JP2012179772A - Film surface transfer device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel film surface transfer device which continuously and accurately transfers a pattern of a nano-order size, in particular, on the surface of a film.SOLUTION: The film surface transfer device is constituted of: a molding roll 1 formed with a fine pattern of a nano size on the surface; a T-die 2 which supplies and inputs a molten synthetic resin material; a heating roll 3 which is positioned immediately after the T-die and pressure-contacts with and separates from the molding roll 1; a metal roll 4 which is positioned in a position apart from the heating roll 3 at the rear of the rotation direction of the molding roll 1, and is adjustable in a direction in which the metal roll pressure-contacts with and separates from the molding roll 1; and a rubber roll 10 which is pressed against the molding roll 1 via a first heating metal belt 6 which is woundedly arranged so as to surround the heating roll 3 and the metal roll 4. The film surface transfer device is also characterized in that a supply film is adjusted in thickness by a gap between the heating roll 3 and the molding roll 4 from the T-die 2, moved by a rotation force of the molding roller 1, and transferred to the synthetic resin film of the fine pattern of the surface of the molding roll by a pressing force of the rubber roll 10.

Description

  The present invention relates to a film surface transfer apparatus for continuously manufacturing a nano-sized fine pattern on a surface of a synthetic resin film.

In recent years, non-reflective films, high-efficiency solar cell concentrating films, light diffusion films, water-repellent films, etc. have been manufactured using optical characteristics by forming nano-sized fine patterns on the film surface. Applications are also being developed for semiconductors and biotechnology. Up to now, as a means to transfer a fine pattern, a film is inserted between press devices having a flat mold subjected to fine pattern processing, and compression, heating, cooling, opening and peeling are repeated repeatedly. Many press molding methods are used.
Also, with a similar device, it has a roll and a thin metal belt, the surface of the belt is given a mirror surface or an uneven pattern, and the belt is pressed against the resin to continuously apply the mirror surface or uneven pattern to the sheet surface. There is known an extrusion molding apparatus for transferring a film. (For example, Patent Document 1)
Japanese Patent No. 2808251

  A transfer device that performs press molding using a flat mold is usually transferred to a film by heating the mold near the glass transition temperature Tg of the resin, holding the pressure for a certain time, and then cooling the mold. Therefore, there is a demerit that takes a long time to mold one transfer film, and an apparatus capable of continuous production has been desired.

  In addition, in the example of Patent Document 1, the outer peripheral surface of a rotating forming roll and the surface of a radially flexible thin pipe that rotates while contacting an arc along a part of the outer peripheral surface of the forming roll are mirror surfaces or A cylindrical forming drum (thin belt made of nickel) that has been processed with an uneven pattern is pressed against it, and the molten resin flowing from the T-die of the extruder is poured between the forming roll and the forming drum to narrow it. This is an apparatus for continuously transferring and molding one side of a sheet into a mirror surface or an uneven pattern by pressing.

The texture processing (leather pattern, wood grain pattern, etc.) applied to the resin sheet surface in general is a rough uneven pattern of micron size or larger, and it can be easily transferred by narrow pressure, but it is nano-size (for extracting optical properties) It is not easy to accurately transfer a pattern of 1 nanometer = 1 billionth of a meter) to the film surface. In order to transfer accurately, it is generally known that holding pressure is required for 30 seconds or more at a surface pressure of 30 Kg / cm ² near the glass transition temperature Tg of the film. In addition, the film accurately transferred to the nano-order fine pattern strongly adheres to the mold of the other party, so that the film is sufficiently cooled to peel off the thin film from the mold, ensuring the peel strength and peeling. Some kind of device to support is required.

In the example of Patent Document 1, it is difficult to actually apply a surface pressure of 30 Kg / cm ² because of the strength of a thin nickel belt, so the temperature is increased and the pressure is reduced from the relationship of temperature-pressure-holding time. For this purpose, the temperature of the belt and the forming roll itself is set to be higher than the crystallization temperature Tg of the film, and after the transfer is completed, the film is cooled to the crystallization temperature or less to ensure the strength of the film, and then molded again. It is necessary to quickly control the temperature of the belt and forming roll, for example, by raising the temperature to a high temperature. I can't hope for transfer molding.
The present invention provides a novel film surface transfer apparatus for continuously and accurately transferring a particularly nano-order size pattern onto a film surface.

  For this purpose, the film surface transfer apparatus of the present invention comprises a forming roll having a nano-sized fine pattern processed on its surface, a T die for supplying and supplying a molten synthetic resin material, and positioned immediately after the T die. A heating roll that can be adjusted in a direction in which it is pressed against and separated from the forming roll, and a metal roll that is located in a position away from the heating roll in the rotation direction of the forming roll and that can be adjusted in a direction in which it is pressed and separated from the forming roll; A first heating metal belt wound around the heating roll and the metal roll, and a metal belt positioned between the heating roll and the metal roll and placed inside the first heating metal belt. The thickness of the synthetic resin film supplied from the T-die is adjusted by the gap between the heating roll and the molding roll, and the heating roll and the gold Move the first rotational force of the thermoforming roll while pressing a metal belt between rolls, it is characterized in that to transfer a fine pattern of the forming roll surface by the pressing force of the rubber roll to the synthetic resin film.

The molding roll is formed in a hollow shape, and before the resin is supplied from the T-die, the outer peripheral surface of the molding roll is heated and controlled from the outside in a non-contact manner.
The heating roll is heated by an electric heater inside the roll, approaches and separates from the forming roll by driving the cylinder, and a gap adjustment with the forming roll is performed.

The rubber roll is configured to be able to pressurize the synthetic resin film with an arbitrary surface pressure by changing a cylinder driving pressure.
Synthetic resin, which is supported between the forming rolls, with the metal roll being pivotally supported at one end of a V-arm driven by a cylinder and applying tension to the first heating metal belt by the pressing force of the metal roll driven by the cylinder. It is characterized in that surface pressure is applied to the film.

A second cooling metal belt wound around a pair of cooling rolls in which a cooling medium circulates is provided behind the first heating metal belt, and the second cooling metal belt is pressed against the forming roll. It is characterized by that.
A plurality of air blowing pipes having slit-like grooves are provided inside the second cooling metal belt to cool the second cooling metal belt.

A cooling heat medium controlled at a temperature not higher than the glass transition temperature Tg of the synthetic resin film is circulated in the hollow inside of the molding roll so that the liquid height level of the medium can be adjusted to an arbitrary level below the rubber roll. It is characterized by that.
An air blowing pipe having a slit-like groove for peeling the transferred synthetic resin film from the forming roll is provided behind the second cooling metal belt.

  The film surface transfer apparatus of the present invention comprises a molding roll having a nano-sized fine pattern processed on the surface thereof, a T die for supplying and feeding a molten synthetic resin material, and a film positioned immediately after the T die. A heating roll that can be adjusted in the direction of pressing and separating, a metal roll that is positioned away from the heating roll in the rotation direction of the forming roll and adjustable in the direction of pressing and separating from the forming roll, and the heating A first heated metal belt wound around the roll and the metal roll, and positioned between the heated roll and the metal roll, and is placed inside the first heated metal belt via the metal belt The thickness of the synthetic resin film supplied from the T-die is adjusted by the gap between the heating roll and the molding roll, and is formed between the heating roll and the metal roll. Since it is moved by the rotational force of the forming roll while pressing with one heating metal belt, and the fine pattern on the surface of the forming roll is transferred to the synthetic resin film by the pressing force of the rubber roll, the synthetic resin film is a heating roll. It is pressed by the first heated metal belt and moved between the metal roll and the metal roll, heated by the pressure of the rubber roll, the temperature-pressure-pressurization time can be adjusted, and the nano pattern is transferred to the synthetic resin film Thus, there is an effect that the nano pattern is processed and the synthetic resin film can be continuously formed and provided.

It is a perspective view of the film surface transfer apparatus of this invention. It is a front view of the film surface transfer apparatus of this invention. It is a perspective view of a pressure roll.

  The molten resin from the T-die 2 of the extruder has a nano-sized pattern on the surface, a molding roll 1 that is rotated by a variable speed motor, a cartridge heater inside, and a temperature equal to or higher than the resin crystallization temperature Tg. Between the first heating metal belt 6 inserted between the controllable free-rotating heating roll 3 and the gap and wound around the heating roll 3 and the lower free-rotating metal roll 4 and the forming roll 1. The resin is formed into a film shape while being pressed by the first heated metal belt 6 by the rotation of the forming roll 1 and is transferred to the lower metal roll 4 side.

  Between the heating roll 3 and the metal roll 4 inside the first heating metal belt 6, there is a rubber roll 10 that can be adjusted in the direction of pressing and separating from the forming roll 1 from the cylinder 11, and the film is interposed via the first heating metal belt 6. By applying pressure to the film, the nano-sized pattern is transferred to the film and transferred to the metal roll 4 side. By the time the transfer film reaches the metal roll 4, the surface of the forming roll 1 is cooled with a cooling medium in the roll so that the film is in a semi-solidified state at a crystallization temperature Tg or lower.

  Here, the heating roll 3 can be adjusted in a direction in which the heating roll 3 approaches and separates from the forming roll 1 with the cylinder 7, and the movement of the heating roll 3 approaching the forming roll 1 side is restricted so that the gap with the forming roll 1 can be adjusted. For this purpose, a stopper screw 28 with a gap scale 29 is provided so that the thickness of the film can be adjusted. Also, in order to make the transfer film uniform, the cartridge heater uses a distributed winding of internal heating wires so that the temperature is uniform in the roll width direction. In order to solve this problem, for example, the rotary connector 30 is used.

  The forming roll 1 has a hollow inside and is thinned to accelerate heat conduction, and an infrared heater 20 that heats the roll surface to a temperature equal to or higher than the crystallization temperature Tg of the resin in a non-contact manner on the top of the roll, or An induction heating bar of the high-frequency induction heating device is arranged, and the temperature can be controlled to an arbitrary temperature while measuring the surface temperature with the radiation thermometer 25.

  Also in the case of this heating device 21, in order to make the transfer film uniform, the heating wire is distributed in the case of the infrared heater 20 and the coil is distributed in the case of induction heating so that the temperature becomes uniform in the roll width direction. It is a volume. Since the infrared heater 20 has a low heat transfer rate, it can be used when the resin viscosity is low and the crystallization temperature is high, or when the difference between the temperature at the position pressed by the so-called rubber roll 10 and the temperature at which it is semi-solidified is small. In the reverse case or when transferring the image quickly, a high-frequency induction heating device that is expensive but has a high transmission speed may be used.

  In addition, a heating medium controlled below the glass transition temperature of the resin film is fed into the hollow forming roll 1 through a rotary joint attached to the hole of the roll shaft portion, and the medium is formed. A plurality of holes are made in the side surface of the forming roll 1 so that the liquid height level in the roll 1 can be adjusted to an arbitrary level lower than the height position of the rubber roll 10, and the internal heat medium is caused to flow out of the holes, It can be adjusted by adjusting the throttle valve attached in the middle of the circulation hose from the outflow container to the heating tank, or by the supply amount adjustment valve of the circulation tank. Since this liquid level affects the temperature of the film, a level gage is attached to the front surface of the forming roll 1 so that it can be adjusted.

  The first heating metal belt 6 is, for example, a seamless nickel-based metal or stainless steel metal and has a thickness of about 0.1 mm to 0.2 mm, and the surface in contact with the resin (the back surface of the transferred film) has good optical characteristics. In order to do this, a mirror-finished one is used.

The lower metal roll 4 applies tension to the first heating metal belt 6 by the pressure of the cylinder 8, and this tension determines the surface pressure on the film by the belt 6. Considering the fatigue strength (fatigue life), the value of the allowable surface pressure varies depending on the size of each roll, but cannot reach the generally known surface pressure of 30 kg / cm ² near the glass transition temperature Tg.
In this apparatus, the forming roll 1 has a diameter of 200 mm and is contacted so that the surface pressure is 1 to 6 kg / cm ² in consideration of fatigue strength.

  Further, since the metal roll 4 is supported by the tip of one side of the V-arm 9 driven by the cylinder, the opening angle of the V-arm 9 is increased by the tension of the belt 6 and by the thermal expansion. In consideration of this, the belt tension is set to be as large as possible within a range not exceeding 180 degrees, so that the belt tension can be increased with a small cylinder by the lever principle.

The rubber roll 10 can be adjusted in a direction in which it is pressed and separated from the molding roll 1 by the cylinder 11, and when the rubber roll 10 is pressed against the molding roll 1, the contact portion of the rubber roll 10 is crushed and becomes surface contact, but the area is small. The surface pressure can be easily increased, and in the case of this apparatus, the load can be applied in the range of 10 to 120 kg / cm ² .

With this configuration, it is impossible to maintain a surface pressure of 30 kg / cm ² at a surface pressure of 30 kg / cm ² for 30 seconds or more at a generally performed glass transition temperature. The transfer is controlled between the belt 6 and the forming roll 1 by controlling the temperature of the forming roll 1 and the first heating metal belt 6 to an appropriate temperature equal to or higher than the crystallization temperature Tg of the resin using the relationship of temperature-pressure-holding time. It is possible to transfer a nano-scale fine pattern processed on the surface of the forming roll 1 to the film by narrowing the high-temperature film with a surface pressure of 120 kg / cm ^{2 at} the maximum via the belt 6. Before reaching the metal roll 4 by pulling, a film having a temperature not higher than the glass transition temperature circulating in the forming roll 1 is used. To reach a semi-solidified state.

  This apparatus has a pair of free-rotating cooling rolls 12 in which cooling water circulates inside the rolls behind the metal rolls 4, and a second cooling metal wound around the pair of cooling rolls 12. A belt 13 is provided and the second cooling metal belt 13 is lightly pressed by a cylinder 14 on the film on which the nano pattern has been transferred, thereby further cooling is performed in a state where the pattern is not deformed. The surface of the second cooling metal belt 13 in contact with the film does not need to be a mirror surface because the film is in a semi-solid state, and may have a general surface roughness of about 2S. When the nanoscale pattern is accurately transferred to the film, it adheres closely to the forming roll 1, so that the film may be stretched and deformed at the time of releasing, so that the film may be cut and cut as close to room temperature as possible. In this apparatus, a plurality of air-cooled slit pipes 16 having slit-shaped grooves 31 are further provided inside the second cooling metal belt 13, and compressed air is blown onto the belt on the forming roll 1 side. It is designed to support cooling.

  An air blowing pipe 19 having a slit-like groove 32 is provided behind the second cooling metal belt 13 in order to easily release the film in close contact with the forming roll 1 from the forming roll 1. Compressed air is blown between the rolls 1.

After the transfer, the forming roll 1 returns to its original state, and the surface of the forming roll 1 is continuously heated in a non-contact manner between the release air blowing pipe 19 and the T die 2 to an appropriate temperature not lower than the glass transition temperature of the resin. The molding of the transfer film is repeated continuously.
The separated transfer film is protected by covering the transfer surface of the film with a protective film 27 disposed at the upper rear portion, and is wound around the rear winding bobbin 18 together.

  The heat-resistant film 24 of the feeding bobbin 23 arranged on the upper part of the forming roll 1 is used only at the start of forming the transfer film. Before flowing the molten resin from the T die 2, the first heated metal belt and the second heat-resistant film 24 are used. The cooling metal belt is placed at a position retracted from the forming roll 1, and after being rubbed against the take-up bobbin 18 through the heat-resistant film 24 in the path through which the transfer film passes, the first heating metal belt and the second cooling metal belt are attached to the forming roll 1. When the resin and the heat-resistant film reach the take-up bobbin 18, the heat-resistant film is cut and the original transfer film is formed. As a result, the transfer film is smoothly read and damage to the pattern of the forming roll 1 due to the direct contact of the belt is protected.

  In the above embodiment, an example in which a nano-sized pattern is applied to the surface of the molding roll and the nano-sized pattern is transferred only to one surface of the synthetic resin film has been described. However, the nano-sized pattern is formed on the surface of the first heated metal belt. The nano-sized pattern can be transferred onto both sides of the synthetic resin transfer film.

DESCRIPTION OF SYMBOLS 1 Forming roll 2 T die 3 Heating roll 4 Metal roll 5 Guide roll 6 First heating metal belt 7 Cylinder 8 Cylinder 9 V-shaped arm 10 Rubber roll 11 Cylinder 12 Cooling roll 13 Second cooling metal belt 14 Cylinder 15 V-shaped arm 16 Air cooling Slit pipe 17 Synthetic resin transfer film 18 Winding bobbin 19 Air blowing pipe 20 Infrared heater 21 Heating device 22 Shaft support 23 Feeding bobbin 24 Heat resistant film 25 Radiation temperature sensor 26 Protective film bobbin 27 Protective film 28 Stopper screw 29 Gap scale 30 Rotary connector 31, 32 Slit groove

Claims (9)

A molding roll with a nano-sized fine pattern processed on the surface, a T die that feeds and feeds a melted synthetic resin material, and a position that is located immediately after the T die and can be adjusted in the direction of pressing and separating from the molding roll. A heating roll, a metal roll positioned at a position rearward from the heating roll in the rotation direction of the forming roll, and adjustable in a direction in which the forming roll is pressed and separated, and so as to surround the heating roll and the metal roll A first heated metal belt provided by winding, and a rubber roll located between the heated roll and the metal roll and placed inside the first heated metal belt and pressed against the forming roll via the metal belt The thickness of the synthetic resin film configured and supplied from the T die is adjusted by the gap between the heating roll and the forming roll, and pressed with the first heating metal belt between the heating roll and the metal roll. Moving at the rotational force form the roll, the film surface transfer apparatus characterized by transferring a fine pattern of the forming roll surface a synthetic resin film by the pressing force of the rubber roll. 2. The molding roll according to claim 1, wherein the molding roll is formed in a hollow shape, and the outer peripheral surface of the molding roll is non-contacted and heated from the outside before the resin is supplied from the T-die. Film surface transfer device. The said heating roll is heated by the electric heater inside a roll, approaches and separates from a forming roll by cylinder drive, and the gap adjustment with a forming roll is made | formed, The said claim 1 or 2 characterized by the above-mentioned. Film surface transfer device. 4. The film surface transfer device according to claim 1, wherein the rubber roll can pressurize the synthetic resin film with an arbitrary surface pressure by changing a cylinder driving pressure. Synthetic resin, which is supported between the forming rolls, with the metal roll being pivotally supported at one end of a V-arm driven by a cylinder and applying tension to the first heating metal belt by the pressing force of the metal roll driven by the cylinder. 5. The film surface transfer apparatus according to claim 1, wherein a surface pressure is applied to the film. A second cooling metal belt wound around a pair of cooling rolls in which a cooling medium circulates is provided behind the first heating metal belt, and the second cooling metal belt is pressed against the forming roll. 6. The film surface transfer device according to claim 1, wherein the film surface transfer device is a film surface transfer device. 7. The second cooling metal belt according to claim 1, wherein a plurality of air blowing pipes having slit grooves are provided inside the second cooling metal belt to cool the second cooling metal belt. The film surface transfer apparatus according to any one of the above. A cooling heat medium controlled at a temperature not higher than the glass transition temperature Tg of the synthetic resin film is circulated in the hollow inside of the molding roll so that the liquid height level of the medium can be adjusted to an arbitrary level below the rubber roll. 8. The film surface transfer device according to claim 1, wherein the film surface transfer device is a film surface transfer device. 9. An air blowing pipe having a slit-like groove for separating the transferred synthetic resin film from the forming roll is provided behind the second cooling metal belt. The film surface transfer apparatus according to any one of the above.

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