold | die characterized by the above-mentioned. In the manufacturing apparatus of the roll metal mold | die of Claim 10,
The roll mold manufacturing apparatus according to claim 1, wherein the rotating unit reciprocally rotates the mold base material in a circumferential direction of the mold base material. In the manufacturing apparatus of the roll metal mold | die as described in any one of Claims 9-11,
The rotating means rotates the mold base material and the bathtub relative to each other while changing one direction of the central axis of the mold base and the central axis of the bathtub. Manufacturing equipment.

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