JP2010202734A - Apparatus and method for producing sheet, and adhered sheet material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and method for producing a sheet, reliably forming a resin layer in a predetermined shape through a relatively simple structure and control, and to provide an adhered sheet material. <P>SOLUTION: To a resin layer R laminated on one surface of a first release sheet RL1, a pattern of a concave-convex surface R1 is transferred by a transferring means 3, as well as the resin layer R is cured by a curing means 4. Then a double-sided adhesive sheet S having a second release sheet RL2 temporarily adhered to one adhesive face S1 is laminated, with the other adhesive face S2 of the sheet S stuck to the concavo-convex face R1. In each step, since use of a resin that easily flows is unnecessary, the structure and control of the apparatus 1 for producing a sheet can be simplified. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a sheet manufacturing apparatus, a manufacturing method, and an adhesive sheet body.

Conventionally, an ionizing radiation curable resin is applied to one surface of a base film, and this base film is wound around a forming roll and pressed with a pressing roll, thereby forming a lenticular lens portion on the resin and irradiating with ionizing radiation. A manufacturing method (manufacturing apparatus) of a transmission screen that cures the resin has been proposed (for example, see Patent Document 1).
In the manufacturing method described in Patent Document 1, a resin that flows easily is poured from a dispenser between a base film and a molding roll to form a resin pool, and is pressed with a pressing roll from the base film side toward the molding roll. Thus, a lenticular lens portion is formed by transferring the lens mold of the molding roll to the resin, whereby a sheet having the lenticular lens is manufactured.

Japanese Patent No. 2883121

  By the way, in the conventional manufacturing method (apparatus) as described in Patent Document 1, a dispenser that supplies resin is necessary, and the flow rate control of the resin in this dispenser becomes complicated. And if the flow rate of the resin is high, the overflowed resin may harden at an unintended position or contaminate the device. If the flow rate of the resin is low, the predetermined lens shape cannot be formed, resulting in poor quality. There is also a problem that the yield decreases. For this reason, a dispenser capable of highly controlling the flow rate of the resin is required, resulting in inconveniences such as an increase in apparatus cost and an increase in size.

  The present invention has been devised by paying attention to the inconveniences as described above, and an object thereof is a sheet manufacturing apparatus capable of reliably forming a resin layer having a predetermined shape by a relatively simple structure and control, It is in providing a manufacturing method and an adhesive sheet body.

  In order to achieve the above object, the sheet manufacturing apparatus of the present invention includes a feeding means for feeding a raw material in which a first resin layer is laminated on a first strip-shaped release sheet, and unevenness on the first resin layer of the fed raw material. Transfer means for transferring the surface, curing means for hardening the first resin layer to which the unevenness has been transferred, and the other surface of the second resin layer temporarily attached to one side of the belt-like second release sheet. The structure of having a sticking means for sticking to the uneven surface of one resin layer is adopted.

  At this time, in the sheet manufacturing apparatus of the present invention, a peeling means for peeling the second release sheet from one surface of the second resin layer, and the first release sheet and the first release sheet are peeled off. Cutting means for cutting the adhesive sheet body in which the first and second resin layers are laminated, holding means for holding the cut adhesive sheet body, and the second resin layer in the adhesive sheet body held by the holding means It is preferable to provide a pressing means for pressing and adhering one surface of the substrate to the adherend.

On the other hand, in the sheet manufacturing method of the present invention, the original fabric in which the first resin layer is laminated on the first strip-shaped release sheet is fed out, and the irregularities are transferred to the first resin layer of the fed-out raw material. The transferred first resin layer is cured, and the other surface of the second resin layer, one surface of which is temporarily attached to the belt-shaped second release sheet, is attached to the uneven surface of the first resin layer. .
At this time, in the sheet manufacturing method of the present invention, the second release sheet is peeled from one surface of the second resin layer, and the first release sheet and the first and second resin layers are laminated. It is preferable to form a sheet body, cut and hold the adhesive sheet body, and then press and adhere one surface of the second resin layer to the adherend.
Furthermore, the adhesive sheet body of the present invention is manufactured by the sheet manufacturing method.

  According to the present invention as described above, by preparing an original fabric in which the first resin layer is laminated on the first release sheet, the original fabric is drawn out and the unevenness is transferred to the first resin layer. Thus, the dispenser for supplying the resin becomes unnecessary, the cost of the apparatus can be reduced, the size can be reduced, and the above problem due to the flow rate of the resin can be avoided. Then, by forming the first resin layer with an appropriate layer thickness in advance on the raw fabric, irregularities having a predetermined shape can be formed by transfer, and the quality and yield of the manufactured sheet can be improved. it can.

  Furthermore, after the first resin layer is cured, the formed unevenness can be protected by sticking the second resin layer to the uneven surface, and the first release sheet and the first and second in the subsequent process. An adhesive sheet comprising a resin layer can be easily attached to an adherend. At this time, a first release sheet is provided on the surface of the first resin layer opposite to the uneven surface, and the adhesive sheet body is pressed and stuck to the adherend through the second resin layer on the uneven surface side. Thus, the first resin layer can be protected by the first release sheet. And since the 1st resin layer can be exposed only by peeling a 1st peeling sheet, an adhesive sheet body can be utilized as a transmissive screen with a lenticular lens, a reflective sheet, etc., for example.

1 is a schematic overall view of a sheet manufacturing apparatus according to an embodiment of the present invention. Operation | movement explanatory drawing of the sheet manufacturing apparatus of FIG. The external view of the product manufactured with the sheet manufacturing apparatus of FIG. FIG. 2 is a cross-sectional view taken along line AA to EE in FIG. 1. FF -II sectional drawing of FIGS. 1-3.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic overall view of a sheet manufacturing apparatus 1 according to an embodiment of the present invention.
In FIG. 1, the sheet manufacturing apparatus 1 includes a first feeding unit 2 as a feeding unit that feeds an original fabric O in which a resin layer R is laminated on one surface of a first release sheet RL1, and a resin layer R of the original fabric O. Transfer means 3 for transferring irregularities to the substrate, curing means 4 for curing the resin layer R to which the irregularities are transferred, second feeding means 5 for feeding the double-sided adhesive sheet S, and double-sided adhesive sheet S on the uneven surface side of the resin layer R. And a pasting means 6 for pasting. Further, the sheet manufacturing apparatus 1 includes a peeling means 7 for peeling the second release sheet RL2 from the double-sided adhesive sheet S, and a double-sided adhesive sheet S, the resin layer R, and the first release sheet RL1 from which the second release sheet RL2 has been peeled. A cutting means 8 for cutting and holding pressure means 9 for holding the adhesive sheet SA cut to a predetermined length and pressing and sticking to the adherend W are provided. The first feeding means 2, the transfer means 3, the curing means 4, the second feeding means 5, the sticking means 6 and the peeling means 7 are each supported by a frame (not shown).

  Here, as shown in FIG. 4A, the raw fabric O has a resin layer R as a first resin layer laminated on one surface of a strip-shaped first release sheet RL1, and the first release sheet RL1 and It is formed in a tape shape of a three-layer structure in which a release sheet RLa is temporarily attached to the surface of the resin layer R on the opposite side (the lower side in FIG. 4A). The resin layer R is formed, for example, by applying an electron beam curable resin, an ultraviolet curable resin, or the like to one surface of the first release sheet RL1, and the shape of the resin layer alone can be maintained in a normal state. A so-called adhesive sheet which has a viscosity and hardly flows can be exemplified. The first release sheet RL1 is made of a resin that can transmit an electron beam and ultraviolet rays from the curing unit 4. The raw fabric O is not limited to the three-layer structure in which the release sheet RLa is temporarily attached, and the release sheet RLa is omitted, and the release surface is on the back side (the side opposite to the resin layer R) of the first release sheet RL1. It may be formed, and the resin layer R may be wound around the peeling surface.

On the other hand, as shown in FIG. 4E, the double-sided adhesive sheet S as the second resin layer is temporarily attached to the adhesive surface S1 on one side (lower side of FIG. 4E). The release sheet RLb is temporarily attached to the other adhesive surface S2 to form a three-layer tape. The double-sided adhesive sheet S is made of, for example, an electron beam curable resin, an ultraviolet curable resin, or the like, and is a transparent resin. As the resin, for example, an acrylic adhesive or the like can be used. As the double-sided adhesive sheet S, a double-sided adhesive sheet having a known structure, such as one formed by an adhesive layer or a three-layer structure in which an adhesive layer is laminated on both sides of a base sheet, is adopted. Can do. Moreover, as an adhesive agent, the adhesive agent of a well-known composition is employable other than curable resin hardened | cured with an electron beam or an ultraviolet-ray.
In addition, the adherend W is, for example, a transparent glass panel, and is placed on and supported by the support means 10 constituted by an appropriate table.

  The first feeding means 2 collects the peeled release sheet RLa, the support roller 21 that winds and supports the roll O in a roll shape, the guide roller 22 that peels and guides the release sheet RLa from the roll O, and the peeled sheet RLa. A collection roller 23 is provided. The first feeding means 2 is configured to pull the release sheet RLa and feed the first release sheet RL1 and the resin layer R from the support roller 21 by rotationally driving the collection roller 23 by a driving means (not shown). .

  The transfer means 3 includes a stamper 31 having an uneven mold 31A (see FIG. 4C) formed on the outer peripheral surface, a pressing roller 32 that presses the first release sheet RL1 and the resin layer R toward the stamper 31, and a stamper. The first release sheet RL <b> 1 and the guide roller 33 that guides the resin layer R over a predetermined section 31 are provided. As shown in FIGS. 4C and 4D, the transfer unit 3 presses the resin layer R against the stamper 31 with the pressing roller 32 from the first release sheet RL1 side. An uneven surface R1 is formed on the resin layer R.

  The curing unit 4 includes an electron beam irradiation device that irradiates an electron beam and an ultraviolet irradiation device that irradiates ultraviolet rays between the pressing roller 32 and the guide roller 33 of the transfer unit 3. The curing means 4 cures the resin layer R on which the uneven surface R1 is formed by irradiating the resin layer R with an electron beam or ultraviolet rays from the first release sheet RL1 side.

  The second feeding means 5 peels the release sheet RLb from the double-sided adhesive sheet S, and the support roller 51 that rolls and supports the double-sided adhesive sheet S temporarily attached with the second release sheet RL2 and the release sheet RLb. And a collection roller 53 that collects the peeled release sheet RLb. The second feeding means 5 is configured to pull the release sheet RLb and to feed the double-sided adhesive sheet S and the second release sheet RL2 from the support roller 51 by rotating the collection roller 53 by a driving means (not shown). Yes.

  The sticking means 6 includes a first pressing roller 61 provided on the first release sheet RL1 side and a second pressing roller 62 provided on the second release sheet RL2 side. These first and second pressing rollers 6 are provided. The first release sheet RL1, the resin layer R, the double-sided adhesive sheet S and the second release sheet RL2 are sandwiched between the rollers 61 and 62, and the resin layer R and the double-sided adhesive sheet S are adhered by pressing them. It has become. At this time, as shown in FIG. 5F, the other adhesive surface S2 of the double-sided adhesive sheet S is deformed along the uneven surface R1 of the resin layer R, so that the uneven surface R1 and the adhesive surface S2 are There are no gaps between them so that they are closely adhered to each other. In addition, in order to prevent a space | gap being formed between uneven | corrugated surface R1 and adhesive surface S2, the pressure reduction means which surrounds the sticking means 6 and sucks air may be provided.

  The peeling means 7 includes a peel plate 71 that folds the second release sheet RL2 at an acute angle, a guide roller 72 that guides the folded second release sheet RL2, and a guide roller 72 that is driven by a motor (not shown). The driving roller 73 sandwiches the second release sheet RL2, and a recovery roller 74 that recovers the second release sheet RL2 by a driving unit (not shown). The peeling means 7 peels the second release sheet RL2 from the adhesive surface S1 of the double-sided adhesive sheet S by pulling the second release sheet RL2 folded back by the peel plate 71 by the driving roller 73, and the first release sheet RL1, The resin layer R and the double-sided adhesive sheet S are sent out to the holding and pressing means 9 side.

  The cutting means 8 has an appropriate cutter blade, and is supported by a drive mechanism (not shown) so as to be vertically movable. The cutting means 8 cuts the first release sheet RL1, the resin layer R, and the double-sided adhesive sheet S fed from the peel plate 71 to form an adhesive sheet SA having a predetermined length.

  The holding and pressing unit 9 includes a holding unit 91 as a holding unit that holds and holds the adhesive sheet SA (the first release sheet RL1, the resin layer R, and the double-sided adhesive sheet S laminated) cut by the cutting unit 8. A pressing roller 92 is provided on one end side of the holding portion 91 and serves as a pressing means for pressing and sticking the adhesive sheet SA to the adherend W. The holding and pressing means 9 is supported by a moving mechanism (not shown) so as to be movable up and down and left and right, and receives the adhesive sheet SA cut by the cutting means 8 and above the adherend W supported by the supporting means 10. It can move between positions. Further, as shown in FIG. 2, the holding and pressing means 9 is controlled to move so that the pressing roller 92 rolls and presses the adhesive sheet SA along the upper surface of the adherend W. Yes.

Hereinafter, the operation procedure of the sheet manufacturing apparatus 1 will be described with reference to FIGS. Here, a lens portion L (see FIGS. 3 and 5I) that can be used as a lenticular lens is formed by the resin layer R and the double-sided adhesive sheet S, and this lens portion L is formed on the adherend W (glass). Explain the procedure up to pasting to the panel.
First, as shown in FIG. 4 (A), the first feeding means 2 is a raw fabric O in which the resin layer R is laminated on the first release sheet RL1 and the release sheet RLa is temporarily attached to the surface of the resin layer R. As shown in FIG. 4B, the release sheet RLa is peeled from the resin layer R, and the first release sheet RL1 and the resin layer R are sent out toward the transfer means 3.
Next, as shown in FIG. 4C, the transfer unit 3 presses the concave / convex mold 31 </ b> A of the stamper 31 against the resin layer R to form the concave / convex surface R <b> 1 on the resin layer R. Then, the curing means 4 irradiates the resin layer R on which the uneven surface R1 is formed with an electron beam or ultraviolet rays from the first release sheet RL1 side to cure the resin layer R, and then the stamper 31 is moved to the resin layer R. Release from the mold. Then, as shown in FIG. 4D, the cured resin layer R and the first release sheet RL1 formed with the uneven surface R1 are sent to the pasting means 6.

On the other hand, as shown in FIG. 4 (E), the double-sided adhesive sheet S on which the second release sheet RL2 and the release sheet RLb are temporarily attached is fed out by the second feeding means 5. The second feeding means 5 peels the release sheet RLb from the other adhesive surface S2 of the second release sheet RL2, and sends the double-sided adhesive sheet S and the second release sheet RL2 toward the pasting means 6.
Next, the sticking means 6 presses the first release sheet RL1, the resin layer R, the double-sided adhesive sheet S and the second release sheet RL2 with the pressing rollers 61 and 62, and deforms the adhesive surface S2 along the uneven surface R1. Then, the double-sided adhesive sheet S is stuck to the resin layer R to form a sheet body having a four-layer structure as shown in FIG.

The first release sheet RL1, the resin layer R, the double-sided adhesive sheet S and the second release sheet RL2 attached as described above are sent to the release means 7, which is shown in FIG. 5 (G). Then, the second release sheet RL2 is peeled from the adhesive surface S1 of the double-sided adhesive sheet S, and the first release sheet RL1, the resin layer R, and the double-sided adhesive sheet S are sent to the cutting means 8 and the holding and pressing means 9.
Next, the holding and pressing means 9 sucks and holds the first release sheet RL1, the resin layer R, and the double-sided adhesive sheet S from which the second release sheet RL2 has been peeled by the holding portion 91. And the cutting | disconnection means 8 cut | disconnects 1st peeling sheet RL1, resin layer R, and double-sided adhesive sheet S by predetermined length, and forms adhesive sheet body SA.

Next, the holding and pressing means 9 conveys the adhesive sheet body SA sucked and held by the holding portion 91 to the upper surface position of the adherend W, and is bonded by the pressing roller 92 as shown in FIG. 2 and FIG. The sheet body SA is pressed against the adherend W, and the adhesive surface S1 of the double-sided adhesive sheet S is attached to the upper surface of the adherend W.
After the application of the adhesive sheet SA to the adherend W is repeated an appropriate number of times, the double-sided adhesive sheet S is irradiated by irradiating the double-sided adhesive sheet S from the side of the adherend W with an electron beam or ultraviolet rays. Harden. Then, by peeling the first release sheet RL1 from the resin layer R, an optical component in which a plurality of lens portions L are formed on the surface of the adherend W is manufactured as shown in FIGS. Is done. Such an optical component is used as a transmission screen, a reflection sheet, a diffusion plate, etc. by cutting the adherend W into an appropriate size.

According to this embodiment as described above, the following effects are obtained.
That is, by transferring the uneven surface R1 to the resin layer R laminated on one surface of the first release sheet RL1, the structure of the sheet manufacturing apparatus 1 and its control can be simplified. Then, by forming the resin layer R having an appropriate layer thickness on the raw fabric O, the uneven surface R1 can be formed in a predetermined shape, and the quality and yield of the lens portion L can be improved. .

  As described above, the best configuration, method and the like for carrying out the present invention have been disclosed in the above description, but the present invention is not limited to this. That is, the invention has been illustrated and described with particular reference to certain specific embodiments, but without departing from the spirit and scope of the invention, Various modifications can be made by those skilled in the art in terms of material, quantity, and other detailed configurations. In addition, the description of the shape, material, and the like disclosed above is exemplary for ease of understanding of the present invention, and does not limit the present invention. The description by the name of the member which remove | excluded the limitation of one part or all of such restrictions is included in this invention.

  For example, in the above-described embodiment, the case where an optical component that can be used as a transmission screen, a reflection sheet, a diffusion plate, etc. is manufactured, and the lens portion L (lenticular lens) is formed by the resin layer R and the double-sided adhesive sheet S has been described. However, the sheet manufacturing apparatus (manufacturing method) of the present invention is not limited to the manufacture of optical components including lenticular lenses. That is, the object to be manufactured in the present invention may be a sheet-like product in which the second resin layer (double-sided adhesive sheet) is pasted on the uneven surface side of the resin layer having predetermined unevenness, The use, shape, size, etc. are not particularly limited. Moreover, as a to-be-adhered body, it is not limited to a glass panel, An appropriate resin-made sheet | seat, tape, other plate-shaped members, etc. may be sufficient.

  Moreover, although the case where the lens part L of the two-layer structure which consists of the resin layer R and the double-sided adhesive sheet S was manufactured was demonstrated in the said embodiment, not only this but the resin layer R and the double-sided adhesive sheet S are mutually connected. After the application, the first release sheet RL1 may be released from the resin layer R, and another adhesive sheet may be attached to the surface of the resin layer R on the release side. Furthermore, the second release sheet RL2 may be released from the double-sided adhesive sheet S, and another sheet, tape, or other resin layer may be attached to the adhesive surface S1. That is, a sheet having a multilayer structure is manufactured by providing a plurality of other feeding means similar to the first and second feeding means 2 and 5 in the embodiment, and a plurality of pasting means similar to the pasting means 6. can do. Furthermore, by adding a transfer unit and a curing unit similar to the transfer unit 3 and the curing unit 4 in the above embodiment, irregularities are formed on both surfaces of the resin layer R, or irregularities are also formed on the surfaces of other resin layers. Sheets with various layer structures such as forming can be manufactured.

DESCRIPTION OF SYMBOLS 1 Sheet manufacturing apparatus 2 1st feeding means (feeding means)
3 Transfer means 4 Curing means 6 Pasting means 7 Peeling means 8 Cutting means 91 Holding part (holding means)
92 Pressing roller (pressing means)
O Raw fabric R Resin layer R1 Concavity and convexity S Double-sided adhesive sheet S1 One adhesive surface S2 The other adhesive surface RL1 First release sheet RL2 Second release sheet W Substrate

Claims (5)

A feeding means for feeding out the original fabric in which the first resin layer is laminated on the first strip-like release sheet;
Transfer means for transferring irregularities to the unrolled first resin layer of the original fabric;
Curing means for curing the first resin layer to which the irregularities are transferred;
An apparatus for manufacturing a sheet, comprising: a sticking means for sticking the other surface of the second resin layer, one surface of which is temporarily attached to the belt-shaped second release sheet, to the uneven surface of the first resin layer. Peeling means for peeling the second release sheet from one surface of the second resin layer;
Cutting means for cutting the adhesive sheet body in which the second release sheet is peeled and the first release sheet and the first and second resin layers are laminated;
Holding means for holding the cut adhesive sheet body;
The sheet manufacturing apparatus according to claim 1, further comprising: a pressing unit that presses and adheres one surface of the second resin layer to the adherend in the adhesive sheet held by the holding unit. The raw material in which the first resin layer is laminated on the first strip-shaped release sheet is drawn out,
Transfer the unevenness to the unrolled first resin layer, cure the first resin layer transferred the unevenness,
A method for producing a sheet, comprising affixing the other surface of the second resin layer, one surface of which is temporarily attached to a strip-shaped second release sheet, to the uneven surface of the first resin layer. Peeling the second release sheet from one surface of the second resin layer to form an adhesive sheet body in which the first release sheet and the first and second resin layers are laminated;
The sheet manufacturing method according to claim 3, wherein the adhesive sheet body is cut and held, and then one surface of the second resin layer is pressed against the adherend to be adhered.   An adhesive sheet produced by the sheet production method according to claim 4.

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