JP2010105314A - Method of molding film intermittently and device using the method - Google Patents

Method of molding film intermittently and device using the method Download PDF

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JP2010105314A
JP2010105314A JP2008281124A JP2008281124A JP2010105314A JP 2010105314 A JP2010105314 A JP 2010105314A JP 2008281124 A JP2008281124 A JP 2008281124A JP 2008281124 A JP2008281124 A JP 2008281124A JP 2010105314 A JP2010105314 A JP 2010105314A
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film
mold
surface
intermittent
molding
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JP2008281124A
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Japanese (ja)
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Kiyoshi Minoura
Fumiyasu Nomura
潔 箕浦
文保 野村
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Toray Ind Inc
東レ株式会社
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Abstract

【Task】
An object of the present invention is to provide an intermittent film forming apparatus capable of suppressing wrinkles generated in an intermittent portion between a forming portion and an adjacent forming surface due to an influence of a heat load from a press portion.
[Solution]
The intermittent film forming apparatus of the present invention includes a mold, a press device that presses the film against the surface of the mold, a film is released from the surface of the mold, and a film to be formed next is formed on the mold surface. An intermittent film forming apparatus including at least a conveying device for supplying, comprising gripping means for gripping the film across the film width direction in the vicinity of the mold edge on the downstream side in the conveying direction from the molding surface. Is.
[Selection] Figure 1

Description

  The present invention provides, for example, a molding method and a molding apparatus in which a continuous film wound in a roll shape is supplied to a molding apparatus while sequentially rewinding, and a fine uneven shape is intermittently press-molded on the film surface. About.

  In particular, the present invention relates to an intermittent film forming method and an intermittent film forming apparatus capable of obtaining a good state of flatness with few wrinkles at an intermittent portion between a forming portion and a film after press forming.

  As a means for producing an optical film such as a light guide plate, a light diffusing plate, and a lens, a method of transferring a fine uneven pattern on the surface of the film has been conventionally known.For example, for a roll-like long film, An apparatus and a method for intermittently forming fine concavo-convex patterns have been proposed (Patent Document 1, Patent Document 2).

  In these apparatuses and methods, the concavo-convex pattern is formed on the film surface by press-transferring the film supplied from the unwinding roll into the press apparatus to a die having a fine concavo-convex pattern. When press-transferring, the mold is heated to a temperature equal to or higher than the glass transition point of the film. After the transfer is completed, the mold is cooled under a certain condition while continuing the press. When the cooling proceeds to below the glass transition point of the film, the press pressure is released and the film is released from the mold only by applying a certain tension to the film. Thereafter, the film is sent downstream, the film forming surface to be formed next is supplied to the mold surface, and press transfer is repeated.

Moreover, as a method of releasing the film from the mold and supplying it, the peeling roll and the auxiliary roll arranged in parallel are rotated on the surface of the mold after the transfer while the film is held and held downstream. Have been proposed (Patent Document 3 and Patent Document 4).
JP 2005-199455 A Japanese Patent Laying-Open No. 2005-310286 JP 2008-105407 A JP 2008-105409 A

  However, even when intermittent molding of the film by these methods and release conveyance are performed, it is inevitable that there is an intermittent part between the molding surface and the molding surface. Wrinkles may enter the intermittent part. In particular, this wrinkle becomes noticeable in a thin film and depends on the film characteristics and molding conditions. However, in general, a film having a thickness of 0.05 mm or less is clearly a problem in appearance. In addition, this wrinkle may deteriorate the flatness of the adjacent completed region, or may cause a conveyance wrinkle in the conveyance process up to winding, which causes a reduction in product quality.

  The present invention was obtained as a result of intensive studies to solve the above problems, and was obtained by feeding a continuous film to a molding apparatus while sequentially rewinding the mold surface to the film surface. The present invention relates to a molding method and a molding apparatus for intermittently press-molding a shape, and is an intermittent film molding capable of suppressing wrinkles generated in an intermittent portion between the molding portion due to the influence of a thermal load from the pressing portion. An object is to provide an apparatus.

The intermittent film forming method of the present invention that solves the above problems comprises the following methods (1) and (2).
(1) Supplying a film intermittently in the vicinity of the mold surface, and forming a shape corresponding to the shape of the mold surface on the film surface by pressing the film against the mold An intermittent film forming method including at least a step and a release step of releasing and transporting the film attached to the surface of the mold after molding, and transporting from an area during molding in the molding step An intermittent film forming method in which the film is gripped across the film width direction between a region being formed and a region formed one cycle before on the downstream side in the direction.
(2) Supplying step of supplying a film intermittently in the vicinity of the mold surface, and forming the shape corresponding to the shape of the mold surface on the film surface by contacting and pressing the film against the mold An intermittent film forming method including at least a step and a release step of releasing and transporting the film attached to the surface of the mold after molding, and transporting from an area during molding in the molding step An intermittent film forming method in which the film is gripped across the film width direction so as to include the upstream side edge in the transport direction of the region formed before one cycle on the downstream side in the direction.

In the intermittent film forming method of the present invention of the above (1) and (2), preferably, the following specific methods (3) to (6) are included.
(3) The intermittent film forming method, wherein the gripping is to hold the surface of the film opposite to the surface on the mold side by suction.
(4) The intermittent film forming method, wherein the gripping is sandwiching both surfaces of the film.
(5) An intermittent film forming method in which, in the forming step, the gripped region is moved in a direction to bring it close to the mold.
(6) An intermittent film forming method for cooling the film in the region to be gripped in the forming step.

Moreover, the intermittent film-forming apparatus of the present invention that solves the above-mentioned problems comprises the following apparatus (7).
(7) a mold, a pressing device that presses the film against the surface of the mold, and a conveying device that releases the film from the surface of the mold and then supplies the film to be molded to the surface of the mold. Is an intermittent film forming apparatus including gripping means for gripping the film across the film width direction in the vicinity of the edge of the mold on the downstream side in the transport direction from the mold surface.

In the above intermittent film forming apparatus of the present invention (7), preferably, the following specific means (8) to (12) are provided.
(8) Adsorption holding means for adsorbing and holding the gripping means by depressurizing the film at a position downstream of the mold surface on the opposite side to the mold side with respect to the film side across the pass line of the film. An intermittent film forming apparatus.
(9) The intermittent film forming apparatus, wherein the adsorption holding means includes at least a porous body and a decompression means.
(10) The intermittent film forming apparatus, wherein the gripping means is configured by a plurality of rolls arranged opposite to each other across the film pass line at a position downstream of the mold surface in the transport direction.
(11) An intermittent film forming apparatus having a drive mechanism for moving the gripping means in the direction of approaching the mold.
(12) The intermittent film forming apparatus having a structure in which the gripping means circulates a fluid therein.

According to the intermittent film forming apparatus and the forming method of the present invention, a good forming surface can be obtained as follows.
(I) According to the intermittent film forming method and apparatus of the present invention described in the above (1), (2), and (7), the film is gripped across the width direction to prevent deformation of the film, thereby pressing In addition, the intermittent portion that is likely to be generated by the heat load from the molding surface and the wrinkles in the adjacent molding completed area one cycle before are suppressed. In particular, the effect is great when a film with a thickness of 0.05 mm or less that is easy to wrinkle is applied.
(Ii) In particular, according to the intermittent film forming method and apparatus of the present invention described in the above (3) and (8), since the surface opposite to the shaping surface is gripped, scratches and grip marks on the product surface are removed. To prevent.
(Iii) In particular, according to the intermittent film forming apparatus of the present invention described in (9) above, wrinkles can be suppressed by reliably gripping the film at the intermittent portion while suppressing the trace of the suction holes.
(Iv) In particular, according to the intermittent film forming method and apparatus of the present invention described in (4) and (10) above, the suction hole trace is generated because the film is reliably gripped by the intermittent portion in a suction-free state. There is nothing to do.
(V) In particular, according to the intermittent film forming method and apparatus of the present invention described in (5) and (11) above, it is possible to alleviate the tension caused by thermal shrinkage during molding, It is possible to prevent wrinkling in a region where the molding has been completed before one adjacent cycle.
(Vi) In particular, according to the intermittent film forming method and apparatus of the present invention described in the above (6) and (12), the film is held in the gripping portion while being cooled, thereby suppressing thermal shrinkage of the film and causing wrinkles. To prevent.

A preferred embodiment of the present invention will be described in detail with reference to the drawings.
The intermittent film forming apparatus of the present invention includes a mold, a press device that presses the film against the surface of the mold, a film is released from the surface of the mold, and a film to be formed next is formed on the mold surface. In the intermittent film forming apparatus including at least a conveying device for supplying, gripping means is provided for gripping the film across the film width direction in the vicinity of the mold edge, on the downstream side in the conveying direction from the mold surface. It is an intermittent film forming device characterized.

  In FIG. 1, the schematic sectional drawing which looked at the intermittent film forming apparatus 1 of this invention from the film width direction is shown. In the following, the case where the fine uneven shape is processed on the surface 3a of the mold 3 will be described, but the same applies to the case where other shapes are processed.

  As shown in FIG. 1, the first intermittent film forming apparatus 1 of the present invention includes a press unit 10 that is the press device, an unwind unit 50 and a take-up unit 60 that are the transport devices, and a fine surface. A mold adhering to the mold 3 having the irregular shape is released, a mold release supply unit 20 for supplying a film to be molded next, a heater unit 30 for heating and cooling the mold, and cooling And a gripping means 100 for gripping the film across the film width direction in the vicinity of the mold edge on the downstream side in the transport direction from the molding surface.

  As an operation of the intermittent film forming apparatus 1, the film 2 wound in a roll shape by the unwinding unit 50 is unwound, and the surface 3 a on which the fine uneven shape of the mold 3 is processed by the press unit 10. When pressed, a shape corresponding to the shape of the surface of the mold 3 on the molding surface 2 a of the film, that is, a fine uneven shape having a pattern opposite to the fine uneven shape of the mold 3 is transferred and formed into a roll shape by the winding unit 60. Then, the film 2 to be transferred and molded next is unwound from the unwinding unit 50. This operation is defined as one cycle, and unwinding, transfer molding, and winding are intermittently and sequentially repeated. The molding process is not limited to the heat molding method, and can be performed by a molding method using light, for example. In the case of not using the heat forming method, the heating unit 30 and the cooling unit 40 which are temperature control devices are not necessary in the apparatus and method of the present invention.

An example of the gripping means 100 that is a characteristic part of the present invention will be described with reference to the drawings.
FIG. 2 shows a schematic cross-sectional view of the configuration including the gripping means 100 viewed from the film running direction (winding side), and FIG. 3 shows a schematic cross-sectional view of the configuration including the gripping means 100 viewed from the film width direction.

  The gripping means 100 is composed of a suction plate 101 and a pneumatic unit 200 connected thereto. The suction plate 101 has a plurality of holes 104 formed on the film side surface. The hole 104 communicates with the pneumatic unit 200 as shown in FIG. 1 through a hole 102 machined inside the suction plate 101. The pneumatic unit 200 is connected to the compressor 106, the vacuum pump 107, and the leak line 105 through the switching valves 108a to 108c, and can control the opening and closing of the switching valves 108a to 108c to switch paths. Further, it is preferable that the suction plate 101 is connected to cylinders 103a and 103b at the end of the suction plate 101 in the film width direction so that the suction plate 101 is moved away from the mold surface. In addition, although the example of the mechanism which carries out adsorption | suction holding was shown above, what is necessary is just what can hold | grip a film in the width direction, and is not restricted to the said mechanism.

  When gripping the film, the suction hole 104 is communicated with the vacuum pump 107 to suck and hold the film. At this time, the film is adsorbed and held at a position on the opposite side to the mold side across the pass line of the film (where the film exists at the time of press molding) and on the downstream side in the transport direction from the mold surface, This is preferable because it can be held in a non-contact manner with respect to the molding surface and the quality of the molding surface is not deteriorated by scratches or the like.

  When a film is press-molded, the film is often subjected to a heat load at and near the molding surface. The heat load received by the film is usually generated by heating the mold, but in the molding method using light such as ultraviolet light, there can be an influence due to light absorption of the film and the resin layer on the surface. In general, a film subjected to a heat load shrinks and tends to wrinkle. The intermittent part between the molding surfaces is affected by the thermal load and shrinkage at the edge of the molding region and often wrinkles. Furthermore, when the area of the intermittent portion is narrow, wrinkles also occur in the area that has already been molded one cycle before, leading to a decrease in appearance quality. If the molding apparatus provided with the gripping means 100 of the present invention is applied, during molding, the intermittent portion is gripped from the opposite surface in contact with the mold to prevent deformation of the film, thereby preventing the film from being deformed. Wrinkles at the intermittent part due to heat load can be suppressed.

  When releasing the grip of the film, the compressor 106 and the suction hole 104 are communicated to blow out gas such as air, and then shut off from the compressor and communicated with the leak line to be in an atmospheric pressure state.

  Further, when the release supply unit 20 is moved in parallel on the mold surface in order to release the film or supply the film, the cylinders 103a and 103b are driven as necessary to fix the suction plate 101 to the mold 3. And move away from each other.

  Further, the adsorption holding means may be constituted by making the adsorption plate 101 a porous body and connecting a vacuum pump 107 as a decompression means. By applying the porous body, since the suction part is dispersed in the width direction of the film, the trace of the hole is suppressed, which is preferable in terms of quality. The porous body may be any of metal, ceramics, and resin, and may be properly used depending on the film material or product application. For example, in the case of a film material that is easily damaged, it is preferable from the viewpoint of preventing damage to the film that the porous body is made of resin. In addition, when there is a concern about contamination of the product due to wear of the porous body, it is preferable to use a metal or ceramic. As the metal, stainless steel, aluminum, titanium, copper, nickel, aluminum, or an alloy containing these can be used. For ceramics, alumina, zirconia, silicon carbide, aluminum nitride, silicon nitride, or the like can be used. As the resin, polyethylene, polypropylene, or the like can be applied. However, the material is not limited to the materials described above, and any material that can be processed into a porous body may be used.

  Further, the suction plate 101 is not necessarily limited to a plate shape. A cylindrical shape or a columnar shape may be used as long as it is a mechanism that can be suction-held on the surface in the width direction.

  In the above configuration, when the suction mark remains on the product surface, as another gripping means, as shown in FIG. 4, on the downstream side in the transport direction from the mold surface, a plurality of pieces arranged opposite to each other across the film pass line It is preferable to use gripping means composed of a plurality of rolls.

  The gripping means 110 is composed of a gripping roll A111 and a gripping roll B112 arranged in parallel so as to face each other with a film interposed therebetween. The gripping roll A111 is held at both ends in the film width direction. Further, it is preferable to connect the cylinders 113a and 113b at the end in the width direction and move the gripping roll A111 in a direction away from the mold surface. Further, an electromagnetic brake 114 is connected to one end of the gripping roll B112 so that the brake can be freely controlled.

  When the film is gripped, the film is nipped by the gripping roll A111 and the gripping roll B112, and is held almost in line contact. Since the suction holding mechanism is not used, the suction mark does not become a problem. The gripping roll B112 is preferably held so as not to rotate by applying a brake. In addition, when the release supply unit 20 is moved in parallel on the mold surface in order to release the film or supply the film, the cylinders 113a and 113b are driven as necessary to hold the gripping roll A111 on the mold surface. And move away from each other.

  Moreover, it is preferable to have a drive mechanism that automatically moves the gripping means in the direction of approaching the mold.

  FIG. 5 is a schematic cross-sectional view of a state in which the gripping means 100 is connected to the motor driving unit 122 via the bracket 120 and the ball screw 121 as viewed from the film width direction.

  During press molding, the film shrinks on and near the molding surface due to heat load or the like, and tension is applied to the film between the gripping portion and the mold. Depending on the thermal and elastic properties of the film, this tension may distort the film and induce wrinkles. At the timing when tension is applied to the film, the above moving mechanism is driven to bring the gripping part close to the mold side and loosen the film, thereby relaxing the tension and preventing distortion.

  Although a combination of a ball screw and a motor has been exemplified as the moving mechanism of the gripping means described above, it is only necessary to have a mechanism that can move directly, such as a pneumatic cylinder or an electromagnetic cylinder. However, in the case of applying a plurality of films having different shrinkage rates, a combination that can control the movement amount is preferable.

  Furthermore, it is preferable to have a structure for circulating a fluid inside the gripping means.

  FIG. 6 illustrates the structure of the adsorption plate 131 provided with the refrigerant flow path in a cross-sectional view seen from the film traveling direction. Although a refrigerant circulation device is not shown, it has a structure communicating with the refrigerant flow path 132 processed inside the adsorption plate 131. Except for the addition of the refrigerant flow path, the structure is the same as that of the adsorption plate shown in FIG. The film is held against the heat load received from the molding surface while being cooled by the gripping portion, thereby suppressing the shrinkage of the film and preventing wrinkles.

  As the refrigerant, water is preferable from the viewpoint of heat transfer efficiency and handling, and it may be controlled in the range of 20 ° C. to 30 ° C. depending on the film forming temperature conditions. If it is 20 ° C. or lower, the structural member may be condensed, and if it is 30 ° C. or higher, the effect of cooling is hardly exhibited. Further, as a system other than the refrigerant circulation, there is a method of spraying a cooled gas or the like, and any mechanism that can cool the film may be used.

  Hereinafter, the structure of the apparatus other than the gripping means will be described with reference to FIG.

  The press unit 10 is connected to the press cylinder 12 so that the pressure plate (upper) 14a can be moved up and down using the support column 11 as a guide. The support column 11 is disposed so as to be sandwiched between the frame (upper) 16a and the frame (lower) 16b. A temperature control plate (upper) 15a is attached to the lower surface of the pressure plate (upper) 14a. On the other hand, a temperature control plate (lower) 15b is attached to the upper surface of the pressure plate (lower) 14b. A heating unit 30 and a cooling unit 40 are connected to each temperature control plate via piping, wiring, and the like. And the metal mold | die 3 is attached to the upper surface of the temperature control plate (lower) 15b, and heating and cooling control are carried out via the lower temperature control plate. In addition, the metal mold | die 3 may be attached to the lower surface of the temperature control plate (upper) 15a.

  The press cylinder is connected to a hydraulic pump (not shown) and an oil tank, and the hydraulic pump controls the raising / lowering operation of the pressure plate (upper) 14a and the pressurizing force. In this embodiment, a hydraulic press cylinder is applied, but any mechanism can be used as long as it can control the applied pressure.

  The pressure range is preferably controllable in the range of 0.1 MPa to 20 MPa, more preferably 1 MPa and in the range of 10 MPa. If the pressure is 20 MPa or more, the mold may be damaged or deformed. If the pressure is 0.1 MPa or less, the resin does not flow sufficiently, and there is a possibility that shaping according to the pattern shape cannot be performed.

  The pressurization speed of the press cylinder is preferably controllable in the range of 0.01 MPa / s to 10 MPa / s, more preferably in the range of 0.05 MPa / s to 5 MPa / s. At the time of high pressure increase of 10 MPa / s or more, the deformation of the resin does not follow, and there is a possibility that shaping according to the pattern shape cannot be performed. Further, if the pressure is increased slowly at 0.01 Pa / s or less, molding takes time, and productivity is extremely reduced.

  In addition, when a temperature control plate is used so that the film can be formed on the entire surface even if there is some thickness unevenness, a heat resistance temperature of 130 ° C. or higher is required between the temperature control plate (top) 15a and the film 2. It is preferable to install the elastic plate 17 having the same. As the elastic plate 17, for example, ethylene / propylene / diene rubber (EPDM) having a thickness of 0.3 mm to 1.0 mm, silicone rubber, fluorine rubber, or the like can be preferably used. The thing which gave is good. Here, the heat resistant temperature refers to a temperature at which the rate of change in tensile strength when left at that temperature for 24 hours exceeds 10%.

  The mold 3 used in the present invention will be described. The transfer surface of the mold has a fine pattern, and methods for forming the pattern on the mold include machining, laser processing, photolithography, and electron beam drawing. Here, the “fine concavo-convex shape” formed on the mold is a convex shape that is periodically repeated with a height of 10 nm to 1 mm and a period of 10 nm to 1 mm. The height of the convex shape is more preferably 1 μm to 100 μm, and the period is more preferably 1 μm to 100 μm. As examples of convex shapes, protrusions of any shape typified by triangular pyramids, cones, quadrangular prisms, lens shapes, etc. are arranged in a discrete or dot shape, and the cross section is triangular, square, trapezoidal , Projections having an arbitrary shape typified by a semicircle, an ellipse and the like are arranged in a stripe shape. As the material of the mold, any material can be used as long as desired pressing strength, pattern processing accuracy, and film releasability can be obtained. For example, metallic materials including stainless steel, nickel, copper, etc., silicone, glass, Ceramics, resins, or those whose surfaces are coated with an organic film for improving releasability are preferably used. The fine pattern of the mold is formed corresponding to the fine uneven pattern desired to be applied to the film surface.

  The mold release supply unit 20 reciprocates in the transport direction while holding the film surface so as to hold the film so that the film sticks to the mold after molding, and then supplies the film to be molded. To do. Although it is not always necessary depending on the characteristics of the film and the pattern shape of the mold surface, it is preferable to provide it from the viewpoint of preventing damage to the mold surface and releasing traces to the film.

  In FIG. 7, the schematic sectional drawing which looked at the mold release supply unit 20 from the winding side of a film conveyance direction is shown. The release unit is composed of a unit in which a peeling roll 21 that reciprocates in the transport direction and an auxiliary roll 22 are connected while holding the film near the mold surface so as to hold the film. The peeling roll 21 not only peels off the film attached to the mold after molding, but also wrinkles the film by moving in the film transport direction while rotating the surface of the film supplied to the mold surface. It also has a function to perform. Here, the peeling roll rotating means 23 is connected to the peeling roll 21. A rotation controller 28 is connected so that it can operate at a specified number of rotations in either the forward rotation or the reverse rotation according to a command from a host controller (not shown). For example, a configuration in which a servo motor is combined as the peeling roll rotating means and a servo amplifier is combined as the rotation controller is preferable. Further, a linear guide (not shown) is attached to the upper surface of the pressure plate (lower) 14b so that the peeling roll 21 can smoothly move substantially parallel to the surface of the mold 3 while rotating.

  On the other hand, the auxiliary roll 22 has a structure that can be turned along the outer surface of the peeling roll 21 shown in FIG. As a means for turning the auxiliary roll, any means may be used as long as the auxiliary roll can be moved up and down along the outer periphery of the peeling roll around the peeling roll, such as an electromagnetic motor and an actuator using pneumatic pressure. The both ends of the auxiliary roll are attached so as to freely rotate around the roll axis.

  Further, a unit linear motion means 29 such as a linear drive motor is connected to the unit of the peeling roll and the auxiliary roll. The unit linear motion means that synchronizes the operation with the peeling roll rotation drive means is preferable for obtaining a smooth operation, and servo motor drive is suitable, but an electromagnetic actuator, a pneumatic actuator, or the like may be used. When peeling the film, peeling is performed while rotating the peeling roll and driving the unit linear movement means to move the release unit to the unwinding side. When the frictional force between the film and the peeling roll is sufficiently high, the linear movement force of the release unit can be obtained only by the frictional force and the film tension.

  Furthermore, when the surface unevenness pattern of the mold is very fine and is easily damaged by contact with the peeling roll, the distance (clearance) H between the peeling roll and the mold surface shown in FIG. 5 mm is good, more preferably 0.1 mm to 1 mm.

  Moreover, a cooling water circulation mechanism etc. may be added to a peeling roll and an auxiliary | assistant roll, and each roll may be temperature-controlled to fixed temperature. Since the temperature of the film is high immediately after release, it is preferable that the temperature of the peeling roll and auxiliary roll that are in contact immediately after the release is kept constant. It also has the effect of lowering the temperature of the film at the time of mold release and immediately after the mold release, and is also effective for stable conveyance and winding after press molding.

  On the other hand, the film contact portion of the auxiliary roll may be of the same surface material as the above-described peeling roll, but in particular, when the frictional resistance with the film to be used is high, wrinkles may be induced on the roll surface, It is preferable to apply a fluororesin or metal having a highly slippery surface.

  Next, the heating unit 30 will be described. The heating unit 30 is preferably a temperature control plate (upper), (lower) 15a, 15b made of an aluminum alloy and controlled by an electric heater cast in the plate. Further, the heating control may be performed by flowing a temperature-controlled heat medium into a copper or stainless steel pipe cast in the temperature control plate or a hole processed by machining. Furthermore, the apparatus structure which combined both may be sufficient.

As the heat medium, Barrel Therm (Matsumura Oil Co., Ltd.), NeoSK-OIL (Soken Techniques Co., Ltd.) or the like may be used, and water heated to 100 ° C. or higher may be circulated. And it is preferable that the number of lay nozzles in the pipe is in the range of 1.0 × 10 4 to 12 × 10 4 so that heat can be transferred efficiently.

  Moreover, when using a cast heater, a cartridge heater, etc., it is preferable that the temperature control plate can be divided and controlled.

  It is preferable that the temperature control plate falls within a temperature distribution within 10 ° C., more preferably within 5 ° C., in the range during temperature increase, temperature decrease, and constant temperature control.

  Alternatively, the heat medium piping line may be processed directly on the mold to directly control the temperature of the mold.

  Next, the cooling unit 40 will be described. The cooling unit performs cooling control by flowing a temperature-controlled refrigerant body into copper or stainless steel pipes cast into temperature control plates (upper) (lower) 15a and 15b, or holes machined.

As the coolant, water is optimal, but an ethylene glycol solution or the like may be used. The temperature is preferably in the range of 10 ° C. to 50 ° C., and the number of lay nozzles in the pipe is preferably in the range of 1.0 × 10 4 to 12 × 10 4 so that heat can be transferred efficiently.

  The unwinding unit 50 and the winding unit 60, which are the film conveying devices, will be described. The unwinding unit 50 includes an unwinding roll rotating means 51, transport rolls 52a to 52d, a drawing buffer unit 53, and a film fixing unit 54. The winding unit 60 includes a winding roll rotating means 61, conveying rolls 62 a to 62 d, a winding buffer unit 63, a conveying driving roll 64, and a film fixing unit 65.

  The drawer buffer unit 53 and the take-up buffer unit 63 are respectively composed of boxes 55 and 66 and suction / exhaust means 56 and 67 connected thereto. The suction / exhaust means 56, 67 may be any device that can suck and exhaust air, such as a vacuum pump. By exhausting the air in the box, a pressure difference is given between the front and back surfaces of the film inserted in the box. Apply a certain tension and loosen and hold the film in the box. The length of the film inserted into the box is appropriately the length of the film that is intermittently conveyed before and after the film is formed. Further, sensors 57a, 57b, 68a, 68b are mounted in the boxes 55, 66. The sensor may be any sensor that can detect the film at a predetermined position. When the film is released and conveyed by the release unit described above and the film is removed from the sensor detection position in the box, the upstream / downstream unwinding roll rotating means 51 or the winding roll rotating means 61 is driven. The film can be unwound or taken up and the film can always be loosened in place in the box.

  Further, the film fixing portions 54 and 65 are preferably flat plates having suction holes formed on the surface, but may be those having a mechanism for sandwiching the film with clips, or a combination thereof.

  The film fixing portions 54 and 65 are both operated when performing the pressing operation. And when releasing a film, it is preferable to operate the film fixing | fixed part 54, to fix a film, and to open the film fixing | fixed part 65. FIG. When the film is sent from upstream to downstream, both the film fixing parts 54 and 65 are opened.

  Although not shown, the conveyance drive roll 64 is connected to a rotation driving means such as a motor, and the nip roll 64a is close to the conveyance drive roll 64 when the film is conveyed, and the film is sandwiched between the films and the torque is controlled by the conveyance drive roll 64. Transport under a constant tension.

Next, the first and second intermittent film forming methods of the present invention will be described.
The first intermittent film forming method of the present invention includes a supply step of intermittently supplying a film in the vicinity of the mold surface, and contacting the film against the mold to press the mold surface on the film surface. An intermittent film forming method including at least a forming step for forming a shape corresponding to the shape, and a releasing step for releasing and transporting the film attached to the surface of the mold after forming, In the process, the film is gripped across the film width direction between the region being formed and the region formed one cycle before, on the downstream side in the transport direction from the region being formed.

  The second intermittent film forming method of the present invention includes a supply step of intermittently supplying a film in the vicinity of the mold surface, and the mold surface on the film surface by contacting and pressing the film against the mold. An intermittent film forming method including at least a forming step for forming a shape corresponding to the shape, and a releasing step for releasing and transporting the film attached to the surface of the mold after forming, In the process, the film is gripped across the film width direction so as to include the upstream edge in the transport direction of the region formed one cycle before the downstream side in the transport direction from the region being formed.

  An embodiment in which the first and second series of film forming operations are performed using the intermittent film forming apparatus 1 will be described with reference to FIGS. FIGS. 8 to 10 are schematic cross-sectional views of only the operation of the pressing portion as seen from the film width direction. FIG. 8 shows the molding process, FIG. A series of molding operations is performed by the following processes (A) to (H). In addition, after setting the die 3 in the press unit 10 in advance, the film 2 is set in the unwinding unit 50, the unwinding part of the film 2 is pulled out, and the surface of the die in the press unit is passed through the guide roll. Further, the winding unit 60 is in a state of being wound up via the release unit 20. Further, the heating unit is operated to raise both the temperature control plate (upper) 15a and the temperature control plate (lower) 15b to the molding temperature. (A) to (C) are molding steps, (D) and (E) are release steps, and (F) to (H) are supply steps.

  (A) The operation of the press section is shown in FIG. The press unit 10 is operated to lower the temperature control plate (upper) 15a, and press is started so that the film is sandwiched between the surface of the mold 3 and the temperature control plate (upper). Conditions such as temperature, press pressure, pressurization speed, and pressurization time depend on the material of the film, the transfer shape, particularly the aspect ratio of the unevenness. In general, the molding temperature is set to 100 to 180 ° C., the press pressure is set to 1 to 10 MPa, the molding time is set to 1 second to 60 seconds, and the pressurization speed is set in the range of 0.05 MPa / s to 1 MPa / s. At the same time, the film is gripped across the width direction by the suction plate 101. By gripping the intermittent portion where wrinkles easily occur due to the heat load from the edge of the molding surface, wrinkles at the intermittent portion can be suppressed. In particular, when the thickness of the film is thin, wrinkles are easily generated, so the method of the present invention is effective. Further, as shown in the figure, the film is sucked and held from the surface opposite to the mold with the film interposed therebetween, so that it can be held in a non-contact manner with respect to the molding surface, and the quality of the molding surface is lowered due to scratches or the like. This is preferable because it is eliminated. Further, in FIG. 8A, a mechanism for sucking and holding from the surface opposite to the mold is illustrated, but when the suction hole traces are remarkably generated, the roll nip mechanism from both sides shown in FIG. 4 can be used. It is preferable because the adsorption hole trace can be eliminated. Furthermore, although depending on molding conditions and film characteristics, when the thermal load at the intermittent portion is large, the mechanism shown in FIG. 5 is used to hold the grip portion while cooling to suppress wrinkles due to thermal shrinkage. It is preferable.

  (B) The operation of the next press section is shown in FIG. Since the film may shrink on the molding surface and in the vicinity thereof due to a thermal load or the like, tension may be applied to the film between the gripping area by the suction plate 101 and the mold, so depending on the film characteristics and molding conditions, It is preferable to move the gripping part to the mold 3 side by a linear motion mechanism constituted by a combination of motors 122 and the like. Depending on the thermal and elastic properties of the film, this tension may distort the film and induce wrinkles. At the timing when tension is applied to the film, the above moving mechanism is driven to bring the gripping part close to the mold side and loosen the film, thereby relaxing the tension and preventing distortion. Furthermore, if the film in the region to be gripped is forcibly cooled, film deformation due to heat shrinkage can be further suppressed, which is effective in preventing wrinkles.

  (C) The operation of the next press section is shown in FIG. During press molding, the cooling unit is operated to lower the temperature of the temperature control plate (upper) 15a and the temperature control plate (lower) 15b. In addition, it is preferable that pressurization is continued during cooling. The cooling temperature is set so that the temperature on the mold surface is sufficiently cooled to release the film. For example, the surface temperature of the mold 3 is preferably cooled to a glass transition point or less of the film. During this time, the film is continuously held.

  (D) The operation of the next press section is shown in FIG. After the cooling is completed, the press pressure is released, and the temperature control plate (upper) 15a is raised so that a sufficient space can be secured for the release unit 20 to move horizontally in the press apparatus. Further, the suction plate 101 is disconnected from the vacuum pump and connected to the compressed air line to release the film suction state. Thereafter, the suction plate 101 is moved upward to return to atmospheric pressure and secure a space in which the release unit 20 can move horizontally. At the same time, the auxiliary roll turning means is driven to turn the auxiliary roll 22 to the upper part of the peeling roll 21 so that the film 2 is held by the peeling roll 21 and the auxiliary roll 22.

  (E) The operation of the next press section is shown in FIG. At the same time as the peeling roll rotating means is rotated by the peeling roll rotating means, the peeling roll 21 and the auxiliary roll 22 are moved to the upstream side (in the direction of arrow A) while maintaining the relative position by the unit linear movement means 29 to release the film. To do. At this time, it is preferable to synchronize so that the peripheral speed of the roll and the linear motion speed are the same so that the film does not slip on the surface of the peeling roll.

  (F) The operation of the next press section is shown in FIG. The unit linear motion means 29 is braked and held so that the unit does not move, and the peeling roll rotating means rotates the peeling roll 21 to feed the film to the winding side (downstream in the conveying direction) by intermittent feeding. Do. This intermittent film feeding operation can also be performed by rotating the peeling roll (free side) and rotating the conveyance driving roll on the winding side (downstream in the conveyance direction).

  (G) The operation of the next press section is shown in FIG. Thereafter, the peeling roll rotating means 23 rotates the peeling roll 21 in the direction opposite to that at the time of releasing the mold, and at the same time, the unit linear movement means 29 keeps the peeling roll 21 and the auxiliary roll 22 in the relative downstream positions while maintaining the relative positions ( Directly move in the direction of arrow B) to supply the film to the mold surface. At this time, it is preferable to synchronize so that the peripheral speed of the roll and the linear motion speed are the same so that the film does not slip on the surface of the peeling roll.

  (I) The operation of the next press section is shown in FIG. When the supply of the film to the mold surface is completed and the units of the peeling roll 21 and the auxiliary roll 22 reach the winding side end (downstream in the transport direction), the suction plate 101 is lowered, and the film is sucked to the width. Grip in the direction. Then, the auxiliary roll is turned and returned to the original position, and the operation from FIG.

  By the series of film forming operations described above, since the deformation is suppressed by gripping the width direction of the intermittent portion with respect to the heat load from the edge of the forming portion, the intermittent portion or the adjacent portion is already formed one cycle before. Wrinkles due to heat shrinkage in the finished area can be prevented.

  11 and 12 are schematic views of the state where the intermittent portion is gripped as viewed from above. In the molding process, the film is held in the width direction by the holding unit 150. FIG. 11 shows the gripping of the film across the film width direction between the molding surface 151 and the molding surface 152 of the previous cycle (intermittent part) on the downstream side in the conveyance direction (arrow B) from the molding surface 151 in the molding process. To do. Prevents deformation at the intermittent part and suppresses wrinkling. Further, FIG. 12 shows that in the molding step, the film is formed across the film width direction so as to include the upstream edge in the conveyance direction of the molding surface 152 one cycle before the outer side on the downstream side (arrow B) in the conveyance direction from the molding surface 151. Is to hold. In any method, the deformation at the intermittent portion and the upstream end portion of the molding surface 152 before one cycle is prevented, and the generation of wrinkles is suppressed. In particular, in the method shown in FIG. 12, since the product part is directly gripped, the effect of preventing the deterioration of quality due to wrinkles in the product part is high.

  The sheet-like substrate applied to the method and apparatus of the present invention preferably has a glass transition temperature Tg of 40 to 180 ° C, more preferably 50 to 160 ° C, and most preferably 50 to 120 ° C. It is a sheet | seat which uses the thermoplastic resin which is these as a main component. When the glass transition temperature Tg is lower than 40 ° C., the heat resistance of the molded product is lowered, and the shape changes with time. Further, if Tg exceeds 180 ° C., the molding temperature must be increased, resulting in inefficiency in energy, and volume fluctuation during heating and cooling of the sheet increases, and the sheet bites into the imprint mold. However, even if it can be released, it is not preferable because the transfer accuracy of the pattern may be reduced or the pattern may be partially broken to cause a defect.

  Specifically, the sheet-like base material mainly composed of the thermoplastic resin applied to the present invention is preferably a polyester-based resin such as polyethylene terephthalate, polyethylene-2, 6-naphthalate, polypropylene terephthalate, polybutylene terephthalate, or polyethylene. Polyolefin resins such as polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, polyamide resins, polyimide resins, polyether resins, polyester amide resins, polyether ester resins, acrylic resins, polyurethane resins, It is made of polycarbonate resin or polyvinyl chloride resin. Among these, there are various types of monomers to be copolymerized, and it is particularly easy to adjust material properties, so that polyester resins, polyolefin resins, polyamide resins, acrylic resins, or mixtures thereof are used. It is preferable that the thermoplastic resin is mainly formed from the selected thermoplastic resin, and it is more preferable that the above-mentioned thermoplastic resin is 50% by weight or more.

  The sheet-like base material applied to the present invention may be a sheet made of the above-mentioned resin alone or a laminate made of a plurality of resin layers. In this case, compared with a single sheet, surface characteristics such as slipperiness and friction resistance, mechanical strength, and heat resistance can be imparted. Thus, when it is a laminate composed of a plurality of resin layers, it is preferable that the entire sheet satisfies the above-mentioned requirements, but even if the entire sheet does not satisfy the above-mentioned requirements, there is a layer that satisfies at least the above-mentioned requirements. If it is formed on the surface layer, the surface can be easily formed.

  Moreover, it is preferable that it is the range of 0.01-1 mm as preferable thickness (thickness, film thickness) of the sheet-like base material applied to this invention. If the thickness is less than 0.01 mm, the thickness is not sufficient for molding. If the thickness exceeds 1 mm, the sheet is generally difficult to convey due to the rigidity of the sheet. In the case of a film having a thickness of 0.05 mm or less, wrinkles are likely to occur at the intermittent portion between the forming surface and the forming surface in the forming step, and the apparatus and method of the present invention described above are effective for suppressing wrinkles.

  Although the film has been described as a thermoplastic resin, the present invention can also be applied to a known intermittent molding apparatus and method in which a photocurable resin is used as a base material.

FIG. 1 is a schematic view of an embodiment of the intermittent film forming apparatus of the present invention viewed from the film width direction. FIG. 2 is a schematic view of a configuration including gripping means for gripping a film by suction holding as viewed from the film running direction (winding side) in an embodiment of the intermittent film forming apparatus of the present invention. FIG. 3 is a schematic view of a configuration including gripping means for gripping a film by suction holding as viewed from the film width direction in an embodiment of the intermittent film forming apparatus of the present invention. FIG. 4 is a schematic view of a configuration including gripping means for gripping a film with a roll as viewed from the film running direction (winding side) in an embodiment of the intermittent film forming apparatus of the present invention. FIG. 5 is a schematic view of the configuration in which the film gripping means is moved in the direction of approaching the mold in the embodiment of the intermittent film forming apparatus of the present invention as viewed from the film width direction. FIG. 6 is a schematic view of a configuration including film gripping means having a fluid circulation mechanism as viewed from the film running direction (winding side) in one embodiment of the intermittent film forming apparatus of the present invention. FIG. 7 is a schematic view of the film release supply mechanism as viewed from the winding side in the film transport direction in one embodiment of the intermittent film forming apparatus of the present invention. FIG. 8 is a schematic view of the operation of the pressing part in the forming step as seen from the film width direction in one embodiment of the intermittent film forming method of the present invention. FIG. 9 is a schematic view of the operation of the pressing part in the mold release step as seen from the film width direction in one embodiment of the intermittent film forming method of the present invention. FIG. 10 is a schematic view of the operation of the pressing unit in the supplying step as viewed from the film width direction in one embodiment of the intermittent film forming method of the present invention. FIG. 11: is the schematic which looked at the state which is holding the shaping | molding surface intermittent part at the shaping | molding process from one side of the press part in one embodiment of the intermittent film shaping | molding method of this invention. FIG. 12 is a schematic view of the state where the forming surface intermittent portion is held in the forming step as viewed from above the press portion in one embodiment of the intermittent film forming method of the present invention.

Explanation of symbols

1: intermittent film forming apparatus 2 of the present invention 2: film 3: mold 10: press unit 20: release supply unit 30: heater unit 40: cooling unit 50: unwinding unit 60: winding unit 100: gripping means 101 : Suction plate 103a, b: cylinder 104: hole 105: leak line 106: compressor 107: vacuum pump 108a, b, c: switching valve 110: gripping means 111: gripping roll A
112: Holding roll B
113a, b: Cylinder 114: Electromagnetic brake 120: Bracket 121: Ball screw 122: Motor drive part 131: Suction plate 132: Refrigerant flow path 150: Grasping part 151, 152: Molding surface 200: Pneumatic unit A: Unwinding direction B: Winding side direction

Claims (13)

  1. A supply step of intermittently supplying a film in the vicinity of the mold surface;
    A molding step of forming a shape corresponding to the shape of the mold surface on the film surface by contacting and pressing the film to the mold; and
    A mold release step of releasing and transporting the film attached to the mold surface after molding, and an intermittent film forming method including at least
    In the forming step, an intermittent film forming method in which the film is gripped across the film width direction between a region being formed and a region formed one cycle before, on the downstream side in the transport direction from the region being formed.
  2. A supply step of intermittently supplying a film in the vicinity of the mold surface;
    A molding step of forming a shape corresponding to the shape of the mold surface on the film surface by contacting and pressing the film to the mold; and
    A mold release step of releasing and transporting the film attached to the mold surface after molding, and an intermittent film forming method including at least
    In the forming step, an intermittent film forming method for gripping the film across the film width direction so as to include the upstream end in the transport direction of the region formed one cycle before the downstream side in the transport direction from the region being formed.
  3.   3. The intermittent film forming method according to claim 1, wherein the gripping is to suck and hold a surface of the film opposite to the surface on the mold side.
  4.   The intermittent film forming method according to claim 1 or 2, wherein the gripping is sandwiching surfaces on both sides of the film.
  5.   The intermittent film forming method according to any one of claims 1 to 4, wherein, in the forming step, the gripped region is moved in a direction in which the gripped region is brought close to the mold.
  6.   The intermittent film forming method according to claim 1, wherein the film in the region to be gripped is cooled in the forming step.
  7.   The film by which the shape corresponding to the shape of the said mold surface was shape | molded by the shaping | molding method in any one of said 1-6.
  8. Mold,
    A pressing device that presses the film against the surface of the mold;
    A transfer device for releasing the film from the surface of the mold and supplying a film to be molded next to the mold surface,
    An intermittent film forming apparatus comprising gripping means for gripping the film across the film width direction in the vicinity of the mold end side on the downstream side in the transport direction from the mold surface.
  9.   The gripping means is suction holding means for sucking and holding the film by depressurizing the film at a position downstream of the mold surface on the opposite side to the mold side across the pass line of the film in the transport direction. Item 9. The intermittent film forming apparatus according to Item 8.
  10.   The intermittent film forming apparatus according to claim 9, wherein the adsorption holding unit includes at least a porous body and a decompression unit.
  11.   9. The intermittent film according to claim 8, wherein the gripping means is constituted by a plurality of rolls arranged opposite to each other across the film pass line at a position downstream of the mold surface in the transport direction. Molding equipment.
  12.   The intermittent film forming apparatus according to any one of claims 8 to 11, further comprising a drive mechanism that moves the gripping means in a direction to approach the mold.
  13.   The intermittent film forming apparatus according to any one of claims 8 to 12, wherein the gripping means has a structure for circulating a fluid therein.
JP2008281124A 2008-10-31 2008-10-31 Method of molding film intermittently and device using the method Pending JP2010105314A (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE112011103391T5 (en) 2010-10-08 2013-07-11 Toshiba Kikai Kabushiki Kaisha demolding
JP2015507355A (en) * 2012-11-22 2015-03-05 蘇州蒙斯威光電科技有限公司Suzhou Mons−Way Photoelectric Technology Limited Company UV forming apparatus and method for roll-to-roll alignment
WO2016102125A1 (en) * 2014-12-22 2016-06-30 Obducat Ab Mounting and demolding device
KR20160095232A (en) * 2015-02-02 2016-08-11 주식회사 에이앤디코퍼레이션 Mold removal apparatus for nano imprint

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE112011103391T5 (en) 2010-10-08 2013-07-11 Toshiba Kikai Kabushiki Kaisha demolding
US9415537B2 (en) 2010-10-08 2016-08-16 Toshiba Kikai Kabushiki Kaisha Demolding device
JP2015507355A (en) * 2012-11-22 2015-03-05 蘇州蒙斯威光電科技有限公司Suzhou Mons−Way Photoelectric Technology Limited Company UV forming apparatus and method for roll-to-roll alignment
US9096024B2 (en) 2012-11-22 2015-08-04 Suzhou Mons-Way Photoelectric Technology Limited Company UV curable resin embossing apparatus and method for roll to roll alignment
WO2016102125A1 (en) * 2014-12-22 2016-06-30 Obducat Ab Mounting and demolding device
KR102025904B1 (en) 2014-12-22 2019-09-26 오브듀캇 아베 Mounting and Demolding Devices
CN107000308A (en) * 2014-12-22 2017-08-01 奥贝达克特公司 Install and stripper apparatus
KR20170097770A (en) * 2014-12-22 2017-08-28 오브듀캇 아베 Mounting and demolding devices
EP3037236B1 (en) * 2014-12-22 2017-12-20 Obducat AB Mounting and demolding device
KR101703811B1 (en) 2015-02-02 2017-02-09 주식회사 에이앤디코퍼레이션 Mold removal apparatus for nano imprint
KR20160095232A (en) * 2015-02-02 2016-08-11 주식회사 에이앤디코퍼레이션 Mold removal apparatus for nano imprint

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