JP2013140314A - Manufacturing method of antireflection film, manufacturing method of mold for manufacturing antireflection film, and mold for manufacturing antireflection film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an antireflection film according to a moth-eye structure capable of avoiding all various problems relating to a roll plate, manufacturing a fine structure in a uniform and accurate manner, and effectively avoiding deterioration during manufacture.SOLUTION: A substrate 2 that is a long roll material; and a metallic mold 25 for manufacture that is a long roll material, and an aluminum film having a concave-convex shape that contributes to molding of a moth-eye structure manufactured on the surface, are laminated to mold the concave-convex shape manufactured on the metallic mold 25 for manufacture on the substrate 2.

Description

  The present invention relates to an antireflection film according to a moth-eye structure.

  In recent years, attention has been focused on a technique for preventing reflection by forming a fine concavo-convex pattern on the surface with a concavo-convex cycle controlled to be equal to or less than the wavelength of visible light as one of the antireflection techniques in flat panel displays (patent) Reference 1-6). Such a method is based on the principle of a so-called moth-eye structure, in which the refractive index for incident light is continuously changed in the thickness direction of the substrate, and the discontinuous interface of the refractive index. The reflection of light is prevented by eliminating the light.

  Such a moth-eye structure is generally manufactured by transferring the concavo-convex shape to an arbitrary resin layer using a manufacturing mold having a shape obtained by inverting the fine concavo-convex shape. Therefore, as a method for producing an antireflection film having a moth-eye structure, a resin layer made of an ultraviolet curable resin or the like is formed on a substrate, and then the moth-eye structure is formed on the surface of the resin layer using the manufacturing mold as described above. And forming the resin layer by curing the resin layer. Such a manufacturing method can manufacture an antireflection film continuously with a simple method and high manufacturing efficiency.

  With respect to the production of such an antireflection film, Patent Document 7 discloses that a manufacturing die (a so-called roll plate) having a cylindrical shape in which fine irregularities for transfer are produced on the peripheral side surface is used efficiently. A device for producing an antireflection film has been proposed. In addition, this type of manufacturing mold is manufactured by densely forming fine holes by utilizing anodization of aluminum. For example, Patent Document 8 proposes a device for manufacturing this type of manufacturing mold. Yes.

  By the way, when producing an antireflection film using a roll plate, an antireflection film can be easily mass-produced easily and in large quantities because it can be produced by continuously treating a long film material. However, in the production of an antireflection film using a roll plate, there is a problem that is still insufficient in practice.

  In other words, the mold used for shaping needs to produce a fine uneven shape uniformly and accurately. In the roll plate, it is necessary to produce such a fine uneven shape on the peripheral side surface, which makes it difficult to easily produce a highly accurate roll plate.

  An antireflection film according to this type of moth-eye structure has a fine concavo-convex structure with a period equal to or shorter than the wavelength of visible light. As a result, this type of mold has a problem that it gradually deteriorates due to stress applied at the time of mold release after molding.

JP-T-2001-517319 JP 2004-205990 A JP 2004-287238 A JP 2001-272505 A JP 2002-286906 A International Publication No. 2006/059686 Pamphlet JP 2005-156695 A Special Table 2003-531962

  The present invention has been made in view of such a situation, and regarding the antireflection film according to the moth-eye structure, various problems related to the roll plate are avoided at once, and a fine structure is produced uniformly and accurately, and It is an object of the present invention to provide an antireflection film manufacturing method, an antireflection film manufacturing mold manufacturing method, and an antireflection film manufacturing mold capable of effectively avoiding deterioration due to production.

  The present inventor has intensively studied to solve the above-mentioned problems, and has come to the idea of producing a mold for production using a long aluminum film, and has completed the present invention.

    Specifically, the present invention provides the following.

(1) Laminating a base material made of a long roll material and a production die made of an aluminum film, which is a long roll material and has a concavo-convex shape for forming a moth-eye structure on the surface. , A forming step of forming the uneven shape produced in the manufacturing mold on the base material,
A peeling step of peeling the base material from the manufacturing mold.

  A long roll material, on the surface of which an uneven shape for forming a moth-eye structure is produced, an aluminum mold for production can be produced by continuous treatment of an aluminum film, thereby A fine shape for shaping can be produced with uniform and high accuracy. Further, for example, since it can be used only once, it is possible to produce an antireflection film without considering deterioration due to manufacturing. Thus, various problems related to the roll plate can be avoided at once, and the antireflection film can be efficiently mass-produced with high accuracy.

  (2) In (1), the method further includes a mold manufacturing step in which an aluminum film made of a long roll material is anodized and etched to produce the uneven shape.

  According to (2), it is possible to specifically produce a production die made of an aluminum film, which is a long roll material and has a concavo-convex shape to be used for shaping a moth-eye structure on the surface.

(3) In (1) or (2),
The aluminum film is
A protective film was provided on the side opposite to the surface on which the uneven shape was produced.

  According to (3), it is possible to produce a manufacturing mold using various film materials provided with an aluminum foil. Moreover, strength can be ensured.

(4) It has the reinforcement process which arrange | positions the said protective film on the opposite side to the surface which produces the said uneven | corrugated shape.
According to (4), the strength and the like can be variously set so as to correspond to the requirements at the time of manufacture.

(5) In the manufacturing method of the metal mold | die for antireflection film manufacture which manufactures an antireflection film by the shaping | molding of the uneven | corrugated shape to a base material,
It has the metal mold | die preparation process which produces the said uneven | corrugated shape by anodizing and etching the aluminum film by a long roll material.

  According to (5), it can produce by the continuous process of the film of aluminum, and, thereby, the fine shape which uses for shaping with uniform and high precision can be produced. Further, for example, since it can be used only once, it is possible to produce an antireflection film without considering deterioration due to manufacturing. Thus, various problems related to the roll plate can be avoided at once, and the antireflection film can be efficiently mass-produced with high accuracy.

(6) In an antireflection film manufacturing mold for manufacturing an antireflection film by forming an uneven shape on a substrate,
An aluminum film made of a long roll material,
By the anodizing treatment and the etching treatment, the concavo-convex shape for forming was produced on the surface.

  According to (6), it can produce by the continuous process of the film of aluminum, and, thereby, the fine shape used for shaping can be produced with uniform and high precision. Further, for example, since it can be used only once, it is possible to produce an antireflection film without considering deterioration due to manufacturing. Thus, various problems related to the roll plate can be avoided at once, and the antireflection film can be efficiently mass-produced with high accuracy.

  With respect to the antireflection film related to the moth-eye structure, various problems related to the roll plate can be avoided at once, a fine structure can be produced uniformly and accurately, and deterioration due to production can be effectively avoided.

It is a figure which shows the antireflection film which concerns on 1st Embodiment of this invention. It is a figure which shows the manufacturing process of the antireflection film of FIG. It is a figure which shows a metal mold | die preparation process. It is a figure which shows an ultraviolet curable resin application process. It is a figure which shows an ultraviolet curable resin hardening process. It is a figure which shows a peeling process. It is a figure where it uses for detailed description of a metal mold | die preparation process. It is a figure which shows the manufacturing process which concerns on 2nd Embodiment of this invention. It is a figure which shows an original fabric preparation process. It is a figure which shows the other example of a raw fabric preparation process.

[First Embodiment]
FIG. 1 is a view showing an antireflection film according to the first embodiment of the present invention. The antireflection film 1 is produced by disposing the concavo-convex film 3 on a substrate 2 made of a transparent film. Here, various transparent films such as TAC (Triacetylcellulose), acrylic, PET (Polyethylene terephthalate), and PC (Polycarbonate) can be applied to the substrate 2. The antireflection film 1 is produced by forming a fine concavo-convex shape on the surface of the base material 2 using the ultraviolet curable resin 4 on the surface of the base material 2 using a mold for producing the antireflection film. The antireflection film 1 is manufactured so that the refractive index gradually changes in the thickness direction due to the fine uneven shape by the uneven film 3, and prevents reflection of incident light in a wide wavelength range by the principle of the moth-eye structure.

  FIG. 2 is a diagram showing a manufacturing process of the antireflection film 1. In the manufacturing process 10, a mold used for forming a moth-eye structure is manufactured in the mold manufacturing process 11. More specifically, in the metal mold manufacturing step 11, a fine hole for forming is densely prepared by repeating anodizing treatment of aluminum and an etching process (indicated by reference numeral 12), and the hole is formed while the fine hole is being dug. A mold is produced with an enlarged diameter.

  Subsequently, in the molding process 13, the manufacturing process 10 molds the microstructure related to the moth-eye structure on the substrate 2 using the mold manufactured in the mold manufacturing process. That is, in this shaping process 13, the base material 2 is supplied by a long roll material. In the molding step 13, after the ultraviolet curable resin 4 is applied to the substrate 2 in the ultraviolet curable resin coating step (UV resin coating) 14, the substrate 2 is applied to the manufacturing mold manufactured in the mold manufacturing step 11. In the subsequent UV curable resin curing step (UV curing) 15, the ultraviolet curable resin is cured by irradiating ultraviolet rays, thereby forming a fine structure relating to the moth-eye structure on the substrate 2.

  Subsequently, in the manufacturing process 10, in the peeling process 16, the manufacturing mold used for shaping is peeled from the base material 2. In the production process 10, an anti-reflection film 1 is produced by producing an adhesive layer or the like on the substrate 2 as necessary and then cutting it into a desired size. Thereby, the antireflection film 1 is efficiently mass-produced by continuous processing of the long base material 2 using a roll material.

  FIG. 3 is a diagram showing the mold manufacturing process 11 in detail. In this metal mold manufacturing step 11, a fine structure relating to the moth-eye structure is manufactured by repeating anodizing treatment and etching treatment on a long aluminum film made of a roll material, and a manufacturing mold for molding is prepared. . Here, a high-purity rolled film with few impurities and no pinholes is applied to the aluminum film. In addition, at least the surface on which the moth-eye structure is manufactured has a mirror finish (for example, arithmetic average roughness Ra is 0.05 μm or less), and a reflectance of 90% or more is applied. Also, a certain so-called waist-thickness to which a series of processes described later can be applied is applied.

  In this embodiment, by using a manufacturing die produced by processing a long aluminum film with this roll material, a fine uneven shape relating to the moth-eye structure is formed, thereby using a roll plate Various problems in doing so are solved at once, and mass production of antireflection films is efficiently performed with high accuracy.

  That is, in the manufacturing mold produced by processing a long aluminum film with such a roll material, as will be described later, anodizing treatment is performed by continuous processing while conveying the aluminum film, By performing the etching process, it is possible to produce a fine shape to be subjected to shaping with uniform and high accuracy. Further, for example, since it can be used only once, it is possible to produce an antireflection film without considering deterioration due to manufacturing.

In the mold manufacturing process 11, the aluminum film 20 is sequentially supplied from the supply roll 21. In this mold making process 11, after the aluminum film 20 is electropolished (12A), the processes of anodization 12B, water washing 12C, and etching 12D are repeated a predetermined number of times to perform water washing 12E. Further, the production mold 25 is produced by drying with a dryer 22 and thereby producing a fine structure to be formed on an aluminum film, and the production mold 25 is wound around an intermediate reel 23 to perform the next step. Transport to. At this time, if necessary, silicone or the like may be applied to the intermediate reel 23 as a release agent.

  FIG. 4 is a diagram showing the ultraviolet curable resin coating step 14. In the ultraviolet curable resin coating process 14, the base material 2 is continuously supplied from the supply roll 30 using a long roll material. In the ultraviolet curable resin coating process 14, the base material 2 is conveyed via a roller 31, and the ultraviolet curable resin 4 is applied by applying a gravure coating technique. That is, the ultraviolet curable resin coating step 14 guides the substrate 2 to the cylinder roll 33 and the back roll 32. Further, the substrate 2 is sandwiched and conveyed by the cylinder roll 33 and the back roll 32, and the coating liquid of the ultraviolet curable resin 4 held on the ink pan 34 is applied by the cylinder roll 33.

  In the ultraviolet curable resin coating process 14, the substrate 2 is subsequently conveyed to the dryer 36 via the roller 35, where the ultraviolet curable resin 4 is dried. Further, the base material 2 is superposed on the manufacturing die 25 pulled out from the intermediate reel 23 and conveyed to the pressing rollers 38A and 38B, where the manufacturing die 25 is pressed against the base material 2 and applied to the base material 2. The curable resin 4 is shaped. Subsequently, in this process, the manufacturing mold 25 and the base material 2 are superposed on each other and wound around the intermediate reel 39 and conveyed to the next process.

  FIG. 5 is a diagram showing the ultraviolet curable resin curing step 15. In this step 15, the laminated body of the base material 2 and the manufacturing mold 25 is pulled out from the intermediate reel 39 and conveyed, and the laminated body is wound around the roller 43 while being pressed by the roller 41. Here, the roller 43 is provided with a light source 44 for irradiating ultraviolet rays around the roller 43, whereby the ultraviolet rays applied to the substrate 2 are cured by the ultraviolet rays emitted from the light source 44. Thereafter, in the ultraviolet curable resin curing step 15, the laminate of the base material 2 and the manufacturing die 5 is conveyed via the rollers 42 and 45, wound around the intermediate reel 46, and conveyed to the next step.

  FIG. 6 is a diagram showing the peeling process 16. In this step 16, the laminated body of the base material 2 and the manufacturing mold 5 is pulled out from the intermediate reel 46 and conveyed to the rollers 51 and 52. Here, in this step 16, the laminate of the base material 2 and the manufacturing mold 5 is conveyed by being sandwiched by the rollers 51 and 52, the base material 2 side is wound around the reel 54, and the manufacturing gold is supplied from the base material 2. The mold 5 is peeled off and wound on the reel 53. As a result, in the peeling process 16, the antireflection film 1 is wound on the reel 54, and in the manufacturing process, the antireflection film 1 wound on the reel 54 is transported to a process such as cutting.

  FIG. 7 is a diagram for explaining the processing of anodization 12B and water washing 12C (FIG. 7A) and etching 12D (FIG. 7B) in the mold manufacturing step 11. In the anodizing step, the aluminum film 20 is transported to the cleaning tank 62 through the roller 61 that also serves as a voltage supply electrode for anodizing and cleaned, and then the first to third anodizing tanks 63A and 63B. , 64B, anodization is sequentially performed. Subsequently, the chemical solution subjected to the anodic oxidation is washed by the washing tank 64 and then dried by a drier (not shown) and conveyed to the next process by the roller 65.

  In the etching step, the pretreatment is performed in the pretreatment tank 66, the etching process is performed in the etching tank 67, and the chemicals subjected to the etching are sequentially washed and conveyed in the subsequent washing tanks 68A and 68B and the pure water treatment tank 68C.

  According to the above configuration, by processing a long aluminum film with a roll material to produce a production mold, it is possible to produce a fine shape to be subjected to shaping with uniform and high accuracy. Since it can be made disposable once, an antireflection film can be produced without considering any deterioration due to production. Accordingly, various problems relating to the roll plate can be avoided at once, and the antireflection film can be mass-produced efficiently with high accuracy.

  Also, at this time, an aluminum film made of a long roll material is anodized and etched to produce a mold for molding, so that a concavo-convex shape to be used for molding a moth-eye structure on the surface is produced. A mold for production of the aluminum film thus produced can be produced.

[Second Embodiment]
FIG. 8 is a diagram showing a manufacturing process of the antireflection film according to the second embodiment of the present invention in comparison with FIG. This manufacturing process 10 is configured in the same manner as in the above-described embodiment except that in the raw fabric manufacturing process 70, an aluminum film is processed in advance.

  Here, in the original fabric production process 70, a protective film for reinforcement is disposed on the back surface of the aluminum film. Thereby, in this embodiment, the usage-amount of aluminum is reduced and sufficient intensity | strength is ensured. As the reinforcing protective film, various films such as TAC, acrylic, PET, and PC can be applied. Various arrangements such as laminating using an adhesive layer and laminating using an adhesive can be applied to this arrangement.

  FIG. 9 is a diagram showing the original fabric production process 70 in detail. In this embodiment, PET is applied to the protective film, and the protective film is arranged by bonding using an adhesive. That is, in the original fabric production process 70, the protective film 83 coated with an adhesive is supplied from the supply roll 81, and the protective film 83 is conveyed to the rollers 85A and 85B via the roller 82. Also, in this step 70, the aluminum film 71 is supplied from the supply roll 84, and the aluminum film 71 is conveyed to the rollers 85A and 85B. In this step 70, the protective film 83 and the aluminum film 71 are laminated and pressed by the rollers 85 </ b> A and 85 </ b> B, whereby the protective film 83 is disposed on the aluminum film 71 and wound around the intermediate reel 87.

  In the second embodiment, an aluminum film wound on the intermediate reel 87 is processed in the same manner as in the first embodiment to produce an antireflection film.

  In this embodiment, even if a protective film is disposed on an aluminum film, the same effect as that of the first embodiment can be obtained. Further, by disposing the protective film in this way, it is possible to produce a production die so as to be able to flexibly meet various demands required in a series of manufacturing processes of the antireflection film.

[Third Embodiment]
FIG. 10 is a diagram showing an original fabric manufacturing process according to the third embodiment of the present invention in comparison with FIG. This embodiment has the same configuration as that of the second embodiment except that the configuration shown in FIG. 10 is different. In this embodiment, PET is applied to the protective film, and the protective film is disposed by bonding using an adhesive that is a dry laminate.

  That is, in the original fabric manufacturing process 70, the protective film 92 is supplied from the supply roll 91. In this step 70, the protective film 92 is conveyed through the roller 93, and an adhesive is applied by applying a gravure coating technique. That is, in this step 70, the protective film 92 is guided to the cylinder roll 95 and the back roll 94. Further, the protective film 92 is sandwiched and conveyed by the cylinder roll 95 and the back roll 94, and the coating liquid held in the ink pan 96 is applied by the cylinder roll 95.

  In this step 70, subsequently, the protective film 92 is conveyed to the dryer 98 via the roller 97, where the coating liquid is dried. Further, a protective film 92 is superimposed on the aluminum film 71 drawn out from the supply roll 84 and conveyed to the pressing rollers 99A and 99B, where the protective film 92 is pressed and bonded to the aluminum film 71. Subsequently, in this step, the bonded film 101 is wound around the intermediate reel 100. In the third embodiment, an aluminum film wound on the intermediate reel 100 is processed in the same manner as in the first embodiment to produce an antireflection film.

  In this embodiment, even if the protective film is disposed by adhesion, the same effect as that of the second embodiment can be obtained.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above. However, the present invention is combined with the configuration of the above-described embodiment, and further the configuration of the above-described embodiment without departing from the spirit of the present invention. Can be variously changed and further combined with the conventional configuration.

  That is, in the above-described embodiment, the case where the manufacturing mold is made disposable once is described. However, the present invention is not limited to this, and may be repeatedly used as necessary.

  In the above-described embodiment, the case where the film is wound around the intermediate reel and conveyed to the next process is described for each process. However, the present invention is not limited to this, and a series of processes may be executed by a continuous process. good.

  In the above-described embodiment, the case where the anodizing treatment and the etching treatment are repeated has been described. However, the present invention is not limited to this, and in the case where a fine hole can be formed in a desired shape sufficiently for practical use, It may be executed by processing.

  Further, in the above-described embodiment, the case where the ultraviolet curable resin is applied to the base material side for shaping is described. However, the present invention is not limited to this, and the case where the ultraviolet curable resin is applied to the mold side is also described. Can be widely applied.

  Further, in the above-described embodiment, the case where molding is performed using an ultraviolet curable resin that is a resin that is cured by irradiation with ultraviolet rays has been described. However, the present invention is not limited to this, and there is a resin material used for molding. For example, a resin material that is cured by irradiation with various energy such as an electron beam, a resin material that is cured by supplying various energy by supplying heat, and the like can be widely applied.

  In the above-described embodiment, the case where the uneven shape of the mold is transferred (molded) by molding of the ultraviolet curable resin is described. However, the present invention is not limited to this, and for example, a heated thermoplastic resin is pressed. Thus, it can be widely applied to molding.

DESCRIPTION OF SYMBOLS 1 Antireflection film 2 Base material 3 Uneven film 4 Ultraviolet curable resin 10 Manufacturing process 11 Mold production process 12 Anodizing treatment, etching treatment 12A Electropolishing treatment 12B Anodizing treatment 12C, 12E Washing treatment 12D Etching treatment 13 Molding step 14 UV curable resin coating process 15 UV curable resin curing process 16 Peeling process 20, 71 Aluminum film 21, 30, 81, 84, 87, 91 Supply roll 22, 36, 98 Dryer 23, 39, 46, 100 Intermediate reel 25 Production mold 31, 35, 41, 42, 43, 45, 51, 52, 61, 65, 82, 85A, 85B, 93, 97 Roller 32, 94 Back roll 33, 95 Cylinder roll 34, 96 Ink pan 38A, 38B, 99A, 99B Press roller 44 Light source 53 , 54 Reels 62, 68A, 68B Water washing tanks 63A, 63B, 64B Anodizing tanks 64 Cleaning tanks 66 Pretreatment tanks 67 Etching tanks 68C Pure water treatment tanks 70 Raw fabric preparation processes 83, 92 Protective films

FIG. 7 is a diagram for explaining the processing of anodization 12B and water washing 12C (FIG. 7A) and etching 12D (FIG. 7B) in the mold manufacturing step 11. In the anodic oxidation process, via the B over La 61, it was washed by conveying the aluminum film 20 to the cleaning tank 62, the first to third anodization bath 63A, 63B, sequentially anodized by 64B Execute. Subsequently, the chemical solution subjected to the anodic oxidation is washed by the washing tank 64 and then dried by a drier (not shown) and conveyed to the next process by the roller 65.

Claims (6)

Laminating a base material made of a long roll material and a production die made of an aluminum film, which is a long roll material and has a concavo-convex shape for forming a moth-eye structure on the surface, the production A molding step of molding the uneven shape produced in the mold for the substrate into the substrate;
The manufacturing method of an antireflection film provided with the peeling process which peels the said base material from the said metal mold | die for manufacture. The method for producing an antireflection film according to claim 1, further comprising a mold production step of producing an irregular shape by anodizing and etching an aluminum film using a long roll material. The aluminum film is
The method for producing an antireflection film according to claim 1, wherein a protective film is provided on a side surface opposite to a surface on which the uneven shape is produced. The method for producing an antireflection film according to claim 3, further comprising a reinforcing step of disposing the protective film on a side surface opposite to a surface on which the uneven shape is formed. In the manufacturing method of the antireflection film manufacturing mold for manufacturing the antireflection film by forming the uneven shape on the substrate,
The manufacturing method of the metal mold | die for anti-reflective film manufacture which has the metal mold | die preparation process which anodizes and etches the aluminum film by a long roll material, and produces the said uneven | corrugated shape. In the mold for producing an antireflection film for producing an antireflection film by forming an uneven shape on a substrate,
An aluminum film made of a long roll material,
A mold for producing an antireflective film, in which the concavo-convex shape for shaping is produced on the surface by anodizing treatment and etching treatment.

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