JP2017030160A - Apparatus for transferring pattern of film and method for transferring pattern of film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an apparatus for transferring a pattern enabling stable conveyance of a film in a gravity direction and pattern formation in a state in which the pattern is surely in the gravity direction.SOLUTION: There is provided an apparatus for transferring a pattern of a film which includes: a resin layer forming section 4 for forming a resin layer 22 on a base film 2; a pattern transfer section 5 for transferring a shape-imparting surface 31 on the resin layer to form a pattern 21; a resin layer curing section 6 for curing the resin layer to generate a transfer film 20; a shape-imparting film peeling section 7 for peeling a shape-imparting film 3 from the transfer film; and a film conveyance section 8 which unwinds the base film, passes the resin layer forming section, the pattern transfer section, the resin layer curing section and the shape-imparting film peeling section, and winds the transfer film, where the film conveyance section includes a guide roll 83 for making the conveyance direction of the base film oriented from an upper direction to a lower direction before the resin layer forming section, and the resin layer forming section includes a pair of dies 43 that make the position of a resin discharge port 431 arranged so as to shift vertically from each other, and the die arranged in the upper side is arranged on a surface side which does not come in contact with the guide roll of the base film.SELECTED DRAWING: Figure 1

Description

  An embodiment of the present invention relates to an apparatus for simultaneously transferring a film-like mold (shaped surface of a shaped film) onto both surfaces of a film (base film) serving as a base for pattern transfer, a so-called roll-to-roll type double-sided simultaneous transfer apparatus and It relates to the transfer method.

  For example, in Patent Document 1, a photoreactive composition is applied to both sides of a base film to form a photoreactive composition layer, and a light transmissive film is bonded onto the formed photoreactive composition layer. An apparatus is disclosed in which after the composition layer is cured by irradiating light, the bonded light-transmitting film is peeled off. Such an apparatus includes a light-transmitting film feeder and a winder on both one side and the other side of the base film, respectively. Therefore, if a shaped film in which a resin layer is formed of a transparent resin having ultraviolet curable properties on the film surface and the surface of the resin layer is processed as a shaped surface (uneven portion), the photoreaction of the base film is performed. It is possible to transfer the shaping surface to the conductive composition layer and to form a predetermined pattern (uneven portions obtained by inverting the unevenness of the shaping surface) on both sides simultaneously on the base film.

  As described above, the apparatus described in Patent Document 1 can be used as an apparatus (a double-sided simultaneous transfer type apparatus) that simultaneously forms a pattern having a shaping surface transferred on both sides of a base film. The operation in this case will be described. . In such an apparatus, the base film is fed out in a horizontal direction (a predetermined direction on a plane orthogonal to the direction of gravity) from the feed roll. In this case, for example, an ultraviolet curable resin is applied to the upper and lower film surfaces from the upper side and the lower side of the drawn base film to form an ultraviolet curable resin layer (hereinafter simply referred to as a resin layer). In addition, upper and lower are defined on the basis of the direction of gravity, and in the following description, for convenience, the upper film surface of the base film is referred to as the front surface, and the lower film surface is referred to as the rear surface.

  Next, a surface shaping film is bonded to the resin layer on the surface of the base film. At that time, the shaped film for the surface directs the shaped surface to the surface of the base film. At the same time, a shaping film for the back surface is bonded to the resin layer on the back surface of the base film. At that time, the shaped film for the back surface has the shaped surface facing the back surface of the base film. A pressing roll is arranged at the bonding site, and by pressing the shaped film against the base film from above and below, the shaped surface of the shaped film is transferred to the resin layer on the front and back surfaces of the base film, respectively. It has become. Thereby, a pattern is formed on the surface of the resin layer of the base film.

  Then, the resin layer on the front and back surfaces of the base film is irradiated with ultraviolet rays from the light source of the resin layer curing portion while being sandwiched between the shaping films from above and below, and the resin layer on which the pattern is formed is cured and fixed to the base film. Let Thereby, a transfer film is produced as a base film having a pattern on the surface of the resin layer. Thereafter, the shaped film is peeled off from the transfer film with a peeling roll. As described above, according to the apparatus described in Patent Document 1, the pattern transferred from the shaped film can be simultaneously formed on both surfaces of the base film.

JP 2004-322408 A

  However, when the same pattern is formed on both sides of the base film, the apparatus described in Patent Document 1 has the following problems.

  In the apparatus described in Patent Document 1, the base film is transported horizontally, and the UV curable resin is applied to the base film from above and below. The coating solution of the ultraviolet curable resin has fluidity until it is cured after being applied, and therefore spreads in a plane (leveling). Leveling improves the uniformity of the resin layer formed on the base film. Since the base film is continuously transported, the applied ultraviolet curable resin tends to spread in the transport direction. On the other hand, the applied ultraviolet curable resin hardly spreads in the direction (hereinafter referred to as the width direction) orthogonal to the transport direction on the film surface of the base film. That is, on the upper side (front side) of the base film, the coating liquid is discharged in the direction of gravity (downward) when the resin layer is formed, so that it is relatively easy to spread in the width direction. On the other hand, the coating liquid is discharged in the direction opposite to the direction of gravity (upward) on the lower side (back side) of the base film, so that it is difficult to spread in the width direction. Accordingly, there is a possibility that a difference occurs in the leveling level between the front surface and the back surface of the base film, and a difference in the thicknesses of the resin layers on the front surface and the back surface.

  In the pattern transfer part (placement part of the press roll) that presses the shaped film to the base film and transfers the shaped surface to the resin layer, the shaped film is supplied from the top to the surface of the base film and from the bottom to the back. The At the part where the shaping surface of the shaping film and the resin layer of the base film merge, the UV curable resin that forms the resin layer of the base film is in contact with the shaping surface of the shaping film. The air (air) between the resin layer and the resin layer is pushed out by the ultraviolet curable resin and escapes from the shaping surface. Therefore, if the resin layer is cured by irradiation with ultraviolet rays before the air is completely removed between the shaping surface and the resin layer, the accuracy of the pattern formed on the resin layer may be reduced by the remaining air. In particular, when the transport speed of the base film is high, the resin layer is cured before the air between the shaping surface and the resin layer is completely removed, and the pattern accuracy of the resin layer is likely to further decrease. The air between the shaping surface and the resin layer rises due to buoyancy, but the back side of the base film is more difficult to escape than the front side because the upper part is blocked by the base film. For this reason, in order to bleed the air between a shaping surface and a resin layer in the back surface side of a base film, the conveyance speed of a base film may have to be suppressed.

  In the pattern transfer portion, the pressing rolls are arranged side by side so as to sandwich the upper and lower shaping films bonded to the resin layer of the base film. The pressing roll is deformed so as to bend downward due to its own weight. Therefore, the base film and the resin layer are deformed so that the central portion in the width direction on the front surface side bends downward and the back surface side protrudes accordingly. If the resin layer is cured in this state, the base film may be bent downward, and as a result, the patterns of the front and back patterns are likely to be different.

  Ultraviolet irradiation lamps that irradiate the resin layer with ultraviolet rays are arranged above and below the resin layer curing portion that cures the resin layer on which the pattern is formed and adheres to the base film. Since the ultraviolet irradiation lamp also generates light having a wavelength other than ultraviolet light, and when the resin layer is cured, heat of polymerization is generated, so that the ambient temperature of the resin layer cured portion rises. The warmed air goes up. Therefore, an upward airflow is generated toward the ultraviolet irradiation lamp on the front surface side of the base film, but the upward airflow is blocked by the base film on the back surface side, so that heat tends to be trapped. For this reason, a difference in ambient temperature occurs between the front surface side and the back surface side of the base film, and there may be a difference in curability between the front surface side resin layer and the back surface side resin layer. In this case, there is a possibility that a difference occurs in the pattern forms of the front surface and the back surface.

  In the resin layer curing portion, when the tension of the base film and the shaped film is small, these films are deformed so as to sag downward due to their own weight. Such deformation due to its own weight occurs in both the transport direction and the width direction, but since the width direction is supported by the pressing roll, sagging in the transport direction becomes a problem. In particular, when the base film and the shaped film have to be transported at a low tension, there is a risk that these films will be largely sagging in the transport direction. In such a state, a compressing force acts on the front surface side of the base film, and a pulling force acts on the back surface side. Therefore, when the resin layer is cured in this state, the forces acting on the front surface side and the back surface side of the base film are different, and thus there is a possibility that a difference in pattern form between the front surface and the back surface occurs.

  As described above, in the apparatus described in Patent Document 1, when forming a pattern in which the shaping surface of the shaping film is transferred on both surfaces of the base film, the conditions of the formation environment are the front side (upper side) and the back side (lower side). In many cases).

  In this case, from the resin layer forming part for forming the resin layer on the base film to the pattern transfer part and the resin layer curing part, the transfer film provided with the resin layer having the pattern formed on the base film and the base film is moved in the gravity direction. It is conceivable to solve the above-described problems by transporting from above to below.

  If it is such an apparatus structure, it will become possible to make the influence of the gravity in the one surface side and other surface side of a base film correspond. On the other hand, it is necessary to arrange the resin layer forming part, the pattern transfer part, and the resin layer curing part along the direction of gravity, and the height of the device (dimension along the direction of gravity) increases accordingly. Therefore, even when the height of the apparatus is increased, it is required to ensure that the transport path (pass line) of the base film and the transfer film is along the direction of gravity.

  Therefore, a film pattern that can stably form a film on both sides of the film in a state where the film is stably conveyed from the top to the bottom along the direction of gravity and the film is surely along the direction of gravity. A transfer apparatus and a film pattern transfer method are provided.

  The film pattern transfer device of the embodiment includes a resin layer forming portion that forms a resin layer by applying a liquid resin on both sides of a base film, and a shaped film is pressed against the resin layer of the base film to apply the shaped film. A pattern transfer part that forms a pattern on the surface of the resin layer by transferring the shape surface to the resin layer, and a resin layer that cures the resin layer on which the pattern is formed and adheres it to the base film to form a transfer film A cured part, a shaped film peeling part that peels the shaped film from the transfer film, and a base film are drawn out, and a resin layer forming part, a pattern transfer part, a resin layer cured part, and a shaped film peeling part are passed through and generated. A film transport unit for winding the transferred film. The film transport unit includes a guide roll that directs the transport direction of the base film from top to bottom along the direction of gravity in front of the resin layer forming unit. The resin layer forming part has a pair of dies that are arranged on the both sides of the base film, with the positions of the respective resin discharge ports shifted up and down. Of the pair of dies, the die disposed on the upper side is disposed on the surface side that does not contact the guide roll of the base film.

  According to the film pattern transfer apparatus and the film pattern transfer method of the embodiment, the film can be stably conveyed from top to bottom along the direction of gravity. Moreover, a pattern can be simultaneously formed on both surfaces of the film in a state where the film is surely aligned in the direction of gravity.

The schematic block diagram which shows the pattern transfer apparatus of the film for enforcing the pattern transfer method of the film of embodiment. In the film pattern transfer apparatus of the embodiment, a transfer film having a pattern in which the shaping surface of the shaping film is transferred to the resin layer of the base film is generated, and an aspect until the shaping film is peeled off from the transfer film is shown. FIG. The schematic block diagram which shows the apparatus (general roll-to-roll type single-sided UV transfer apparatus) which forms a shaping surface in a shaping film. It is a figure which shows the example of a shaping surface and a pattern, Comprising: (a) is a top view of the shaping surface made into the line and space (a vertical groove or a horizontal groove), (b) is the shaping | molding in the arrow A41 part of (a). The figure which shows the cross section of a shape surface from an arrow direction, (c) is a figure which shows the pattern corresponding to the line and space of (a) with the same cross section as (b), (d) is the shaping surface which used the cross groove | channel. (E) is a view showing a cross section of the shaping surface at the arrow A42 portion of (d) from the direction of the arrow, (f) is a pattern corresponding to the cross groove of (d) in the same cross section as (e) (G) is a plan view of the shaping surface formed as a dot, (h) is a diagram showing a cross section of the shaping surface in the arrow A43 portion of (g) from the direction of the arrow, (i) is a dot of (h) The figure which shows the pattern corresponding to 1 in the cross section similar to (e). It is a figure which shows the aspect example of the alignment mark formed in a base film, Comprising: (a) is a figure which shows the form of the alignment mark of the surface of a base film and a back surface from a back surface side, (b) is a figure of a base film The figure which shows the aspect of the position shift of the conveyance direction of the alignment mark which arises on the surface and a back surface, and the width direction. It is a figure which shows the relationship between the holding angle (wrap angle) of the base film with respect to a guide roll, and the position of the die | dye in the both surfaces side of a base film, Comprising: (a) is a die | dye on the back surface side. The figure which shows the example of the aspect which arranged the upper side rather than the side and enlarged the holding angle, (b) is the example of the aspect which arrange | positioned the die | dye of the back surface side of a base film above the die | dye of the surface side, and made the holding angle small FIG. It is a figure which shows the movement aspect of the die | dye and guide roll by a moving mechanism, Comprising: (a) is the state which the base film and the shaping film have shifted to the back surface side of the base film with respect to the gravity direction (pass line). (B) is a figure which shows the state which moved the die | dye and the guide roll to the direction shown by arrow A7 of (a), and made the base film and the shaping film follow the pass line. It is a figure which shows the movement aspect of the die | dye and guide roll by a moving mechanism, Comprising: (a) is the state which the base film and the shaping film have shifted to the surface side of the base film with respect to the gravitational direction (pass line). (B) is a figure which shows the state which moved the die | dye and the guide roll to the direction shown by arrow A8 of (a), and made the base film and the shaping film follow the pass line. The figure which shows the cross section in the arrow A11 part of FIG. 1 from an arrow direction. The figure which shows the example of an aspect of the press roll of a resin layer hardening part. The figure which shows the modification of the aspect of the press roll of a resin layer hardening part. The figure which shows the cross section in the arrow A12 part of FIG. 1 from an arrow direction. The schematic block diagram which shows the moving mechanism of the shaping film delivery axis | shaft for surfaces (roll of the shaping film for surfaces).

  Hereinafter, a film pattern transfer apparatus and a film pattern transfer method according to an embodiment of the present invention will be described with reference to FIGS. 1 to 13.

  FIG. 1 is a schematic configuration diagram showing a film pattern transfer apparatus 1 for carrying out the film pattern transfer method of the present embodiment. The pattern transfer device 1 is a device that forms a pattern by simultaneously transferring a film-like mold (shaped film) 3 onto both surfaces of a film (base film) 2 that serves as a base for pattern transfer, and generates a transfer film 20 ( Roll-to-roll type double-sided simultaneous transfer device).

  As shown in FIG. 1, the pattern transfer apparatus 1 includes a resin layer forming unit 4, a pattern transfer unit 5, a resin layer curing unit 6, a shaped film peeling unit 7, and a film transport unit 8. The resin layer forming part 4, the pattern transfer part 5, the resin layer curing part 6, and the shaped film peeling part 7 are arranged in this order from top to bottom along the direction of gravity. The film transport unit 8 sequentially transports the base film 2 to the resin layer forming unit 4, the pattern transfer unit 5, and the resin layer curing unit 6, and sequentially transfers the transfer film 20 to the resin layer curing unit 6 and the shaped film peeling unit 7. Is transporting.

  In FIG. 2, the shaping surface (uneven portion) 31 of the shaping film 3 is transferred to the resin layer 22 of the base film 2, and the pattern 21 (uneven portion obtained by inverting the uneven portion of the forming surface 31) is formed. Then, it is the schematic which shows the aspect until the shaping film 3 peels from the base film 2 which hardened | cured and fixed this resin layer 22. FIG. In the following description, the base film 2 obtained by curing and fixing the resin layer 22 on which the pattern 21 is formed is referred to as a transfer film 20 and is appropriately distinguished from the base film 2.

  As shown in FIG. 2, the base film 2 is a resin film in which a flat film surface is continuous over a predetermined length. In the present embodiment, the base film 2 having light transmittance (translucency), specifically, ultraviolet light transmittance is applied as an example, but a light shielding film (for example, an opaque film such as a metal foil) is used as a base. It is also possible to apply as the film 2. In the following description, for convenience, among the film surfaces of the base film 2, the film surface on one side of the base film 2 that does not come into contact with a guide roll 83 described later (surface on the outer peripheral side of the curve) is the surface 2 a, and the back surface side thereof. The film surface (the surface on the inner peripheral side of the curve that contacts the guide roll 83) is referred to as the back surface 2b. For the transfer film 20 described later, the film surfaces corresponding to the front surface side and the back surface side of the base film 2 are referred to as the front surface and the back surface, respectively.

  The shaped film 3 is a transparent resin film having ultraviolet transparency in which the film surface is continuous over a predetermined length. The shaping film 3 is configured as a resin mold, and a predetermined shaping surface 31 is formed on one side. A shaping surface 31 corresponding to the pattern 21 is formed in advance on the film surface on one side of the shaping film 3 before the pattern 21 is formed on the base film 2. That is, the pattern 21 and the shaping surface 31 are irregularities obtained by inverting the irregularities of each other, and the shaping surface 31 corresponds to the mold for the pattern 21. The formation of the shaping surface 31 on the shaping film 3 will be described later.

  The resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, the shaped film peeling unit 7, and the film transport unit 8 are divided into a plurality of spaces that are separated by a flooring material and line up and down along the direction of gravity. Are arranged. Each of these spaces may be, for example, each floor of a two-story or higher building, or an arrangement area in which one floor of a building or a single-story building is divided into a plurality of layers having different heights from the floor surface. It may be. Specifically, the arrangement area can be formed by applying a frame structure in which square tubes are combined or a structure in which plate members are connected by stays.

  As described above, the resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, the shaped film peeling unit 7, and the film transport unit 8 are arranged in layers so that individual work can be performed with a certain length. Even when the process distance is necessary, the resin layer forming part 4, the pattern transfer part 5, the resin layer curing part 6, and the shaped film peeling part 7 are arranged along the direction of gravity (in the height direction, simply The base film 2 or the transfer film 20 can be transported to the respective sections 4 to 7 by the film transport section 8. For example, as described later, when the ultraviolet curable resin layer of the base film 2 is cured by the resin layer curing unit 6, even when it is necessary to irradiate ultraviolet rays over a certain conveyance distance (time), The pattern transfer apparatus 1 can be configured as a vertical type.

  In this embodiment, as shown in FIG. 1, the inside of a building is divided | segmented by the floor materials 11-13, and four arrangement | positioning areas F1-F4 are formed. The flooring materials 11 to 13 are supported by a support column 14 provided on the floor surface 10 of the building. In this case, the third flooring 13 raises the floor surface 10, the first flooring 11 raises the third flooring 13, and the second flooring 12 raises the first flooring 11 respectively. ing. The pattern transfer unit 5 and the resin layer curing unit 6 are separated by a first floor material 11, and the resin layer forming unit 4 and the pattern transfer unit 5 are separated by a second floor material 12. Moreover, the resin layer hardening part 6 and the shaping film peeling part 7 are arrange | positioned at the arrangement | positioning area F2, the pattern transfer part 5 is arrange | positioned at the arrangement | positioning area F3, and the resin layer formation part 4 is arrange | positioned at the arrangement | positioning area F4. The film conveyance part 8 is arrange | positioned over all the arrangement areas F1-F4.

  In the flooring materials 11 to 13, through holes 11 a to 13 a arranged in a straight line along the direction of gravity are formed, respectively. The base film 2 (transfer film 20) and the shaping film 3 are passed through the through holes 11a to 13a. In this case, both the base film 2 and the shaping film 3 are passed through the first through hole 11a, the base film 2 is passed through the second through hole 12a, and the transfer film 20 is passed through the third through hole 13a. Yes. The imaginary straight line passing through the through holes 11a to 13a corresponds to the normal conveyance path of the base film 2 (transfer film 20) and the shaping film 3, and hereinafter this virtual straight line (conveyance path) is passed. It is called line PL.

  The pattern transfer apparatus 1 of the present embodiment is an apparatus that simultaneously transfers the shaping surface 31 of the shaping film 3 to both surfaces of the base film 2 to form the pattern 21. The formation of the shape surface 31 will be described.

  In FIG. 3, the schematic structure of the apparatus (general roll-to-roll type single-sided UV transfer apparatus) 30 which forms the shaping surface 31 in the film surface of the one side of the shaping film 3 is shown. As shown in FIG. 3, the shaping film 3 is formed by forming a resin layer 30 b on one side of the shaping film base film 30 a, pressing the molding roll 305 against the resin layer 30 b, The concavo-convex portion (306) serving as the mold 31 is transferred to the resin layer 30b. In the following description, for convenience, the film surface on the forming side of the resin film 30b of the shaped film base film 30a, in other words, the forming side of the shaping surface 31 of the shaping film 3, is the surface, and the film surface on the back side. Is called the back side.

  The shaped film base film 30 a is a transparent resin film having an ultraviolet transparency in which a planar film surface is continuous over a predetermined length, and is fed from a feeding shaft 301. When the shaped film base film 30a is fed by the coating roll 302, the resin is discharged from the die 303 onto the surface, and the resin layer 30b is formed from the discharged resin. As the resin, a transparent resin that has ultraviolet curing properties and is liquid at normal temperature is used.

  The shaping film base film 30a on which the resin layer 30b is formed is pressed against the molding roll 305 by the pressing roll 304, and the molding die 306 of the molding roll 305 is transferred to the resin layer 30b. Thereby, the shaping surface 31 is formed in the resin layer 30b as an uneven part obtained by inverting the uneven part of the mold 306. The resin layer 30b on which the shaping surface 31 is formed is cured by being irradiated with ultraviolet rays from the ultraviolet irradiation lamp 307.

  The shaped film base film 30a fixed on the surface of the resin layer 30b on which the shaping surface 31 is formed, that is, the shaping film 3, is peeled off from the molding roll 305 by the peeling roll 308, and is wound on the winding shaft 309. It is wound up. The shaped film base film 30a and the shaped film 3 are appropriately relayed and conveyed by a plurality of relay rolls 310.

  The shaping surface 31 has an uneven shape in which the unevenness of the mold 306 is inverted. In FIG. 4, the example of the aspect of the shaping surface 31 is shown. 4A and 4B are vertical grooves (horizontal grooves) called line and space, FIGS. 4D and 4E are cross grooves, and FIGS. 4G and H are dot mode examples. However, the shaping surface 31 may be in any form. In this embodiment, the shaping film for the surface 2a of the base film 2 (hereinafter referred to as a surface shaping film as appropriate) 3a and the shaping film for the back surface 2b (hereinafter referred to as a shaping film for back surface as appropriate) 3b Form each one. The shaping surface 31a of the front shaping film 3a and the shaping surface 31b of the rear shaping film 3b may be the same or different.

  For example, when the shaping surface 31a of the shaping film 3a for the front surface and the shaping surface 31b of the shaping film 3b for the back surface are the same, the shaping surface 31a, The same pattern 21 is formed which is composed of uneven portions obtained by inverting the uneven portions 31b. FIG. 4C shows an aspect of the pattern 21 formed when the shaping surfaces 31a and 31b are both line and space shown in FIGS. Similarly, FIG. 4F is formed when the cross grooves shown in FIGS. 4D and 4E are formed, and FIG. 4I is formed when the dots shown in FIGS. 4D and 4E are formed. Each aspect of the pattern 21 is shown.

  Here, since the shaped film base film 30a and the resin layer 30b need to transmit ultraviolet rays to the resin layer 22 of the base film 2 as described later, both are formed of a transparent resin having ultraviolet transparency. As the transparent resin for forming the resin layer 30b, a resin that can be easily peeled off from the resin layer 22 is used.

  In the apparatus 30 shown in FIG. 3, the molding die 306 applied to the resin layer 30b is transferred using a molding roll 305 in which a molding die (uneven portion) 306 is directly engraved on the roll surface. The stamper manufactured in step (a plate-like base material having a concavo-convex portion formed on the surface) may be wound around a solid roll for transfer.

  Moreover, in this embodiment, the alignment mark shaping | molding part for surfaces is formed in the shaping surface 31a of the shaping film 3a for surfaces, and the alignment mark for back surfaces is formed in the shaping surface 31b of the shaping film 3b for back surfaces. Form each part. By monitoring the position of the alignment mark on the base film 2 formed by transferring these alignment mark shaped portions, the accuracy of pattern transfer with respect to the base film 2 (for example, transfer of the pattern 21, displacement of the formation position, etc.) is adjusted. It is possible to do. A forming die (concave portion or convex portion) for the alignment mark forming portion is formed at one or a plurality of locations on the roll surface of the forming roll 305. Thereby, with respect to the shaping films 3a and 3b for the front surface and the back surface, the alignment mark shaping portion (the uneven portion of the molding die for the alignment mark shaping portion of the molding roll 305) is commonly provided at one place or a plurality of places. Is formed).

  FIG. 5 shows an embodiment of an alignment mark 23 (an uneven portion obtained by inverting the uneven portion of the alignment mark forming portion of the shaping film 3) 23 formed on the base film 2 by the front and back shaping films 3. An example is shown. FIG. 5 (a) is a diagram showing an aspect of the alignment mark 23a on the front surface 2a of the base film 2 and the alignment mark 23b on the back surface 2b from the back surface 2b side. In this case, the alignment marks 23a and 23b are circular, but the shape may be any figure, and may be a character or a symbol. The pattern transfer accuracy adjustment using these alignment marks 23a and 23b will be described later.

  Next, the pattern transfer apparatus 1 of the present embodiment will be described along the flow of the base film 2 and the transfer film 20. As shown in FIG. 1, the base film 2 is conveyed from the top to the bottom along the direction of gravity by the film conveyance unit 8 from the resin layer forming unit 4 to the pattern transfer unit 5 and the resin layer curing unit 6. In succession, the transfer film 20 is conveyed from top to bottom along the direction of gravity from the resin layer curing unit 6 to the shaped film peeling unit 7 by the film conveyance unit 8.

  The film transport unit 8 includes a film feeding shaft 81 that feeds the base film 2 and a film winding shaft 82 that winds the transfer film 20 generated from the fed base film 2. Each of the film feeding shaft 81 and the film winding shaft 82 is a rotating shaft that rotates in a predetermined direction (clockwise in FIG. 1) by a motor (not shown), and the film feeding shaft 81 corresponds to the resin layer forming portion 4. The film take-up shaft 82 is disposed in front (upstream side in the transport direction of the base film 2) at the tip (downstream side) of the shaped film peeling portion 7, respectively. Thereby, including the aspect before and behind the production | generation of the transfer film 20, the base film 2 maintains predetermined tension | tensile_strength from the resin layer formation part 4 to the pattern transfer part 5, the resin layer hardening part 6, and the shaping film peeling part 7. Be transported. At that time, the film feeding shaft 81 and the film winding shaft 82 are rotationally controlled by a control unit (not shown) or the like so that the base film 2 and the transfer film 20 are always conveyed at a constant speed (line speed). Yes.

  When the base film 2 (transfer film 20) is disposed on the same side in the horizontal direction, the film feeding shaft 81 and the film winding shaft 82 rotate in the same direction and are disposed on the opposite side in the horizontal direction. The film feeding shaft 81 and the film take-up shaft 82 rotate in opposite directions. In FIG. 1, the film feeding shaft 81 is arranged in the arrangement area F3 and the film take-up shaft 82 is arranged in the arrangement area F2, respectively, but the hierarchy in which these are arranged is not particularly limited.

  The film transport unit 8 includes a guide roll 83 and a plurality of relay rolls 84 disposed on a transport path between the film feeding shaft 81 and the film take-up shaft 82. Each of the guide roll 83 and the relay roll 84 is an idle roll that rotates along with the base film 2 or the transfer film 20 conveyed by the film feeding shaft 81 and the film take-up shaft 82 which are rotating shafts.

  The guide roll 83 is arranged in the arrangement area F4 so that the base film 2 is curved in front of the resin layer forming portion 4 (upstream side) and the conveying direction is directed from top to bottom along the direction of gravity. The relay roll 84 changes the conveying direction of the base film 2 or the transfer roll 20 together with the guide roll 83 between the film feed shaft 81 and the film take-up shaft 82. One of the relay rolls 84 (the relay roll 84b shown in FIG. 1) is disposed below the guide roll 83 along the direction of gravity. The relay roll 84b is arranged in the arrangement area F1 so that the transfer film 20 is transported from the gravitational direction to the other direction (horizontal direction in the present embodiment) at the tip (downstream side) of the shaping film peeling portion 7. Has been. In FIG. 1, the guide roll 83 and the relay roll 84a are arranged in the arrangement area F4, and the relay roll 84b and the relay roll 84c are arranged in the arrangement area F1, respectively, but the hierarchy in which these are arranged is not limited to this.

  The resin layer forming unit 4 forms a resin layer 22 by applying a liquid resin on both surfaces of the base film 2. As shown in FIG. 1, the resin layer forming unit 4 includes a tank 41 for storing resin, a pump 42 for sending resin from the tank 41, and a die for discharging the resin sent from the pump 42 onto both surfaces of the base film 2. 43. As the resin for forming the resin layer 22, a transparent resin that has ultraviolet curability and is liquid at room temperature is used. The tank 41, the pump 42, and the die 43 are connected by a pipe, and one set each for the front surface 2a and the back surface 2b of the base film 2 is arranged in the arrangement area F4. However, the tank 41 and the pump 42 may be used one by one for both the front surface 2a and the back surface 2b, and the resin may be supplied to the pair of dies 43 by branching the piping. .

  As shown in FIGS. 1 and 2, the dies 43 are arranged by shifting the position of the resin discharge ports 431 up and down one by one on both sides (the front surface 2 a side and the back surface 2 b side) with the base film 2 therebetween. ing. Specifically, among the pair of dies 43, the die 43 a disposed on the upper side forms the resin layer 22 a on one side of the base film 2 that does not contact the guide roll 83, that is, on the surface 2 a of the base film 2. The resin discharge port 431 is arranged facing the surface 2a. On the other hand, the die 43b arranged on the lower side is arranged with the resin discharge port 431 facing the back surface 2b so as to form the resin layer 22b on the back surface 2b of the base film 2.

  When the resin is discharged from the resin discharge port 431 of the die 43, the base film 2 is pushed in slightly (about several millimeters) through the resin discharge port 431. Accordingly, as shown in FIG. 6, the die 43a on the front surface 2a side of the base film 2 is disposed above the die 43b on the back surface 2b side (the mode shown in FIG. The holding angle (wrap angle) of the base film 2 with respect to the guide roll 83 can be increased (α1> α2) as compared with the case where it is disposed on the upper side than 43a (the mode shown in FIG. 5B). Accordingly, the guide roll 83 can be smoothly rotated along with the base film 2, and the base film 2 can be stably conveyed from top to bottom along the direction of gravity. As a result, for example, a situation in which the base film 2 slides on the roll surface of the guide roll 83 can be prevented, and problems occurring in the base film 2 can be suppressed.

  The reason why the base film 2 is pushed in by the die 43 when discharging the resin is to adjust the surface state of the resin layer 22 to be formed. Thereby, the resin layer 22 having a smooth surface without streaks can be formed.

  The resin layer 22 of the base film 2 has different thicknesses on the front surface 2a side and the back surface 2b side. In the present embodiment, as shown in FIG. 2, the resin layer 22 is thicker on the back surface 2b side than on the front surface 2a side (Da <Db). Accordingly, the die 43b that forms the resin layer 22b on the back surface 2b side has a larger discharge amount per unit time from the resin discharge port 431 than the die 43a that forms the resin layer 22a on the front surface 2a side. The supply of resin from the tank 41 and the pump 42 to the dies 43a and 43b is adjusted.

  As shown in FIG. 1, the pattern transfer apparatus 1 combines one and the other of the pair of dies 43 (the die 43 a and the die 43 b) and the guide roll 83 into a pattern transfer unit 5, a resin layer curing unit 6, and a shaping process. A moving mechanism 9 for moving the film peeling unit 7 in the horizontal direction is provided.

  7 and 8 are diagrams showing how the dies 43a and 43b and the guide roll 83 are moved by the moving mechanism 9. FIG. As shown in FIGS. 7 and 8, the moving mechanism 9 is configured such that the base film 2 or the base film 2 and the shaping film 3 are along the pass line PL in the gravity direction in the through holes 11 a to 13 a of the floor materials 11 to 13. In this manner, the dies 43a and 43b and the guide roll 83 are moved.

  As shown in FIG. 1, the moving mechanism 9 unitizes the die 43a, the die 43b, and the guide roll 83 into one unit, and moves them together. Therefore, the die 43a, the die 43b, and the guide roll 83 are moved by the moving mechanism 9 while maintaining the mutual positional relationship.

  When the resin is discharged from the resin discharge port 431 of the dies 43a and 43b, the base film 2 is pushed in slightly (several millimeters) at the resin discharge port 431. At this time, the base film 2 is positioned from the pass line PL. It may be displaced. FIG. 7A shows a state in which the base film 2 and the shaping film 3 are displaced to the back surface 2b side (left side in FIG. 8A) with respect to the pass line PL, and FIG. An example of a state in which the base film 2 and the shaping film 3 are displaced to the surface 2a side (the right side in FIG. 5A) with respect to the pass line PL is shown.

  In the state shown in FIG. 7A, the die 43a extends in the direction from the back surface 2b side to the front surface 2a side of the base film 2 along the horizontal direction (the direction of the arrow A7 shown in FIG. 7A). 43b and the guide roll 83 are moved by the moving mechanism 9 by a distance L7. Thereby, as shown in FIG.7 (b), in the pattern transfer part 5, the resin layer hardening part 6, and the shaping film peeling part 7, the base film 2 and the shaping film 3 can be made to follow the pass line PL. .

  Further, in the state shown in FIG. 8A, in the direction from the front surface 2a side to the back surface 2b side of the base film 2 along the horizontal direction (the direction of the arrow A8 shown in FIG. 8A), The dies 43a and 43b and the guide roll 83 are moved by the distance L8 by the moving mechanism 9. Thereby, as shown in FIG.8 (b), in the pattern transfer part 5, the resin layer hardening part 6, and the shaping film peeling part 7, the base film 2 and the shaping film 3 can be made to follow the pass line PL. .

  The moving mechanism 9 can move linearly in a predetermined direction and can be positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanism can be applied.

  As described above, according to this embodiment, the dies 43 a and 43 b and the guide roll 83 can be moved in the horizontal direction by the moving mechanism 9. That is, it is possible to easily adjust the deviation of the base film 2 and the shaping film 3 from the pass line PL when the pattern transfer apparatus 1 is initially installed. In addition, even if a deviation from the pass line PL occurs after the pattern transfer apparatus 1 is operated, the deviation can be easily readjusted. Therefore, transfer of the shaping surface 31 to the resin layer 22 in the pattern transfer portion 5 and formation of the pattern 21, curing and fixing of the resin layer 22 in the resin layer curing portion 6 (generation of the transfer film 20), and peeling of the shaping film Peeling of the shaped film 3 from the transfer film 20 at the part 7 can always be performed along the pass line PL.

  For this reason, the state of transfer of the shaping surface 31 to the resin layer 22 and the formation of the pattern 21, the state of curing and fixing of the resin layer 22 on which the pattern 21 is formed, and the peeling state of the shaping film 3 from the transfer film 20 The front surface 2a and the back surface 2b can be matched. Thereby, the pattern 21 can be simultaneously and accurately formed on the front surface 2 a and the back surface 2 b of the base film 2.

  In the moving mechanism 9 of the present embodiment, the die 43a, the die 43b, and the guide roll 83 are moved as a unit, but the die 43a, the die 43b, and the guide roll 83 are moved individually or collectively and individually. It is good also as a moving mechanism which can be moved also. For example, since the die 43a and the die 43b are arranged so that the positions of the resin discharge ports 431 are shifted up and down as shown in FIG. 2, even if these are individually moved, You can avoid situations where they hit each other and get damaged.

  In the present embodiment, as will be described later, the pattern transfer portion 5, the resin layer curing portion 6, and the shaped film peeling portion 7 can also be moved in the horizontal direction by a predetermined moving mechanism.

  As shown in FIG. 1, the pattern transfer unit 5 moves the shaped film feed shaft 51 that feeds the shaped film 3 and the flow of the shaped film 3 fed from the shaped film feed shaft 51 along the direction of gravity. And a roll 52 that faces downward (in short, along the pass line PL). The shaped film feeding shaft 51 and the roll 52 are in contact with the back surface of the shaped film 3 (the film surface on the back side of the shaped surface 31).

  In addition, the shaped film feeding shaft 51 and the roll 52 are arranged one by one for the front surface 2a and the back surface 2b of the base film 2, respectively. On the surface 2a side of the base film 2, a surface shaping film feeding shaft 51a for feeding the surface shaping film 3a and a backup roll 52a for changing the flow of the drawn surface shaping film 3a downward are arranged. Yes. On the other hand, on the back surface 2b side of the base film 2, a back surface shaping film feed shaft 51b that feeds the back shaping film 3b and an infeed roll 52b that changes the flow of the fed back shaping film 3b downward. Has been placed.

  Both the shaping film feeding shaft 51a for the front surface and the shaping film feeding shaft 51b for the back surface are rotating shafts that are rotated in opposite directions by a motor (not shown). In FIG. 1, the shaping film feeding shaft 51a for the front surface rotates counterclockwise, and the shaping film feeding shaft 51b for the back surface rotates clockwise. At that time, the shaping film feeding shaft 51a for the front surface and the shaping film feeding shaft 51b for the back surface always feed the surface shaping film 3a and the shaping film 3b for the back surface at the same speed as the line speed of the base film 2. The rotation is controlled by a control unit (not shown).

  As shown in FIGS. 1 and 9, the backup roll 52a is a rubber idle roll that rotates along with the surface shaping film 3a fed by the surface shaping film feed shaft 51a. The infeed roll 52b is a metal rotary roll that is rotated by a motor 53, and the roll surface is plated with, for example, hard chrome. The backup roll 52a and the infeed roll 52b flow the top shaping film 3a and the back shaping film 3b from top to bottom, and press the base film 2 from top to bottom while pressing the shaping films 3a and 3b. Opposite to send out.

  When the base film 2 is fed out by the backup roll 52a and the infeed roll 52b, the shaping surface 31a of the surface shaping film 3a is transferred in contact with the resin layer 22a of the base film 2, and is transferred to the surface of the resin layer 22a. A pattern 21a is formed. Further, the shaping surface 31b of the shaping film for back surface 3b is transferred in contact with the resin layer 22b of the base film 2, and a pattern 21b is formed on the surface of the resin layer 22b. Since the shaped films 3a and 3b are brought into contact with the resin layers 22a and 22b of the base film 2, the resin layers 22a and 22b are prevented from becoming uncured due to oxygen inhibition in the subsequent resin layer curing portion 6.

  The infeed roll 52 b is fixed to the first floor material 11, while the backup roll 52 a is movable with respect to the first floor material 11. As shown in FIG. 1, the pattern transfer apparatus 1 includes a moving mechanism 54 that moves the backup roll 52a. The moving mechanism 54 moves the backup roll 52a in the horizontal direction so that the resin layer 22a of the base film 2 can be moved forward and backward with respect to the infeed roll 52b.

  Thereby, the pushing amount of the backup roll 52a with respect to the infeed roll 52b can be adjusted suitably. That is, since the contact pressure of the shaping surfaces 31a and 31b to the resin layers 22a and 22b can be adjusted, the transfer state of the shaping surfaces 31a and 31b to the resin layers 22a and 22b can be adjusted.

  The moving mechanism 54 can be linearly moved in a predetermined direction and positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanism can be applied.

  As shown in FIGS. 1 and 2, the resin layer curing portion 6 includes an action portion 61 that cures the resin layer 22 of the base film 2 on which the shaping surface 31 of the shaping film 3 is transferred and the pattern 21 is formed. And a pressing roll 62 that presses the resin layer 22 cured by the action portion 61 toward the base film 2. Since the resin layer 22 is formed of an ultraviolet curable transparent resin, in the present embodiment, the light source 61a that irradiates the resin layer 22 with ultraviolet light and the light shielding plate 61b that blocks the ultraviolet light emitted from the light source 61a, The action part 61 is configured. Further, since the resin layer 22, the base film 2 and the shaping film 3 are all resins having ultraviolet transparency, a light source 61a is disposed on one side of the base film 2 and a light shielding plate 61b is disposed on the other side. ing. Thus, even if the light source 61a is arranged only on one side, the resin layer 22a on the front surface 2a side and the resin layer 22b on the back surface 2b side of the base film 2 are both cured by the light source 61a, and the resin layers 22a and 22b are The base film 2 can be fixed. In this embodiment, the light source 61a is arrange | positioned at the surface 2a side of the base film 2, and the light-shielding plate 61b is arrange | positioned at the back surface 2b side, respectively.

  As the light source 61a, for example, a high-pressure mercury lamp or an LED lamp can be applied. When the light source 61a is an LED lamp, the amount of heat generated is extremely small, the heat damage to the base film 2 is small, and the base film 2 does not need to be cooled. In addition, the lamp itself is small, and power can be saved. Further, the light source 61a is provided with one or a plurality of light sources 61a so that the resin layer 22 can be cured and fixed to the base film 2 until the base film 2 is conveyed to the shaped film peeling unit 7. A plurality may be arranged side by side along the direction of gravity (pass line PL). When the base film 2 is a light-shielding film (for example, an opaque film such as a metal foil), the light source 61a is disposed on both the front surface 2a side and the back surface 2b side of the base film 2.

  The pressing roll 62 is disposed between the light source 61 a of the action part 61 and the thinner resin layer 22 cured by the action part 61, and presses the thinner resin layer 22 toward the base film 2. In this embodiment, the pressing roll 62 is arrange | positioned at the surface 2a side of the base film 2, and it is comprised so that the resin layer 22a may be pressed. In this case, the pressing roll 62 is made of an ultraviolet transmissive material (for example, a transparent resin having ultraviolet transmissive properties), and is disposed in front of the irradiation direction of the light source 61a. Thereby, the ultraviolet rays can be irradiated to the resin layer 22 b through the resin layer 22 a and further the base film 2 without being blocked by the pressing roll 62.

  In the present embodiment, the resin layer 22b on the back surface 2b side of the base film 2 is thicker than the resin layer 22a on the front surface 2a side. Since the thicker resin layer 22b has a larger shrinkage during curing than the thinner resin layer 22a, when the resin layers 22a and 22b are cured by irradiating ultraviolet rays from the light source 61a, as shown in FIG. There is a risk of warping of the base film 2 so that the back surface 2b side (left side in the figure) is concavely curved (state of broken line shown in the figure).

  For this reason, the press roll 62 is arrange | positioned at the surface 2a side of the base film 2, and presses the surface 2a side so that the curvature to the back surface 2b side may be resisted. This prevents the base film 2 from warping on either the front surface 2b or the back surface 2b. That is, by pressing the surface 2a side of the base film 2 with the pressing roll 62, the resin layers 22a and 22b can be irradiated with ultraviolet rays while the base film 2 is warped so that the surface 2a side is concave. it can.

  Thereby, the curvature to the back surface 2b side of the base film 2 at the time of hardening and fixing of the resin layers 22a and 22b can be reduced, and the base film 2 is in a state along the gravity direction (pass line PL) (solid line state shown in FIG. 10). ). Therefore, even when the resin layer 22b on the back surface 2b side of the base film 2 is thicker than the resin layer 22a on the front surface 2a side, the pattern 21 can be simultaneously formed on the front surface 2a and the back surface 2b of the base film 2 with high accuracy. it can. That is, the generation accuracy of the transfer form 20 can be increased.

  The resin layer curing unit 6 includes a moving mechanism (not shown) that moves the pressing roll 62 alone or together with the light source 61a. The moving mechanism moves the pressing roll 62 in the horizontal direction so as to be able to advance and retreat toward the resin layer 22a of the base film 2. Thereby, the pressing amount of the pressing roll 62 with respect to the resin layer 22a can be adjusted suitably. The moving mechanism can be linearly moved in a predetermined direction and positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanisms can be applied.

  When the two pressing rolls 62 are arranged away from the irradiation direction of the light source 61a (the direction from right to left in the figure) as in the modification shown in FIG. 11, the pressing rolls 62 transmit ultraviolet rays. It does not have to be made of a light-sensitive material (for example, a transparent resin having ultraviolet light permeability), and may be made of an ultraviolet light-shielding material (for example, an opaque resin having ultraviolet light-shielding properties). As shown in FIG. 11, if two pressing rolls 62 are arranged in front of the light source 61a and above and below the light source 61a, even if the pressing roll 62 is made of an ultraviolet light shielding material, Without being interrupted by the roll 62, the resin layer 22a and further the base film 2 can be irradiated with ultraviolet rays to the resin layer 22b.

  As shown in FIG. 1 and FIG. 2, the shaped film peeling portion 7 removes the shaped film 3 from the transfer film 20 (the base film 2 on which the resin layer 22 is cured and fixed) generated by the resin layer curing portion 6. A roll 71 to be peeled off and a shaped film take-up shaft 72 for taking up the shaped film 3 peeled off from the base film 2 are provided. The roll 71 and the shaped film winding shaft 72 are in contact with the back surface of the shaped film 3 (the film surface on the back side of the shaped surface 31).

  Moreover, the roll 71 and the shaping film winding axis | shaft 72 are each arrange | positioned 1 set each for the surface shaping | molding film 3a and the back shaping | molding film 3b. On the surface 2a side of the base film 2, there are a peeling roll 71a for peeling the surface shaping film 3a from the resin layer 22a, and a surface shaping film winding shaft 72a for winding the peeled surface shaping film 3a. Has been placed. On the other hand, on the back surface 2b side of the base film 2, an outfeed roll 71b for peeling the back surface shaping film 3b from the resin layer 22b and a back surface shaping film take-up for winding the peeled back surface shaping film 3b. A shaft 72b is arranged.

  Each of the front surface shaping film winding shaft 72a and the back surface shaping film winding shaft 72b is a rotating shaft that rotates in opposite directions by a motor (not shown). In FIG. 1, the front-side shaped film winding shaft 72a rotates counterclockwise, and the rear-side shaped film winding shaft 72b rotates clockwise. At that time, the surface shaping film winding shaft 72a and the back surface shaping film winding shaft 72b wind the surface shaping film 3a and the back surface shaping film 3b at the same speed as the line speed of the transfer film 20. As shown, the rotation is controlled by a control unit (not shown). The shaped films 3a and 3b wound by the shaped film take-up shafts 72a and 72b should be set on the shaped film feed shaft 51 and reused when there is no damage such as scratches or dirt. Is possible.

  As shown in FIGS. 1 and 12, the peeling roll 71a is a rubber idle roll that rotates along with the surface shaping film 3a peeled from the resin layer 22a. The outfeed roll 71b is a metal rotary roll that is rotated by a motor 73, and the roll surface is plated with, for example, hard chrome. The peeling roll 71a and the outfeed roll 71b are formed by peeling the surface shaping film 3a and the back shaping film 3b from the transfer film 20 (the resin layer 22a and the resin layer 22b of the base film 2). It is opposed to send the flow of 3a, 3b from the direction of gravity toward the horizontal direction. Thereby, the shaping film 3a for front surfaces is peeled from the resin layer 22a, and the shaping film 3b for back surfaces is peeled from the resin layer 22b.

  The outfeed roll 71 b is fixed to the third floor material 13, whereas the peeling roll 71 a is movable with respect to the third floor material 13. As shown in FIG. 1, the pattern transfer apparatus 1 includes a moving mechanism 74 that moves the peeling roll 71a. The moving mechanism 74 moves the peeling roll 71a in the horizontal direction so that the surface shaping film 3a can be moved forward and backward with respect to the outfeed roll 71b.

  Thereby, the pushing amount of the peeling roll 71a with respect to the outfeed roll 71b can be adjusted suitably. That is, since the contact pressure with respect to the resin layers 22a and 22b of the shaping films 3a and 3b can be adjusted, the peeling state of the shaping films 3a and 3b from the resin layers 22a and 22b can be adjusted.

  The moving mechanism 74 can be linearly moved in a predetermined direction and positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanism can be applied.

  The transfer film 20 from which the shaped film 3 has been peeled off by the shaped film peeling unit 7 is wound up by the film winding shaft 82 of the film transport unit 8. Although not particularly illustrated, in this case, for example, in order to protect the pattern 21 of the resin layer 22, the transfer film 20 is placed in a state where the front surface 2 a and the back surface 2 b are laminated or sandwiched by spacers. It may be wound up at 82. Further, the shaped film peeling part 7 is omitted, and the shaped film 3 is not peeled off from the transfer film 20 but is taken up by the film take-up shaft 82 of the film transporting part 8 as it is, and separately shaped in the subsequent process. The shape film 3 may be peeled off.

  As shown in FIG. 1, the film transfer apparatus 1 images the alignment mark 23 of the transfer film 20 (the base film 2 to which the resin layer 22 on which the pattern 21 is formed) is taken up by the film take-up shaft 82. An alignment camera 80 is provided. FIG. 1 shows an example of a configuration of an alignment camera 80 that images the base film 2 that is arranged in the arrangement area F1 and on which the pattern 21 is formed, from the back surface 2b side.

  In the present embodiment, the pattern transfer unit 5 forms the alignment mark 23 on the base film 2 together with the pattern 21 as shown in FIG. In this case, an alignment mark 23a is formed on the resin layer 22a on the front surface 2a side of the base film 2, and an alignment mark 23b is formed on the resin layer 22b on the back surface 2b side. Since both the base film 2 and the resin layer 22 are transparent resins, the alignment mark 23b on the back surface 2b and the alignment mark 23a on the front surface 2a are captured even when the image is taken by the alignment camera 80 from the back surface 2b side of the base film 2. Both can be imaged together. Therefore, you may make it image with the alignment camera 80 from the surface 2a side of the base film 2. FIG.

  When the base film 2 and the resin layer 22 are made of an opaque resin, the alignment camera 80 needs to be arranged on both the front surface 2a side and the back surface 2b side of the base film 2. When the alignment camera 80 is disposed on both the front surface 2a side and the back surface 2b side of the base film 2, the base film 2 and the resin layer 22 may be made of either a transparent resin or an opaque resin.

  By monitoring the positions of the alignment marks 23a and 23b imaged by the alignment camera 80, the accuracy of pattern transfer to the base film 2 (for example, transfer of the pattern 21, displacement of the formation position, etc.) can be adjusted.

  Adjustment of pattern transfer accuracy with respect to the base film 2 using such an alignment mark 23 will be described. In the accuracy adjustment, first, the amount of deviation between the alignment mark 23a on the front surface 2a and the alignment mark 23b on the back surface 2b of the base film 2 imaged by the alignment camera 80, specifically, the amount of deviation in the center of gravity position is measured. In the present embodiment, the pattern position of the front surface 2a is adjusted based on the amount of deviation of the center of gravity positions of the alignment marks 23a and 23b, using the pattern position of the back surface 2b of the base film 2 as a reference.

  For example, as shown in FIG. 5B, with reference to the alignment mark 23b on the back surface 2b, the width is shifted by the reference distance L50 in the transport direction of the base film 2 (the direction of arrow A51 shown in FIG. 5A). The same position is set as the normal position of the alignment mark 23a on the surface 2a (in the direction of arrow A52 shown in FIG. 5A). In the state shown in FIG. 5B, the alignment mark 23a is shifted from the normal position by a distance L51 with respect to the transport direction of the base film 2, and is shifted to the left by a distance L52 with respect to the width direction. Yes.

  When the alignment mark 23a on the front surface 2a is delayed with respect to the alignment mark 23b on the back surface 2b (the state shown in FIG. 5B), the feeding direction displacement (film path) ) Is shortened to advance the formation timing of the alignment mark 23a. On the other hand, when the alignment mark 23a precedes the alignment mark 23b, the film path of the surface shaping film 3a is lengthened to delay the formation timing of the alignment mark 23a.

  In order to adjust the film path of the surface shaping film 3a, the pattern transfer unit 5 is disposed on the compensator roll 55 and on the upstream side and the downstream side of the compensator roll 55 as shown in FIG. The shaping film relay roll 56 is provided. The compensator roll 55 is disposed on the downstream side of the surface shaping film feeding shaft 51 a and on the upstream side of the backup roll 52 a, and can be moved up and down along the direction of gravity by the moving mechanism 57. By moving the compensator roll 55 up and down, the length of the film path of the surface shaping film 3a can be adjusted according to the moving distance. As the moving mechanism 57, a mechanism using a motor and a ball screw is applied as an example. However, a mechanism using an air cylinder and a stopper, a mechanism using a rail and a slider, and the like can be linearly moved in a predetermined direction. A mechanism that can be positioned at a predetermined position can be applied.

  When the alignment mark 23a on the front surface 2a is shifted leftward in the transport direction with respect to the alignment mark 23b on the back surface 2b (the state shown in FIG. 5B), the positional deviation in the width direction is performed on the front side. The feeding position of the film 3a is moved rightward in the transport direction. Conversely, when the alignment mark 23a is shifted to the right in the transport direction with respect to the alignment mark 23b, the feeding position of the surface side shaped film 3a is moved to the left in the transport direction.

  To adjust the feeding position of the surface shaping film 3a, as shown in FIG. 13, the surface shaping film 51a, in other words, the surface shaping film wound around the surface shaping film feeding shaft 51a is used. The roll of the shape film 3a can be moved by the moving mechanism 58 to the left and right in the feeding direction of the surface shaping film 3a. FIG. 13 is a side view showing the vicinity of the surface shaping film feeding shaft 51a from the right side of FIG.

  Thus, the surface shaping film feed shaft 51a (the roll of the surface shaping film 3a) is moved to the left and right to feed the surface shaping film 3a in the horizontal direction (direction of arrow A13 shown in FIG. 13). The position can be adjusted. As the moving mechanism 58, a mechanism using a motor and a ball screw is applied as an example, but it can move linearly in a predetermined direction, such as a mechanism using an air cylinder and a stopper, a mechanism using a rail and a slider, and the like. A mechanism that can be positioned at a predetermined position can be applied.

  The movement of the compensator roll 55 by the moving mechanism 57 and the movement of the surface shaping film feed shaft 51a (the roll of the surface shaping film 3a) by the movement mechanism 58 are the alignment marks 23a and 23b imaged by the alignment camera 80. This is automatically performed by a control unit (not shown) based on the position information.

  It is possible to adjust the feeding position of the surface shaping film 3a by attaching a steering roll, but in this case, a space for attaching the steering roll unit and the guide roll is separately required. Therefore, it is desirable to adjust the feeding position of the surface shaping film 3a with a moving mechanism 58 such as a motor and a ball screw.

  In the pattern transfer portion 5, since the resin layer 22 of the base film 2 has not yet been cured, the backup roll 52a is applied to the surface by a moving mechanism (for example, a motor and a ball screw similar to the moving mechanism 57). You may adjust the delivery position of the base film 2 by the surface shaping film 3a by moving right and left toward the flow direction of the shape film 3a.

  Thus, according to the film pattern transfer apparatus 1 and the film pattern transfer method implemented by the pattern transfer apparatus 1 of the present embodiment, the base film 2 and the shaped film 3 are moved in the direction of gravity (pass line PL). It can be stably conveyed from top to bottom along. Moreover, the pattern 21 can be simultaneously formed on both surfaces of the base film 2 in a state where the base film 2 and the shaping film 3 are surely aligned in the direction of gravity.

  In addition, since the pattern transfer apparatus 1 of this embodiment is conveying the base film 2 and the shaping film 3 from the top to the bottom along the gravity direction (pass line PL), in addition to the effect mentioned above, pattern formation It also has the following effects that equalize the environmental conditions on the front surface 2a side and the back surface 2b side.

  In the resin layer formation part 4, in order to form the resin layer 22 in the surface 2a and the back surface 2b, conveying the base film 2 and the shaping film 3 along a gravity direction (pass line PL), the influence of gravity in that case Can be matched on both sides. Therefore, when the resin layer 22 is formed on both the front surface 2a and the back surface 2b, there is no need to make a difference in resin leveling. For this reason, it can prevent that the difference of the thickness which is not intended arises in the resin layer 22 formed in the surface 2a of the base film 2, and the back surface 2b.

  In the pattern transfer section 5, the shaping film 3 is caused to flow along the direction of gravity (pass line PL), and the base film 2 is sent out from above while pressing the shaping film 3. For this reason, since the air between the resin layer 22 and the shaping surface 31 can be pushed out by the resin forming the resin layer 22, the air can be easily extracted out of the shaping surface 31. Therefore, since it is not necessary to suppress the conveyance speed (line speed) of the base film 2 in order to extract air from between the resin layer 22 and the shaping surface 31, it is possible to increase the line speed and improve the processing efficiency. It becomes.

  Moreover, in the pattern transfer part 5, the backup roll 52a and the infeed roll 52b may be deformed so as to bend downward due to their own weight. However, since these rolls 52a and 52b are arranged side by side in the horizontal direction and send out the base film 2 from the top to the bottom, the base film 2 is not deformed by the deformation of the rolls 52a and 52b. Therefore, it is possible to prevent an unintended difference from occurring in the patterns 21 a and 21 b formed on the front surface 2 a and the back surface 2 b of the base film 2.

  In the resin layer curing unit 6, the resin layer 22 on the front surface 2a and the back surface 2b is cured while the base film 2 and the shaping film 3 are conveyed along the direction of gravity (pass line PL). The difference in ambient temperature can be almost eliminated. Moreover, in the resin layer hardening part 6, when hardening the resin layer 22 of the surface 2a of the base film 2, and the back surface 2b, even if the tension | tensile_strength of the base film 2 is small, it deform | transforms so that the base film 2 may sag below with dead weight. There is no. Accordingly, since the curability of the resin layer 22 can be substantially matched between the front surface 2a and the back surface 2b of the base film 2, it is possible to prevent an unintended difference in the form of the pattern 21 to be formed.

  As mentioned above, although embodiment of this invention was described, embodiment mentioned above is shown as an example and is not intending limiting the range of invention. The above-described novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  For example, the pattern transfer apparatus 1 of the present embodiment forms the pattern 21 on both surfaces (the front surface 2a and the back surface 2b) of the base film 2, but the pattern 21 can be formed only on one surface.

  The pattern transfer apparatus 1 according to the present embodiment includes a base including a mode before and after the generation of the transfer film 20 in the resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, and the shaped film peeling unit 7. Although the film 2 is conveyed from the top to the bottom along the gravity direction (pass line PL), it is also possible to convey the film 2 from the bottom to the contrary. In this case, the resin layer forming part 4, the pattern transfer part 5, the resin layer curing part 6, and the shaped film peeling part 7 are arranged in this order from bottom to top along the direction of gravity. However, when the base film 2 is transported from the top to the bottom as in the present embodiment, there are the following advantages compared to the case of transporting from the bottom to the top.

  As shown in FIG. 1, in this embodiment, a resin layer curing unit 6 is disposed below the pattern transfer unit 5. For this reason, the heat (for example, heat generated by the light source 61a) generated in the resin layer curing unit 6 is easily transmitted to the pattern transfer unit 5 by the rising airflow. If the atmospheric temperature of the pattern transfer part 5 rises, it can be expected that the fluidity of the resin forming the resin layer 22 of the base film 2 increases, and as a result, the transfer accuracy of the shaping surface 31 is improved. When the base film 2 is conveyed from the bottom to the top, since the resin layer curing portion 6 is disposed above the pattern transfer portion 5, such an improvement in the transfer accuracy of the shaping surface 31 cannot be expected.

  In the present embodiment, since the resin layer curing unit 6 is disposed below the pattern transfer unit 5, heat generated in the resin layer curing unit 6 escapes upward, so that the resin layer curing unit 6 is disposed below the resin layer curing unit 6. The shaped film peeling portion 7 is less affected by the heat applied. The peelability of the shaped film 3 at the shaped film peeling portion 7 is improved as the ambient temperature is lower. When the base film 2 is transported from the bottom to the top, since the shaped film peeling part 7 is disposed above the resin layer curing part 6, such an improvement in peelability of the shaped film 3 cannot be expected.

  Considering these, it is preferable to transport the base film 2 from the top to the bottom along the direction of gravity (pass line PL) as in this embodiment.

  DESCRIPTION OF SYMBOLS 1 ... Pattern transfer apparatus, 2 ... Base film, 2a ... Front surface, 2b ... Back surface, 3 ... Shaped film, 4 ... Resin layer formation part, 5 ... Pattern transfer part, 6 ... Resin layer hardening part, 7 ... Shaped film Peeling unit, 8 ... film transport unit, 9 ... moving mechanism, 10 ... floor surface, 11 ... first flooring, 11a ... first through hole, 12 ... second flooring, 12a ... second through hole , 13 ... third floor, 13a ... third through hole, 20 ... transfer film, 21 ... pattern, 22 ... resin layer, 31 ... shaping surface, 41 ... tank, 42 ... pump, 43 ... die, 51 ... Shaping film feeding shaft, 52a ... Backup roll, 52b ... Infeed roll, 61 ... Action part, 61a ... Light source, 61b ... Light shielding plate, 62 ... Pressing roll, 71a ... Peeling roll, 71b ... Outfeed roll, 72 ... Shaped film take-up shaft, 81 ... fill Feeding shaft, 82 ... film winding shaft, 83 ... guide roll, 431 ... resin discharge port, F1, F2, F3, F4 ... arrangement area, PL ... pass line.

Claims (8)

A resin layer forming part for forming a resin layer by applying a liquid resin on both sides of the base film;
A pattern transfer part that forms a pattern on the surface of the resin layer by pressing the shaped film against the resin layer of the base film and transferring the shaped surface of the shaped film to the resin layer;
A resin layer curing portion that cures the resin layer on which the pattern is formed and generates a transfer film by fixing the resin layer to the base film;
A shaped film peeling portion for peeling the shaped film from the transfer film;
A film transport unit that unwinds the base film, passes the resin layer forming unit, the pattern transfer unit, the resin layer curing unit, and the shaped film peeling unit, and winds up the generated transfer film. ,
The film transport unit has a guide roll that directs the transport direction of the base film from top to bottom along the direction of gravity in front of the resin layer forming unit,
The resin layer forming part has a pair of dies arranged one by one on both sides across the base film, with the positions of the respective resin discharge ports being shifted up and down,
Of the pair of dies, a die disposed on the upper side is disposed on a surface side of the base film that does not contact the guide roll. One or the other of the pair of dies and the guide roll are individually or collectively provided with a moving mechanism that moves in a horizontal direction with respect to the pattern transfer unit, the resin layer curing unit, and the shaped film peeling unit. Item 2. The film pattern transfer apparatus according to Item 1. The pattern transfer portion and the resin layer cured portion are separated by a first floor material in which a first through-hole for passing the base film and the shaped film is formed,
The movement mechanism moves one and the other of the pair of dies and the guide roll so that the base film and the shaping film are along the direction of gravity in the first through hole. Film pattern transfer device. The resin layer forming part and the pattern transfer part are separated by a second floor material in which a second through-hole for passing the base film is formed,
4. The film pattern transfer according to claim 3, wherein the moving mechanism moves one and the other of the pair of dies and the guide roll so that the base film follows the direction of gravity in the second through hole. 5. apparatus. The film transport unit is
A feeding shaft for feeding out the base film before the resin layer is formed;
A winding shaft for winding the transfer film;
A plurality of relay rolls that change the conveying direction of the base film or the transfer film together with the guide rolls between the feeding shaft and the winding shaft;
5. The film pattern transfer device according to claim 1, wherein one of the plurality of relay rolls is disposed below the guide roll along a direction of gravity. 6. The film pattern transfer device according to claim 5, wherein the relay roll disposed below the guide roll directs the transfer film transport direction from the gravity direction to another direction at the tip of the shaped film peeling portion. Forming a resin layer by applying a liquid resin on both sides of the base film;
Forming a pattern on the surface of the resin layer by pressing the shaped film against the resin layer of the base film and transferring the shaped surface of the shaped film to the resin layer;
Curing the resin layer on which the pattern is formed, and fixing the base film to produce a transfer film;
Peeling the shaped film from the transfer film;
Unwinding the base film, forming the resin layer on the unrolled base film, transferring the shaping surface to the resin layer and forming the pattern, curing the resin layer, and fixing to the base film And, after peeling the shaped film from the transfer film, winding the generated transfer film,
Before forming the resin layer on the base film, the base film is curved and conveyed from top to bottom along the direction of gravity,
A method of transferring the pattern to the base film, wherein the resin layer is formed on the outer peripheral surface above the inner peripheral surface of the curve. Adjust the horizontal position to curve the base film and the horizontal position to form the resin layer on both sides of the base film,
Formation of the resin layer on the base film, transfer of the shaping surface to the resin layer and formation of the pattern, curing of the resin layer and fixation to the base film, and the transfer film from the transfer film The method of transferring a pattern to the film according to claim 7, wherein peeling of the shaped film is performed along the direction of gravity.

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