JP2012081619A - Method of manufacturing member having unevenly patterned surface - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a shape forming method using an ionization radiation curing resin, which hardly causes imperfect shapes in desired fine uneven patterns, even if a viscosity of the ionization radiation curing resin is very high.SOLUTION: The method of manufacturing a sheet-like or film-like member having an unevenly patterned surface includes steps of: applying a liquid 8 obtained by diluting the ionization radiation curing resin with solvent to a surface with fine uneven patterns of a shape forming die 2 or a shape forming die 14; drying the applied liquid 8; feeding a base material 7 to a portion where the applied liquid 8 is dried, of the shape forming die 2 or the shape forming die 14 and pressing the base material 7 to the shape forming die 2 or the shape forming die 14 by using a roll 5 facing the shape forming die 2 or the shape forming die 14: curing the ionization radiation curing resin by irradiating it with ionization radiation; and releasing a shape formed product composed of an ionization radiation cured resin layer and the base material, the shape formed product having a surface with the uneven patterns, from the shape forming die 2 or the shape forming die 14.

Description

  The present invention relates to a production method for producing a film having a fine uneven shape on the surface.

In recent years, a sheet having a fine concavo-convex pattern on its surface, such as a light diffusion sheet, a brightness enhancement sheet, an optical waveguide sheet, and a prism sheet, has been used for electronic display applications such as liquid crystal. Conventionally, various methods are known as a method for forming such a fine uneven pattern.
For example, in an apparatus having a configuration as shown in FIG. 6, ionizing radiation curable resin 81 is applied in advance to the surface of a continuously running base sheet 7, and the base sheet 7 is formed with a fine uneven pattern. The roll-shaped mold 2 and the nip roller 5 sandwiched between the roll-shaped mold 2 and the concavo-convex pattern of the roll-shaped mold 2 are transferred to the resin, and the resin is irradiated with ionizing radiation to cure. The content which is wound around 6 and peeled off from the roll-shaped mold 2 is disclosed.

  However, when a desired fine concavo-convex pattern is transferred to the ionizing radiation curable resin by a conventional manufacturing apparatus, bubbles are included in the ionizing radiation curable resin depending on conditions such as the shape of the fine concavo-convex pattern to be transferred and the viscosity of the ionizing radiation curable resin. In some cases, the shape of the fine concavo-convex pattern may be incomplete due to cracking or chipping. As a result of investigating the conditions under which such an incomplete shape occurs, the shape of the fine uneven pattern to be formed is not continuous compared to the groove shape continuous in the circumferential direction of the roll, for example, a shape such as a fly-eye lens, particularly a lens. When the lens has a high aspect ratio such that the depth dimension with respect to the width of the lens exceeds 0.5, an incomplete shape is remarkably generated. Such an incomplete shape of the fine concavo-convex pattern not only becomes a fatal defect in optical performance when the molded product is an optical member, but also deteriorates the appearance quality and becomes a problem as a design member. .

  In Patent Document 1, an ionizing radiation curable resin is applied in advance to the surface of a film-like substrate 7 that is continuously run as shown in FIG. 6, and the substrate 7 is formed with a fine uneven pattern. In the method of sandwiching between the shaped mold 2 and the nip roller 5, by molding so that a staying part of the ionizing radiation curable resin is generated at a portion where the base coated with the ionizing radiation curable resin and the roll shaped mold are in contact with each other, A method for suppressing the occurrence of an incomplete shape of a fine uneven pattern is disclosed. Patent Document 2 discloses a method of reducing the viscosity of the resin by limiting the viscosity of the ionizing radiation curable resin, and further heating the mold roll, nip roller, and the like.

  However, the final molded product needs to adjust the hardness, refractive index, etc. of the cured ionizing radiation curable resin depending on its application and required functions. As a result, it must have a very high viscosity in an uncured state. You may not get. For example, metal fine particles such as zirconium oxide are usually contained in a high ratio in order to increase the refractive index of the cured resin. In such an ionizing radiation curable resin, the solvent is diluted to lower the viscosity to form a substrate. Even if the coating is applied, the viscosity increases significantly due to drying, so even if a means such as heating is taken, the viscosity does not decrease to a sufficient level. In such a case, the above method cannot suppress the occurrence of an incomplete shape.

Japanese Patent No. 4108211 JP 2008-074021 A

  In the present invention, when forming a fine concavo-convex pattern using an ionizing radiation curable resin, even if the ionizing radiation curable resin has a very high viscosity, the desired fine concavo-convex pattern does not easily form an incomplete shape. It aims to provide a method.

  The present invention includes a step of applying a solution obtained by diluting an ionizing radiation curable resin to a mold surface having a concavo-convex pattern, a step of drying the applied solution, and a step of drying the applied solution on the mold. Supplying the base material to the part, pressing the base material of the mold with a roll facing the mold, curing the ionizing radiation curable resin by irradiating with ionizing radiation, and ionizing radiation from the mold And a step of releasing a molded article having a concavo-convex pattern comprising a cured resin layer and a substrate, and a method for producing a member having a surface concavo-convex pattern.

In addition, before the step of pressing the substrate against the mold in the above-described invention, the step of applying the ionizing radiation curable resin to the substrate side or the solution obtained by diluting the ionizing radiation curable resin with a solvent is applied. You may have the process of drying.
Moreover, in the said invention, the shaping | molding die may be a belt-shaped thing which has an uneven | corrugated pattern.

  Moreover, this invention is a member which has a fine unevenness | corrugation pattern on the surface manufactured with the manufacturing method of the member which has an above described surface fine unevenness | corrugation pattern, and the member which has a fine unevenness | corrugation pattern on the said surface is after ionizing radiation hardening resin hardens | cures. In this state, 30% by volume or more of oxide fine particles may be included.

  According to the present invention, even a high-viscosity ionizing radiation curable resin can be molded without causing a chipping or the like even in the shape of a fly-eye lens or the like having a relatively high aspect ratio.

It is a conceptual diagram of an example concerning the manufacturing method of the member which has a surface fine concavo-convex pattern used by the present invention. It is a conceptual diagram of the other example concerning the manufacturing method of the member which has the surface fine unevenness | corrugation pattern used by this invention. It is a conceptual diagram of another example concerning the manufacturing method of the member which has the surface fine unevenness | corrugation pattern used by this invention. It is a conceptual diagram of another example concerning the manufacturing method of the member which has the surface fine unevenness | corrugation pattern used by this invention. It is a conceptual diagram of another example concerning the manufacturing method of the member which has the surface fine unevenness | corrugation pattern used by this invention. It is an example concerning the manufacturing method of the member which has the surface fine unevenness | corrugation pattern of a prior art example.

The present invention will be described below with reference to the drawings.
<Embodiment 1>
FIG. 1 shows a conceptual diagram of an example according to a method of manufacturing a member having a surface fine concavo-convex pattern according to the first embodiment of the present invention. In FIG. 1, a fine uneven pattern such as a fly-eye lens is formed on a sheet-shaped mold 14. The sheet-shaped mold 14 is made of a metal such as aluminum, brass, copper, nickel, or a synthetic resin such as silicon resin, urethane resin, epoxy resin, fluorine resin, polymethylpentane resin, or a plate made of stainless steel. A film or sheet with a fine concavo-convex pattern on the surface of a metal such as aluminum, brass, copper or nickel, or a synthetic resin such as silicon resin, urethane resin, epoxy resin, fluororesin or polymethylpentane resin was laminated on the surface of A thing etc. can be used. In the present embodiment shown in FIG. 1, the substrate 7 pressed against the sheet-shaped mold 14 on which the ionizing radiation curable resin layer is formed is a sheet-like sheet or film, and is an acrylic resin or polypolycarbonate. A single sheet or film made of resin, vinyl chloride resin, cellulose triacetate resin, polyester resin, glass, or the like can be used.

  In the present invention, as shown in FIG. 1, an appropriate amount of a liquid 8 in which an ionizing radiation curable resin is diluted with a solvent and reduced in viscosity is applied to a sheet-shaped mold 14 conveyed by a belt conveyor 13 from a coating apparatus 1. A die coater, various roll coaters, a spray coater, or the like can be used as the coating apparatus 1, but it is necessary that the fine uneven pattern on the surface of the mold is not damaged. The applied liquid 8 is dried by the drying device 3. At this time, the solvent evaporates to fill the fine uneven pattern of the mold 14 with the ionizing radiation curable resin, and the entire mold is covered with the ionizing radiation curable resin. Then, the single-wafer substrate 7 is pressed against the sheet-shaped mold 14 by using the nip roller 5, and further ionizing radiation is irradiated by the ionizing radiation irradiation device 4. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured in a state of being pressed against the sheet-shaped mold 14, so that the fine uneven pattern of the sheet-shaped mold is transferred with high accuracy. The substrate 7 is released from the sheet-shaped mold 14 together with the ionizing radiation curable resin layer by the peeling roll 6.

  About the manufacturing method of the member which has the surface fine unevenness | corrugation pattern by 1st Embodiment concerning this invention, a form like the conceptual diagram shown in FIG. 2 may be sufficient. In FIG. 2, a continuous sheet or film is used as the substrate 7, and a roll is used as the mold. The roll-shaped mold 2 is formed with a fine uneven pattern such as a fly-eye lens. The roll-shaped mold 2 is made of a metal such as aluminum, brass, copper, nickel, or a synthetic resin such as silicon resin, urethane resin, epoxy resin, fluorine resin, polymethylpentane resin, or a cylindrical body such as stainless steel. A film or sheet with a fine concavo-convex pattern on the surface of a metal such as aluminum, brass, copper, nickel, or a synthetic resin such as silicon resin, urethane resin, epoxy resin, fluororesin, or polymethylpentane resin was laminated on the surface of A thing etc. can be used. As a continuous base material 7 on which an ionizing radiation curable resin layer is formed and pressed against the roll-shaped mold 2, a continuous sheet made of acrylic resin, polypolycarbonate resin, vinyl chloride resin, cellulose triacetate resin, polyester resin or the like is used. Alternatively, a film can be used.

  In this embodiment, as shown in FIG. 2, an appropriate amount of a liquid 8 in which an ionizing radiation curable resin is diluted and reduced in viscosity with a solvent is applied from the coating apparatus 1 to the roll-shaped mold 2. A die coater, various roll coaters, a spray coater, or the like can be used as the coating apparatus 1, but it is necessary that the fine uneven pattern on the surface of the mold is not damaged. The applied liquid is dried by the drying device 3. At this time, the solvent evaporates to fill the fine uneven pattern of the mold 2 with the ionizing radiation curable resin, and the entire mold is covered with the ionizing radiation curable resin. And the continuous base material 7 is pressed by the roll-shaped shaping | molding die 2 using the nip roller 5, and also ionizing radiation is irradiated by the ionizing radiation irradiation apparatus 4. FIG. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured while being pressed against the roll-shaped mold 2, so that the fine uneven pattern of the roll-shaped mold 2 is transferred with high accuracy. The base material 7 is released from the roll-shaped mold together with the ionizing radiation curable resin layer by a peeling roll 6.

<Embodiment 2>
Next, FIG. 3 shows a conceptual diagram of an example of a method for producing a member having a surface fine concavo-convex pattern according to the second embodiment of the present invention.
In the manufacturing method of the second embodiment, first, as shown in FIG. 3, a liquid 8 obtained by diluting an ionizing radiation curable resin with a solvent is applied to both the continuous base material 7 and the roll-shaped mold 2 by the coating apparatus 1. . Next, the substrate 7 obtained by drying the solution 8 obtained by diluting the ionizing radiation curable resin with the drying device 3 is applied to the roll-shaped mold 2 dried after the application of the solution 8 obtained by diluting the ionizing radiation curable resin with the solvent. Then, the ionizing radiation irradiation device 4 irradiates the ionizing radiation. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured in a state of being pressed against the roll-shaped mold 2, so that the fine uneven pattern of the roll-shaped mold is transferred with high accuracy. The substrate 7 is released from the roll-shaped mold 2 together with the two ionizing radiation curable resin layers by a peeling roll 6.

<Embodiment 3>
Next, FIG. 4 shows a conceptual diagram of an example of a method for manufacturing a member having a surface fine unevenness pattern according to the third embodiment of the present invention.
In the manufacturing method of the third embodiment, as shown in FIG. 4, after applying the base material 7 coated with the ionizing radiation curable resin 81 by the coating apparatus 1 and the liquid 8 obtained by diluting the ionizing radiation curable resin with the solvent, A roll-shaped mold dried by the drying device 3 is pressed using a nip roller 5, and further ionizing radiation is irradiated by an ionizing radiation irradiation device 4. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured in a state of being pressed against the roll-shaped mold 2, so that the fine uneven pattern of the roll-shaped mold is transferred with high accuracy. The substrate 7 is released from the roll-shaped mold 2 together with the two ionizing radiation curable resin layers by a peeling roll 6.

<Embodiment 4>
Next, the conceptual diagram of an example of the manufacturing method of the member which has the surface fine unevenness | corrugation pattern by 4th Embodiment concerning this invention is shown in FIG. As shown in FIG. 5, an appropriate amount of a liquid 8 in which an ionizing radiation curable resin is diluted with a solvent and reduced in viscosity is applied from a coating device 1 to a belt-shaped mold 11. The applied liquid 8 is dried by the drying device 3. At this time, the fine concavo-convex pattern of the mold is filled with the ionizing radiation curable resin, and the entire mold is covered with the ionizing radiation curable resin. Then, the continuous base material 7 is pressed against the belt-shaped mold 11 using the nip roller 5 and the back roll 12, and then the ionizing radiation irradiation device 4 irradiates the ionizing radiation. By irradiating with ionizing radiation, the ionizing radiation curable resin is cured in a state of being pressed against the belt-shaped mold 11, so that the fine uneven pattern of the belt-shaped mold is transferred with high accuracy. The base material 7 is released from the roll-shaped mold together with the two ionizing radiation curable resin layers by a peeling roll 6.

<Embodiment 5>
A member having a surface fine concavo-convex pattern according to the fifth embodiment of the present invention is manufactured by the manufacturing method according to any of Embodiments 1 to 4, and is a sheet or film having a fine concavo-convex pattern on the surface. It is a member.

<Embodiment 6>
The sheet-like or film-like member having the surface fine unevenness pattern according to the sixth embodiment of the present invention contains 30% by volume or more of oxide fine particles in a state after the ionizing radiation curable resin is cured. As the oxide fine particles, silicon dioxide, titanium oxide, zirconium oxide, aluminum oxide, zinc oxide, tin oxide, or the like can be used. Further, the particle diameter of the oxide fine particles is not particularly limited, but when a member having a surface fine unevenness pattern is used for an optical application in particular, the weight average particle diameter may be several hundred nm or less. desirable.

  As mentioned above, although the embodiment example concerning the manufacturing method of the sheet-like or film-like member which has the surface fine unevenness pattern concerning the present invention was described, the present invention is not limited to the example of the above-mentioned embodiment, Embodiments can be taken. For example, in the example of the present embodiment, a mode in which a roll-shaped mold and a belt-shaped mold are used is adopted. However, a mode in which a sheet-shaped mold is arranged on a transportation means such as a belt conveyor is also used. Can be adopted. This is because even such a sheet-like body acts in the same manner as the roll shape and the belt shape, and the same effect can be obtained.

  Hereinafter, the present invention will be specifically described using examples, but the present invention is not limited to these examples.

<Example 1>
An ionizing radiation curable resin liquid (Toyo Ink Co., Ltd.) in which ionizing radiation curable resin and oxide fine particles are diluted with a solvent in a nickel mold (area: 105 mm × 105 mm) in which a plurality of microlenses having a diameter of 20 μm and a height of 20 μm are arranged. Ryoduras TYZ74-01 manufactured by Manufacturing Co., Ltd. was applied to a thickness of about 80 μm, dried at room temperature for 3 minutes, further at room temperature for 3 minutes, and then at 80 ° C. for 5 minutes, and PET film (Cosmo manufactured by Toyobo Co., Ltd.) with a nip roller. Shine A4300 (thickness: 100 μm) is pressed at a pressure of 0.3 MPa, irradiated with ionizing radiation as it is, and then cured to form a desired microlens on the PET film without chipping. did it.
<Example 2>
An ionizing radiation curable resin liquid (Toyo Ink Manufacturing Co., Ltd.) in which ionizing radiation curable resin and oxide fine particles are diluted and dispersed in a nickel mold (area: 105 mm x 105 mm) in which a plurality of microlenses having a diameter of 20 μm and a height of 20 μm are arranged. After applying Rio Duras TYZ74-01 (made by Co., Ltd.) at a thickness of about 80 μm, it was dried at room temperature for 3 minutes and at 80 ° C. for 5 minutes, and ionized radiation curing to PET film (Toyobo Co., Ltd. Cosmo Shine A4300; thickness 100 μm) A resin liquid (Rioduras TYZ74-01 manufactured by Toyo Ink Manufacturing Co., Ltd.) was applied at a thickness of 50 μm, and then dried at room temperature for 2 minutes and at 80 ° C. for 1 minute, and the PET film was brought to a pressure of 0.3 MPa with a nip roller. When the mold is pressed and cured with ionizing radiation as it is, chipping occurs when the mold is released. Desired microlens was formed on the PET film without the.

<Comparative example>
On the PET film (Toyobo Co., Ltd. Cosmo Shine A4300; thickness 100 μm), the ionizing radiation curable resin liquid (Ryoduras TYZ74-01 manufactured by Toyo Ink Manufacturing Co., Ltd.) used in Example 1 was applied at a thickness of about 80 μm, and room temperature was applied. 3 minutes at 80 ° C. for 5 minutes, and then a pressure of 0.3 MPa with a nip roller on a nickel mold (area is 105 mm × 105 mm) in which a plurality of microlenses having a diameter of 20 μm and a height of 20 μm are arranged. After pressing and curing with ionizing radiation as it was, only a micro lens having a height of about several μm was obtained. This is because the ionizing radiation curable resin, in which the solvent component after drying has volatilized, has a very high viscosity, so that the ionizing radiation curable resin is not sufficiently filled in the fine irregularities of the mold.

DESCRIPTION OF SYMBOLS 1 ... Coating apparatus 2 ... Roll-shaped shaping | molding die 3 ... Drying apparatus 4 ... Ionizing radiation irradiation apparatus 5 ... Nip roller 6 ... Stripping roll 7 ... Base material 8 ... Liquid 81 in which ionizing radiation curable resin is diluted with solvent ... Ionizing radiation curable resin 9 ... Back roll 10 for coating apparatus ... Second nip roller 11 ... Belt-shaped mold 12 ... Back roll 13 ..Belt conveyor 14 ... Sheet mold

Claims (6)

  A step of applying a solution obtained by diluting an ionizing radiation curable resin to a mold surface having a concavo-convex pattern, a step of drying the applied solution, and a portion where the applied solution on the mold is dried. Supplying the material, pressing the substrate against the mold with a roll facing the mold, curing the ionizing radiation curable resin by irradiating with ionizing radiation, and a layer of ionizing radiation curable resin from the mold And a step of releasing a molded product having a concavo-convex pattern comprising a substrate and a substrate, and a method for producing a member having a surface concavo-convex pattern.   The production of a member having a surface concavo-convex pattern according to claim 1, further comprising a step of applying and drying a solution obtained by diluting an ionizing radiation curable resin with a solvent on the substrate side before the step of pressing the substrate against the mold. Method.   The manufacturing method of the member which has a surface uneven | corrugated pattern of Claim 1 which has the process of coating ionizing radiation hardening resin also to a base material side before the process of pressing a base material to a shaping | molding die.   The method for producing a member having a surface concavo-convex pattern according to any one of claims 1 to 3, wherein the mold is a belt having a concavo-convex pattern.   A sheet-like or film-like member having a surface concavo-convex pattern, produced by the method for producing a member having a surface concavo-convex pattern according to any one of claims 1 to 4.   6. The sheet-like or film-like member having a surface unevenness pattern according to claim 5, wherein the ionizing radiation curable resin contains 30% by volume or more of oxide fine particles in a state after curing.

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