JP2017209835A - Molding apparatus and molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding apparatus capable of efficiently manufacturing a fine surface pattern.SOLUTION: A molding apparatus 1 includes a flat plate-like molding plate 20 having a molding pattern formed on a printing plate, a molding plate conveyance section 30 conveying the molding plate 20 in a fixed direction, a columnar roll body 40 supported in a rotatable manner around an axis at a position facing the molding plate 20, and an ultraviolet irradiation section 60 capable of irradiating an object with ultraviolet rays, where the molding plate 20 where a substrate 2 having light transparency is arranged on the molding pattern so as to sandwich uncured ultraviolet cured resin 3 is conveyed to the side of the roll body 40 by the molding plate conveyance section 30, the substrate 2 is pressed against to the molding plate 20 by the roll body 40, and then the ultraviolet cured resin 3 is irradiated with ultraviolet rays by the ultraviolet irradiation section 60 from the side of the substrate 2 during conveyance.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a molding apparatus and a molding method.

  A technique for producing a fine surface pattern corresponding to the molding pattern on the surface of a molded product using a roll plate having a fine molding pattern is known (for example, see Patent Document 1).

JP 2014-178701 A

  The subject of this invention is providing the shaping | molding apparatus and the shaping | molding method which can produce a fine surface pattern and an optical member efficiently.

The present invention solves the problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected and demonstrated, it is not limited to this. In addition, the configuration described with reference numerals may be improved as appropriate, or at least a part thereof may be replaced with another configuration.
In a first aspect of the present invention, a plate-shaped molding plate (20) having a molding pattern formed on the plate surface, a molding plate transport section (30) for transporting the molding plate in a fixed direction, and a position facing the molding plate. A cylindrical roll body (40) supported so as to be rotatable about an axis, and an ultraviolet irradiation section (60) capable of irradiating ultraviolet rays, and sandwiching an uncured ultraviolet curable resin on the molding pattern The forming plate on which a substrate having light permeability is arranged is conveyed to the roll body side by the forming plate conveying unit, the substrate is pressed against the forming plate by the roll body, and the substrate being conveyed after being pressed. It is a shaping | molding apparatus (1) which irradiates an ultraviolet-ray from the said ultraviolet irradiation part with respect to the said ultraviolet curable resin from the side.
In the second invention, a substrate transport portion (70) for transporting a substrate coated with an uncured ultraviolet curable resin in a certain direction, a molding pattern is formed on the peripheral side surface, and the substrate is supported so as to be rotatable about an axis. A cylindrical roll plate (80) for pressing the ultraviolet curable resin on the substrate, and an upstream side of the roll plate in the conveyance direction of the substrate, and the ultraviolet curable resin being conveyed before pressing A first ultraviolet irradiation unit (61) that irradiates ultraviolet rays for preliminary curing, and an ultraviolet ray for main curing that is disposed downstream of the roll plate in the conveyance direction of the substrate and is being conveyed after being pressed. And a second ultraviolet irradiation unit (62) that irradiates the molding apparatus (1A).
According to a third aspect of the present invention, there is provided a substrate transport portion (70) for transporting a light-transmitting substrate coated with an uncured ultraviolet curable resin in a certain direction, a molding pattern is formed on a peripheral side surface, and And a cylindrical roll plate (80) that presses the ultraviolet curable resin on the substrate, and is disposed at a position facing the roll plate across the substrate, and applied to the substrate. An ultraviolet irradiation unit (63) for irradiating the ultraviolet curable resin with ultraviolet rays, the substrate coated with the ultraviolet curable resin is conveyed to the roll plate side by the substrate conveyance unit, and the ultraviolet ray is radiated by the roll plate. A molding apparatus that presses a curable resin to form the molding pattern on the ultraviolet curable resin, and irradiates the ultraviolet curable resin being pressed and conveyed with ultraviolet rays by the ultraviolet irradiation unit ( Is a B).
4th invention is a shaping | molding apparatus (1) of 1st invention, Comprising: The roll body support part (50) which supports the said roll body (40) so that raising / lowering with respect to the said shaping | molding plate (20) is possible. It is the shaping | molding apparatus characterized by providing.
A fifth aspect of the invention is the molding apparatus (1A, 1B) of the second or third aspect of the invention, wherein the roll plate support part (90) supports the roll plate (80) so as to be movable up and down with respect to the substrate. It is a shaping | molding apparatus characterized by including.
6th invention is a shaping | molding apparatus (1) of 1st invention, Comprising: The said forming plate conveyance part (30) is a guide part (31) which controls the inclination of the said forming plate in the conveyance direction of the said forming plate. ).
7th invention is a shaping | molding apparatus (1A, 1B) of 2nd or 3rd invention, Comprising: The said board | substrate conveyance part (70) regulates the inclination of the said board | substrate in the conveyance direction of the said board | substrate. (31) It is a shaping | molding apparatus characterized by the above-mentioned.
The eighth invention is the molding apparatus (1B) of the third invention, characterized by comprising a slit portion (13) for regulating the irradiation width of ultraviolet rays in the transport direction of the substrate.
The ninth invention is the molding apparatus (1A, 1B) of the second or third invention, comprising a nitrogen gas supply unit (100) for blowing nitrogen gas to the ultraviolet curable resin irradiated with ultraviolet rays. Is a molding apparatus characterized by
In a tenth aspect of the invention, a molding plate in which a substrate having light permeability is disposed on a molding pattern with an uncured ultraviolet curable resin interposed therebetween is conveyed in a certain direction, and the substrate is transferred by a cylindrically formed roll body. In this molding method, the ultraviolet-curing resin is irradiated with ultraviolet rays from the side of the substrate being conveyed after being pressed against the molding plate.
In an eleventh aspect of the invention, a substrate coated with an uncured ultraviolet curable resin is conveyed in a certain direction, the ultraviolet curable resin is irradiated with ultraviolet rays for preliminary curing, and a molding pattern is formed on the peripheral side surface after irradiation. In this molding method, the ultraviolet curable resin on the substrate is pressed by a rolled plate, and the ultraviolet curable resin being conveyed is irradiated with ultraviolet rays for main curing after being pressed.
In a twelfth aspect of the invention, a substrate coated with an uncured ultraviolet curable resin is conveyed in a certain direction, and the ultraviolet curable resin on the substrate is pressed and pressed by a roll plate having a molding pattern formed on a peripheral side surface. And a molding method of irradiating the ultraviolet curable resin being conveyed with ultraviolet rays.

  ADVANTAGE OF THE INVENTION According to this invention, the shaping | molding apparatus and shaping | molding method which can produce a fine surface pattern and an optical member efficiently can be provided.

It is a figure explaining the shaping | molding apparatus 1 of 1st Embodiment. It is a figure explaining the forming plate conveyance part. It is a figure explaining shaping | molding of the optical member by the shaping | molding apparatus. It is a figure explaining 1A of shaping | molding apparatuses of 2nd Embodiment. It is a figure explaining shaping | molding of the optical member by 1 A of shaping | molding apparatuses. It is a figure explaining the shaping | molding apparatus 1B of 3rd Embodiment. It is a figure explaining shaping | molding of the optical member by the shaping | molding apparatus 1B. It is a figure explaining the base part 10 and the board | substrate conveyance part 70. FIG.

Hereinafter, embodiments of the present invention will be described. In the drawings attached to the present specification, the shape, scale, vertical / horizontal dimension ratio, etc. of each part are changed or exaggerated from the actual ones in consideration of ease of understanding and the like.
In this specification and the like, terms that specify shapes, geometric conditions, and the degree thereof, such as “parallel”, “orthogonal”, “direction”, “orientation”, etc., are added to the strict meaning of the terms. Thus, it includes a range that has the same optical function and can be regarded as substantially parallel, substantially orthogonal, and the like, and a range that can be regarded as its direction and orientation.

  In the drawings described below, an XYZ orthogonal coordinate system is described. In this coordinate system, in a state where the substrate 2 is transported, the vertical direction is the Z direction, the transport direction of the substrate 2 in the horizontal direction is the X direction, and the left-right direction perpendicular to the X direction is the Y direction. . In the vertical direction (Z direction), the upper side is the Z1 side, and the lower side is the Z2 side. Of the transport direction (X direction), the upstream side is the X1 side, and the downstream side is the X2 side. Of the left and right direction (Y direction), the right side when viewed from the upstream side X1 to the downstream side X2 is defined as the Y1 side, and the left side is defined as the Y2 side.

(First embodiment)
FIG. 1 is a diagram illustrating a molding apparatus 1 according to the first embodiment. FIG. 2 is a diagram illustrating the forming plate conveyance unit 30. FIG. 3 is a diagram for explaining the molding of the optical member by the molding apparatus 1. In FIG. 3, illustration of a later-described forming plate conveyance unit 30 and roll body support unit 50 is omitted.

As shown in FIG. 1, the molding apparatus 1 according to the first embodiment includes a base unit 10, a molding plate 20, a molding plate transport unit 30, a roll body 40, a roll body support unit 50, and an ultraviolet irradiation unit 60.
The base portion 10 is a portion that is a basis of the molding apparatus 1 and includes a top plate portion 11 and leg portions 12. The top plate portion 11 is a table-like plate material, and the molding plate conveyance portion 30, the roll body support portion 50 (described later) and the like are placed on the upper (Z1 side) surface (hereinafter also referred to as the “conveyance surface 11a”). Placed. The leg portions 12 are support members provided at the four corners on the lower side (Z2 side) of the top plate portion 11. Both the top plate portion 11 and the leg portion 12 are made of a metal material such as iron or aluminum.

  The molding plate 20 is a flat plate mold (flat plate mold) in which a fine molding pattern (not shown) is formed on the plate surface. The molding plate 20 is placed on the transport surface 11 a of the top plate part 11. The optical member manufactured by the molding plate 20 may be, for example, a light guide plate, a prism sheet, a lens sheet, a diffraction structure, or a moth-eye structure, or a molding die for manufacturing such an optical member. There may be.

The molding plate conveyance unit 30 is a device that conveys the molding plate 20 in the conveyance direction (X direction). As shown in FIG. 2, the forming plate conveyance unit 30 includes a guide unit 31 and a feeding unit 32.
The guide portion 31 is a portion that regulates the inclination of the molding plate 20 in the left-right direction (Y direction) in the conveyance direction (X direction) of the molding plate 20. The guide part 31 includes guide rails 31a and 31b. The guide rail 31a is disposed along the side edge on the right side (Y1 side) of the transport surface 11a. The guide rail 31b is arranged along the side edge on the left side (Y2 side) of the transport surface 11a. The distance between the guide rails 31a and 31b in the left-right direction (Y direction) is set to be slightly wider than the width in the left-right direction (Y direction) of the molding plate 20 (described later).

  The feeding unit 32 is a member that moves the molding plate 20 in the transport direction (X direction). The feed unit 32 includes push plates 32a and 32b. The push plate 32a is configured to be movable along the guide rail 31a. The push plate 32b is configured to be movable along the guide rail 31a. The push plates 32a and 32b can be moved from the upstream side (X1 side) to the downstream side (X2 side) by a drive mechanism (not shown) disposed on the lower side (Z2 side) of the top plate portion 11. it can. Here, as the drive mechanism, for example, a ball screw mechanism, a rack and pinion mechanism, a wire winding mechanism, or the like can be used.

  The roll body 40 is a member for pressing the substrate 2 (described later) against the molding plate 20 and is formed in a columnar shape. As shown in FIG. 1, the roll body 40 is arrange | positioned at the side facing the molding plate 20, and is rotatably supported by the roll body support part 50 (after-mentioned) around an axis. The roll body 40 has an axial direction parallel to the plate surface of the molding plate 20 in a side view (see FIG. 3), and an axial direction orthogonal to the conveying direction (X direction) of the molding plate 20 in a plan view (not shown). Are arranged as follows. Here, the axis refers to a line connecting the centers of both end faces in the longitudinal direction of the roll body 40. The axial direction refers to the direction in which the line extends.

  The roll body support portion 50 is a mechanism that supports the roll body 40 so as to be rotatable about an axis and to be movable up and down in the vertical direction (Z direction) with respect to the forming plate 20. In the roll body support portion 50, the roll body 40 is connected to a drive mechanism for rotation (not shown). As the drive mechanism for rotation, for example, a motor, a reduction gear or the like can be used. By using such a drive mechanism, the roll body 40 can be rotated in synchronization with the conveyance speed of the forming plate 20. Moreover, in the roll body support part 50, the roll body 40 is connected with the drive mechanism (not shown) for raising / lowering. For example, an air cylinder mechanism, a ball screw mechanism, a gear / chain mechanism, or the like can be used as the drive mechanism for lifting. By using such a drive mechanism, it is possible to adjust the force for pressing the substrate 2 when the roll body 40 is lowered.

  The ultraviolet irradiation unit 60 is a device that irradiates the uncured ultraviolet curable resin 3 filled between the molding plate 20 and the substrate 2 with ultraviolet rays. The ultraviolet irradiation unit 60 irradiates ultraviolet rays along the left-right direction (Y direction) orthogonal to the conveying direction (X direction) of the molding plate 20. For example, the ultraviolet irradiation unit 60 includes a plurality of UV-LED lamps arranged linearly along the Y direction.

  As will be described later, at the time of molding, the substrate 2 is pressed against the molding plate 20 by the roll body 40 on the upstream side of the ultraviolet irradiation unit 60. The ultraviolet irradiation unit 60 irradiates the uncured ultraviolet curable resin 3 with ultraviolet rays from the substrate 2 side. Since the substrate 2 has optical transparency, the ultraviolet curable resin 3 filled between the molding plate 20 and the substrate 2 can be cured by a photopolymerization reaction by irradiating ultraviolet rays from the substrate 2 side. .

Next, the manufacturing method of the optical member using said shaping | molding apparatus 1 is demonstrated.
First, as shown in FIG. 2, the forming plate 20 is placed on the transport surface 11 a of the top plate portion 11 on the upstream side (X1 side) of the roll body 40. And the corner | angular part of the left-right direction (Y direction) of the rear end side in the conveyance direction of the molding plate 20 is made to contact | abut to the press plates 32a and 32b of the molding plate conveyance part 30. FIG.

  Next, the uncured ultraviolet curable resin 3 is applied on the plate surface of the molding plate 20. As the ultraviolet curable resin 3, for example, materials such as urethane acrylate, polyester acrylate, epoxy acrylate, polyether acrylate, polythiol, and butadiene acrylate can be used. The ultraviolet curable resin 3 can be applied onto the plate surface of the molding plate 20 by using, for example, a nozzle.

Next, the substrate 2 is laminated on the uncured ultraviolet curable resin 3 applied on the molding plate 20. The board | substrate 2 is a plate-shaped member which has a light transmittance, for example, a glass plate is used.
Next, as shown in FIG. 3, the molding plate 20 on which the substrate 2 and the ultraviolet curable resin 3 are laminated is transported from the upstream side (X1 side) to the downstream side (X2 side) in the transport direction (X direction). To do. Further, the roll body 40 is rotated in synchronization with the conveying speed of the forming plate 20 and the roll body 40 is lowered downward (Z2 side).

  When the laminated molding plate 20 is conveyed downstream (X2 side) and reaches the position of the roll body 40, the substrate 2, the ultraviolet curable resin 3 and the molding plate 20 are separated from the top plate portion 11 (conveying surface 11a) and the roll. The substrate 2 is sandwiched between the body 40 and pressed against the molding plate 20. Thereby, the ultraviolet curable resin 3 filled between the substrate 2 and the molding plate 20 is pressed against the molding pattern of the molding plate 20, and a surface pattern corresponding to the shape of the molding pattern is formed on the ultraviolet curable resin 3. .

Subsequently, when the substrate 2, the ultraviolet curable resin 3 and the molding plate 20 pressed by the roll body 40 reach the position of the ultraviolet irradiation unit 60, ultraviolet rays are irradiated from the ultraviolet irradiation unit 60 toward the substrate 2, The ultraviolet curable resin 3 filled between the substrate 2 and the molding plate 20 is cured.
In the cured ultraviolet curable resin 3, a fine surface pattern corresponding to the molding pattern of the molding plate 20 is formed on the surface pressed against the molding pattern of the molding plate 20. In the cured ultraviolet curable resin 3, the surface opposite to the side pressed against the molding pattern of the molding plate 20 is bonded to the substrate 2.

  Furthermore, the laminated forming plate 20 is conveyed to the downstream side (X2 side) and moved to a position where the rear end side of the laminated forming plate 20 is released from the pressing of the roll body 40. Thereby, the laminated forming plate 20 can be taken out from the forming apparatus 1. Thereafter, the cured ultraviolet curable resin 3 is peeled off together with the substrate 2 from the molding plate 20, whereby an optical member having a fine surface pattern formed on the substrate 2 can be obtained.

According to the molding apparatus 1 of the first embodiment described above, for example, the following effects can be obtained.
The molding apparatus 1 according to the first embodiment conveys a molding plate 20 on which a substrate 2 is disposed with an uncured ultraviolet curable resin 3 interposed therebetween, and presses the substrate 2 against the molding plate 20 by a roll body 40. At the same time, the ultraviolet curable resin 3 is irradiated with ultraviolet rays from the side of the substrate 2 being conveyed after pressing. According to this, since pressing of the substrate 2 by the roll body 40 and irradiation of the ultraviolet curable resin 3 with ultraviolet rays are continuously performed, a fine surface pattern of the optical member can be efficiently produced.
In the molding apparatus 1 according to the first embodiment, when the substrate 2 to be used is flexible, the substrate 2 can be more closely attached to the ultraviolet curable resin 3 on the molding plate 20. It can be formed more stably.

Since the shaping | molding apparatus 1 of 1st Embodiment is provided with the flat plate-shaped shaping | molding plate 20 by which the shaping | molding pattern was formed in the plate surface, it can improve the planarity of the manufactured optical member.
Since the molding apparatus 1 of the first embodiment irradiates the ultraviolet curable resin 3 sandwiched between the substrate 2 and the molding plate 20 with ultraviolet rays, it is formed on the ultraviolet curable resin 3 at the time of ultraviolet irradiation. The return of the shape of the surface pattern can be suppressed. Further, since the molding apparatus 1 of the first embodiment irradiates ultraviolet rays to the ultraviolet curable resin 3 sandwiched between the substrate 2 and the molding plate 20, the ultraviolet rays are irradiated in the vicinity of the downstream side of the roll body 40. There is no need to do. Therefore, in the shaping | molding apparatus 1 of 1st Embodiment, the position which irradiates an ultraviolet-ray can be set arbitrarily.

The molding apparatus 1 according to the first embodiment includes a guide portion 31 (molding plate conveyance unit 30) that regulates the inclination of the molding plate 20 in the left-right direction (Y direction) in the conveyance direction of the molding plate 20. Therefore, the molding apparatus 1 can suppress the damage by the contact between the substrate 2 and another member because the molding plate 20 is inclined during conveyance. Moreover, since the shaping | molding apparatus 1 can stabilize the attitude | position of the shaping | molding plate 20 in conveyance by the guide part 31, it can form the fine surface pattern corresponding to the shaping | molding pattern of the shaping | molding plate 20 more correctly.
Since the forming apparatus 1 according to the first embodiment includes the roll body support portion 50 that supports the roll body 40 so as to be rotatable about the axis and to be movable up and down in the vertical direction (Z direction) with respect to the molding plate 20, the roll body 40. Thus, the substrate 2 can be pressed more stably.

(Second Embodiment)
FIG. 4 is a diagram illustrating a molding apparatus 1A according to the second embodiment. FIG. 5 is a diagram for explaining the molding of the optical member by the molding apparatus 1A. In FIG. 5, illustration of a substrate conveyance unit 70 and a roll plate support unit 90 described later is omitted. In the description and drawings of the second embodiment, the same members as those in the first embodiment are denoted by the same reference numerals as those in the first embodiment, and redundant descriptions are omitted.

  As shown in FIG. 4, the molding apparatus 1A according to the second embodiment includes a base unit 10, a substrate transport unit 70, a roll plate 80, a roll plate support unit 90, a first ultraviolet irradiation unit 61, a second ultraviolet irradiation unit 62, and A nitrogen gas supply unit 100 is provided.

  The substrate transport unit 70 is a device that transports the substrate 2 in the transport direction (X direction). The basic configuration of the substrate transport unit 70 is the same as that of the molding plate transport unit 30 of the first embodiment. As illustrated in FIG. 2, the molding plate conveyance unit 30 of the first embodiment conveys the molding plate 20, whereas the substrate conveyance unit 70 of the second embodiment differs in that the substrate 2 is conveyed. In the present embodiment, the members constituting the substrate transport unit 70 will be described as, for example, the push plates 32a and 32b, similarly to the molding plate transport unit 30 of the first embodiment.

  The roll plate 80 is a cylindrical mold (roll mold) in which a molding pattern (not shown) is formed on the peripheral side surface. The roll plate 80 is disposed on the side facing the substrate 2 and is supported by a roll plate support portion 90 (described later) so as to be rotatable about an axis. The roll plate 80 is disposed so that the axial direction is parallel to the substrate 2 in a side view (see FIG. 5) and the axial direction is orthogonal to the transport direction (X direction) of the substrate 2 in a plan view (not shown). ing.

  The roll plate support unit 90 is a mechanism that supports the roll plate 80 so as to be rotatable about an axis and to be movable up and down in the vertical direction (Z direction) with respect to the substrate 2. In the roll plate support 90, the roll plate 80 is connected to a drive mechanism for rotation (not shown). As the drive mechanism for rotation, for example, a motor, a reduction gear or the like can be used. By using such a drive mechanism, the roll plate 80 can be rotated in synchronization with the conveyance speed of the substrate 2. In the roll plate support 90, the roll plate 80 is connected to a drive mechanism (not shown) for raising and lowering. For example, an air cylinder mechanism, a ball screw mechanism, a gear / chain mechanism, or the like can be used as an elevating drive mechanism. By using such a drive mechanism, it is possible to adjust the force for pressing the ultraviolet curable resin 3 when the roll plate 80 is lowered.

  The first ultraviolet irradiation unit 61 is an apparatus that irradiates the uncured ultraviolet curable resin 3 before being pressed by the roll plate 80 with ultraviolet rays for preliminary curing. The first ultraviolet irradiation unit 61 is disposed on the upstream side (X1 side) of the roll plate 80. The first ultraviolet irradiation unit 61 irradiates ultraviolet rays along the left-right direction (Y direction) orthogonal to the transport direction (X direction) of the substrate 2. The 1st ultraviolet irradiation part 61 is comprised by the some UV-LED lamp arrange | positioned linearly along the Y direction, for example. The first ultraviolet irradiation unit 61 cures the uncured ultraviolet curable resin 3 to such an extent that it can be molded by the roll plate 80.

  The second ultraviolet irradiation unit 62 is an apparatus that irradiates the ultraviolet curable resin 3, which is pressed by the roll plate 80 and has a surface pattern corresponding to the molding pattern of the roll plate 80, with main curing ultraviolet rays. The second ultraviolet irradiation unit 62 is disposed on the downstream side (X2 side) from the roll plate 80. The second ultraviolet irradiation unit 62 irradiates ultraviolet rays along the left-right direction (Y direction) orthogonal to the transport direction (X direction) of the substrate 2. The basic configuration of the second ultraviolet irradiation unit 62 is the same as that of the first ultraviolet irradiation unit 61. The 2nd ultraviolet irradiation part 62 irradiates the ultraviolet-ray for main curing, and hardens the ultraviolet curable resin 3 in which the surface pattern was formed with the roll plate 80 to the level which can be used as a product.

The nitrogen gas supply unit 100 is a device that sprays nitrogen gas onto the ultraviolet curable resin 3 irradiated with the main curing ultraviolet rays by the second ultraviolet irradiation unit 62. The nitrogen gas supply unit 100 includes a blowing nozzle (not shown), a nitrogen gas tank, a gas supply hose, an open / close control valve, and the like (all not shown).
In the ultraviolet curable resin 3 irradiated with the main curing ultraviolet rays by the second ultraviolet irradiation unit 62, radicals disappear due to oxygen in the air, and the progress of the photopolymerization reaction may be hindered. Therefore, the ultraviolet curable resin 3 can be cured more quickly by spraying nitrogen gas on the ultraviolet curable resin 3 being cured to block contact with oxygen.

Next, the manufacturing method of the optical member using said shaping | molding apparatus 1A is demonstrated.
First, on the upstream side (X1 side) of the roll plate 80, the substrate 2 is placed on the transport surface 11 a of the top plate part 11. And the corner | angular part of the left-right direction (Y direction) of the rear end side in the conveyance direction of the board | substrate 2 is made to contact | abut to the push plates 32a and 32b of the board | substrate conveyance part 70 (refer FIG. 2).
Next, an uncured ultraviolet curable resin 3 is applied on the upper surface (Z1 side) of the substrate 2. The material and application method of the ultraviolet curable resin 3 may be the same as those in the first embodiment.

  Next, as shown in FIG. 5, the substrate 2 coated with the ultraviolet curable resin 3 is transported from the upstream side (X1 side) to the downstream side (X2 side) in the transport direction (X direction). When the substrate 2 coated with the ultraviolet curable resin 3 reaches the front of the first ultraviolet irradiation unit 61, the preliminary ultraviolet rays are irradiated from the first ultraviolet irradiation unit 61 toward the substrate 2. Thereby, the ultraviolet curable resin 3 on the substrate 2 can be cured to such an extent that it can be molded by the subsequent roll plate 80.

When the front end side in the transport direction of the substrate 2 reaches the front of the roll plate 80, the roll plate 80 is rotated in synchronization with the transport speed of the substrate 2, and the roll plate 80 is lowered downward (Z2 side). Let
When the substrate 2 preliminarily cured with the ultraviolet curable resin 3 is conveyed downstream (X2 side) and reaches the position of the roll plate 80, the substrate 2 and the ultraviolet curable resin 3 are separated from the top plate portion 11 (conveying surface 11a) and roll. The ultraviolet curable resin 3 on the substrate 2 is pressed against the roll plate 80 by being sandwiched between the plates 80. Thereby, the ultraviolet curable resin 3 on the substrate 2 is pressed against the molding pattern of the roll plate 80, and a surface pattern corresponding to the shape of the molding pattern is formed on the ultraviolet curable resin 3.

  Subsequently, when the substrate 2 and the ultraviolet curable resin 3 pressed by the roll plate 80 reach the position of the second ultraviolet irradiation unit 62, the main curing is performed from the second ultraviolet irradiation unit 62 toward the ultraviolet curable resin 3. Irradiate ultraviolet rays. Thereby, the ultraviolet curing resin 3 on the substrate 2 can be fully cured. Further, in conjunction with the irradiation of the main curing ultraviolet ray from the second ultraviolet irradiation unit 62, the nitrogen gas is blown from the nitrogen gas supply unit 100 to the ultraviolet curable resin 3. The ultraviolet curable resin 3 can be cured more quickly by spraying nitrogen gas.

In the cured ultraviolet curable resin 3, a fine surface pattern corresponding to the molding pattern of the roll plate 80 is formed on the surface pressed against the molding pattern of the roll plate 80. In the cured ultraviolet curable resin 3, the surface opposite to the side pressed against the formation pattern of the roll plate 80 is bonded to the substrate 2.
Furthermore, the board | substrate 2 can be taken out from the shaping | molding apparatus 1A by conveying the board | substrate 2 downstream (X2 side). Thereby, an optical member having a fine surface pattern formed on the substrate 2 can be obtained.

According to 1 A of shaping | molding apparatuses of 2nd Embodiment mentioned above, there exist the following effects, for example.
The molding apparatus 1A of the second embodiment conveys the substrate 2 coated with the uncured ultraviolet curable resin 3 in a certain direction, irradiates the ultraviolet curable resin 3 with ultraviolet rays for pre-curing, and after irradiation, the roll plate The ultraviolet curing resin 3 on the substrate 2 is pressed by 80, and after the pressing, the ultraviolet curing resin 3 being conveyed is irradiated with ultraviolet rays for main curing. According to this, before and after the ultraviolet curing resin 3 is pressed by the roll plate 80, the preliminary curing ultraviolet irradiation and the main curing ultraviolet irradiation are continuously performed. It can be produced efficiently.

In the molding apparatus 1A of the second embodiment, since the roll plate 80 is separated from the ultraviolet curable resin 3 before the ultraviolet curable resin 3 is fully cured, the work of releasing the substrate 2 and the ultraviolet curable resin 3 from the plate after molding is not required. It becomes. This effect is common to the molding apparatus 1B of the third embodiment described later.
The molding apparatus 1A of the second embodiment can continuously form a surface pattern on the ultraviolet curable resin 3 on the substrate 2 to be conveyed. For example, when the roll plate 80 is rotated twice on a single substrate 2, two patterns of the same surface pattern can be formed. Therefore, the molding apparatus 1A of the second embodiment can reduce the manufacturing cost of the optical member. Further, the size of the ultraviolet curable resin 3 on which the surface pattern is formed can be made variable according to the number of times the roll plate 80 is rotated on the substrate 2 (for example, one pattern for one rotation and two for two rotations). pattern). This effect is common to the molding apparatus 1B of the third embodiment described later.

  The molding apparatus 1 </ b> A according to the second embodiment irradiates the uncured ultraviolet curable resin 3 with ultraviolet rays for preliminary curing before pressing the ultraviolet curable resin 3 with the roll plate 80. The ultraviolet curable resin 3 is cured to the extent that it can be molded by the roll plate 80 by the irradiation of the ultraviolet rays for preliminary curing. Therefore, after the ultraviolet curable resin 3 is pressed by the roll plate 80, the ultraviolet curable resin 3 to which the molding pattern of the roll plate 80 is transferred can be cured more rapidly.

  The molding apparatus 1A of the second embodiment includes a guide unit 31 (substrate transport unit 70) that regulates the inclination of the substrate 2 in the left-right direction (Y direction) in the transport direction of the substrate 2. Therefore, 1 A of shaping | molding apparatuses can suppress the damage | wound by the board | substrate 2 inclining during conveyance and contact with the board | substrate 2 and another member. In addition, since the forming apparatus 1A can stabilize the posture of the substrate 2 being conveyed by the guide portion 31, the fine surface pattern corresponding to the forming pattern of the roll plate 80 can be more accurately represented by the ultraviolet curable resin on the substrate 2. 3 can be formed. This effect is common to the molding apparatus 1B of the third embodiment described later.

  Since the forming apparatus 1A of the second embodiment includes the roll plate support portion 90 that supports the roll plate 80 so that the roll plate 80 can rotate about its axis and can move up and down in the vertical direction (Z direction) with respect to the substrate 2. The ultraviolet curable resin 3 on the substrate 2 can be pressed more stably. This effect is common to the molding apparatus 1B of the third embodiment described later.

  The molding apparatus 1 </ b> A of the second embodiment includes a nitrogen gas supply unit 100 that blows nitrogen gas onto the ultraviolet curable resin 3 irradiated with the main curing ultraviolet rays by the second ultraviolet irradiation unit 62. Since the contact between the ultraviolet curable resin 3 and oxygen can be blocked by blowing nitrogen gas from the nitrogen gas supply unit 100, the ultraviolet curable resin 3 can be cured more rapidly. This effect is common to the molding apparatus 1B of the third embodiment described later.

(Third embodiment)
FIG. 6 is a diagram illustrating a molding apparatus 1B according to the third embodiment. FIG. 7 is a view for explaining the molding of the optical member by the molding apparatus 1B. FIG. 8 is a diagram illustrating the base unit 10 and the substrate transfer unit 70. Among these, in FIG. 7, illustration of the board | substrate conveyance part 70, the roll plate support part 90, etc. is abbreviate | omitted. In the description of the third embodiment and the drawings, members and the like that are the same as those in the first and second embodiments are assigned the same reference numerals as in the first and second embodiments, and redundant descriptions are omitted.

As shown in FIG. 6, the molding apparatus 1B of the third embodiment includes a base unit 10, a substrate transport unit 70, a roll plate 80, a roll plate support unit 90, an ultraviolet irradiation unit 63 (see FIG. 7), and a nitrogen gas supply unit. 100.
As shown in FIG. 7, in the molding apparatus 1 </ b> B of the third embodiment, the ultraviolet irradiation unit 63 is arranged on the lower side (Z2 side) of the top plate part 11. As shown in FIGS. 7 and 8, the top plate portion 11 is provided with a slit portion 13. The slit portion 13 is an opening that regulates the irradiation width of ultraviolet rays in the transport direction (X direction) of the substrate 2. As shown in FIG. 8, the slit portion 13 is opened along the axial direction of the roll plate 80. The slit portion 13 is provided in the top plate portion 11 immediately below the roll plate 80 (on the Z2 side).

  In the slit portion 13, the slit length L in the left-right direction (Y direction) and the slit width (irradiation width) W in the transport direction (X direction) shown in FIG. It is set appropriately depending on the type of the cured resin 3 and the like. The ultraviolet light irradiated from the ultraviolet irradiation unit 63 passes through the slit unit 13, thereby suppressing leakage in the left-right direction (Y direction) and the transport direction (X direction) of the substrate 2, and the slit length L and slit width. Irradiated from a range restricted by W.

  The ultraviolet irradiation unit 63 is a device that irradiates the uncured ultraviolet curable resin 3 applied on the substrate 2 with ultraviolet rays. The ultraviolet irradiation unit 63 irradiates ultraviolet rays from the slit unit 13 along the left-right direction (Y direction) orthogonal to the transport direction (X direction) of the substrate 2. The ultraviolet irradiation unit 63 is configured by, for example, a plurality of UV-LED lamps arranged linearly along the Y direction.

  As will be described later, the ultraviolet irradiation unit 63 irradiates the ultraviolet curable resin 3 being pressed by the roll plate 80 from the lower side (Z2 side) of the substrate 2 with ultraviolet rays. Since the substrate 2 has optical transparency, the ultraviolet curable resin 3 being pressed can be cured by a photopolymerization reaction by irradiating ultraviolet rays from the lower side of the substrate 2.

Next, the manufacturing method of the optical member using said shaping | molding apparatus 1B is demonstrated.
First, on the upstream side (X1 side) of the roll plate 80, the substrate 2 is placed on the transport surface 11 a of the top plate part 11. And the corner | angular part of the left-right direction (Y direction) of the rear end side in the conveyance direction of the board | substrate 2 is made to contact | abut to the push plates 32a and 32b of the board | substrate conveyance part 70 (refer FIG. 2).

Next, an uncured ultraviolet curable resin 3 is applied on the upper surface (Z1 side) of the substrate 2. The material and application method of the ultraviolet curable resin 3 may be the same as those in the first embodiment.
Next, as shown in FIG. 7, the substrate 2 coated with the ultraviolet curable resin 3 is transported from the upstream side (X1 side) to the downstream side (X2 side) in the transport direction (X direction). When the front end side in the conveyance direction of the substrate 2 reaches the front of the roll plate 80, the roll plate 80 is rotated in synchronization with the conveyance speed of the substrate 2, and the roll plate 80 is lowered downward (Z2 side). Let

  When the substrate 2 coated with the uncured ultraviolet curable resin 3 is conveyed downstream (X2 side) and reaches the position of the roll plate 80, the substrate 2 and the ultraviolet curable resin 3 are separated from the conveying surface 11a (the top plate portion 11). ) And the roll plate 80, and the ultraviolet curable resin 3 on the substrate 2 is pressed against the roll plate 80. Thereby, the ultraviolet curable resin 3 on the substrate 2 is pressed against the molding pattern of the roll plate 80, and a surface pattern corresponding to the shape of the molding pattern is formed on the ultraviolet curable resin 3.

  Further, when the front end side in the transport direction of the substrate 2 reaches the front of the roll plate 80, ultraviolet rays are irradiated from the ultraviolet irradiation unit 63 toward the substrate 2 through the slit portion 13. Thereby, the ultraviolet curable resin 3 being pressed by the roll plate 80 can be cured on the substrate 2. Further, in conjunction with the irradiation of ultraviolet rays from the ultraviolet irradiation unit 63, nitrogen gas is blown from the nitrogen gas supply unit 100 to the ultraviolet curable resin 3. The ultraviolet curable resin 3 can be cured more quickly by spraying nitrogen gas.

In the cured ultraviolet curable resin 3, a fine surface pattern corresponding to the molding pattern of the roll plate 80 is formed on the surface pressed against the molding pattern of the roll plate 80. Further, in the cured ultraviolet curable resin 3, the surface opposite to the side pressed against the forming pattern of the roll plate 80 is bonded to the substrate 2.
Furthermore, the board | substrate 2 can be taken out from the shaping | molding apparatus 1B by conveying the board | substrate 2 downstream (X2 side). Thereby, an optical member having a fine surface pattern formed on the substrate 2 can be obtained.

According to the molding apparatus 1B of the third embodiment described above, for example, the following effects can be obtained.
The molding apparatus 1B according to the third embodiment conveys the substrate 2 coated with the uncured ultraviolet curable resin 3 in a certain direction, presses the ultraviolet curable resin 3 on the substrate 2 by the roll plate 80, and presses and conveys the substrate. The ultraviolet curable resin 3 in the inside is irradiated with ultraviolet rays. According to this, since pressing of the ultraviolet curable resin 3 by the roll plate 80 and irradiation of ultraviolet rays can be performed simultaneously, a fine surface pattern of the optical member can be efficiently produced.

  The molding apparatus 1 </ b> B of the third embodiment includes a slit portion 13 that regulates the irradiation width of ultraviolet rays in the transport direction of the substrate 2. By providing the slit portion 13, the diffusion of ultraviolet rays to the upstream side (X1 side) in the transport direction of the substrate 2 is suppressed, so that the ultraviolet curable resin 3 is irradiated with more accurate amounts of ultraviolet rays. Can do. Moreover, since unnecessary ultraviolet rays are not irradiated to the uncured ultraviolet curable resin 3 on the near side of the roll plate 80, a fine surface pattern corresponding to the molding pattern of the roll plate 80 can be formed more stably. .

  As mentioned above, although embodiment of this invention was described, this invention is not limited to each embodiment mentioned above, Various deformation | transformation and a change are possible like the deformation | transformation form mentioned later, These are also this book. It is within the technical scope of the invention. In addition, the effects described in each embodiment are merely a list of the most preferable effects resulting from the present invention, and are not limited to those described in each embodiment. Note that each of the above-described embodiments and modifications described later can be used in appropriate combination, but detailed description thereof will be omitted.

(Deformation)
In the molding plate conveyance unit 30 of the first embodiment, the molding plate 20 may be configured to be pulled from the front end side in the conveyance direction. Further, in the molding plate transport unit 30, the molding plate 20 may be fixed on a mounting table and transported together with the mounting table. In the substrate transfer unit 70 of the second and third embodiments, the substrate 2 may be pulled from the front end side in the transfer direction. Moreover, in the board | substrate conveyance part 70, the board | substrate 2 may be fixed on a mounting base, and you may make it convey with this mounting base.

  In the first and third embodiments, the substrate 2 is not limited to being transparent as long as it has optical transparency, and may be colored. Moreover, in 2nd Embodiment, the board | substrate 2 may be comprised with the member which does not have a light transmittance.

  In the roll plate support unit 90 of the second and third embodiments, a mechanism for rotating the roll plate 80 in synchronization with the conveyance speed of the substrate 2 is omitted, and only the configuration for supporting the roll plate 80 so as to be rotatable around the axis is provided. Also good. In this case, since the roll plate 80 rotates freely, the roll plate 80 automatically rotates in synchronization with the transport speed of the substrate 2.

  Further, the roll plate support unit 90 of the second and third embodiments may be configured such that the drive device for raising and lowering the roll plate 80 is omitted. In this case, an appropriate nip interval can be formed between the roll plate 80 and the transport surface 11a (top plate portion 11) according to the position of the roll plate 80 in the vertical direction (Z direction).

  Moreover, in the roll plate support part 90 of the second and third embodiments, a mechanism for pressing the roll plate 80 downward (Z2 side) may be provided. Thereby, the gap of the nip between the roll plate 80 and the transport surface 11a (the top plate portion 11) can follow a slight thickness variation in the surface of one substrate 2 or in each substrate 2. .

In the second and third embodiments, the roll plate 80 is not limited to a roll mold, and may be a resin roll plate in which a resin plate is wound around the surface of a roll body. A plurality of surface patterns can be formed on one substrate 2 by applying multiple molding patterns to the resin plate. In addition, a plurality of optical members can be formed on one substrate 2 by applying multiple molding patterns of one optical member on the resin plate.
In 2nd and 3rd embodiment, although the nitrogen gas supply part 100 is arrange | positioned in the downstream of the roll plate 80, it is not limited to this. The nitrogen gas supply unit 100 may be disposed on the downstream side and the upstream side of the roll plate 80, respectively.

In the molding apparatus 1 </ b> B of the third embodiment, the slit portion 13 may be provided with a shutter mechanism. By providing such a shutter mechanism, it is possible to irradiate ultraviolet rays with more accurate timing. Further, by providing the shutter mechanism, it is possible to reduce the amount of ultraviolet light leaking to a region other than directly below the roll plate 80, so that the ultraviolet curable resin 3 can be irradiated with a more accurate amount of ultraviolet light.
In the molding apparatus 1B of the third embodiment, a mechanism that can adjust the slit width W of the slit portion 13 may be provided. By providing such a mechanism, the irradiation amount of ultraviolet rays can be optimized according to the material used, product specifications, and the like.

  In the molding apparatus 1B of the third embodiment, the slit portion 13 is provided directly below the lower side (Z2 side) of the roll plate 80, but is not limited thereto. The slit portion 13 may be provided on the upstream side (X1 side) of the roll plate 80 in the transport direction (X direction) of the substrate 2 or may be provided on the downstream side (X2 side). The distance for moving the slit portion 13 from directly below the roll plate 80 is about several millimeters.

  In the molding apparatus 1B of the third embodiment, the substrates 2 may be transported continuously instead of transporting them one by one. At that time, a light shielding material (for example, black tape) is attached to the side surface of the substrate 2 adjacent in the transport direction, so that the ultraviolet rays propagated through the downstream substrate 2 are applied on the upstream substrate 2. Irradiation to the cured ultraviolet curable resin 3 can be suppressed.

DESCRIPTION OF SYMBOLS 1,1A, 1B Molding apparatus 13 Slit part 20 Molding plate 30 Molding plate conveyance part 31 Guide part 40 Roll body 60,63 Ultraviolet irradiation part 61 1st ultraviolet irradiation part 62 2nd ultraviolet irradiation part 70 Substrate conveyance part 80 Roll plate 100 Nitrogen gas supply unit

Claims (12)

A plate-shaped molding plate having a molding pattern formed on the plate surface;
A molding plate transport section for transporting the molding plate in a certain direction;
A columnar roll body that is rotatably supported around an axis at a position facing the molding plate,
An ultraviolet irradiation unit capable of irradiating ultraviolet rays,
The molding plate in which a substrate having light permeability is arranged on the molding pattern with an uncured ultraviolet curable resin interposed therebetween is conveyed to the roll body side by the molding plate conveyance section, and the substrate is molded by the roll body. A molding apparatus that presses against a plate and irradiates ultraviolet rays from the ultraviolet irradiation unit to the ultraviolet curable resin from the substrate side being conveyed after being pressed. A substrate transport section for transporting a substrate coated with an uncured UV curable resin in a certain direction;
A cylindrical roll plate that is formed on the peripheral side surface and is supported rotatably around an axis and presses the ultraviolet curable resin on the substrate;
A first ultraviolet irradiation unit that is arranged on the upstream side of the roll plate in the conveyance direction of the substrate and irradiates the ultraviolet curing resin being conveyed before pressing with ultraviolet rays for preliminary curing;
A second ultraviolet irradiation unit that is disposed on the downstream side of the roll plate in the conveyance direction of the substrate and irradiates the ultraviolet curable resin being conveyed after pressing with ultraviolet rays for main curing;
A molding apparatus comprising: An uncured UV-curing resin is applied, and a substrate transport unit that transports a light-transmitting substrate in a certain direction;
A cylindrical roll plate that is formed on the peripheral side surface and is supported rotatably around an axis and presses the ultraviolet curable resin on the substrate;
An ultraviolet irradiation unit that is disposed at a position facing the roll plate across the substrate and irradiates the ultraviolet curable resin applied to the substrate with ultraviolet rays;
The substrate coated with the ultraviolet curable resin is conveyed to the roll plate side by the substrate conveying unit, the ultraviolet curable resin is pressed by the roll plate, and the molding pattern is formed on the ultraviolet curable resin, A molding apparatus for irradiating ultraviolet rays to the ultraviolet curable resin being pressed and conveyed by the ultraviolet irradiation unit. The molding apparatus according to claim 1,
A roll body support part for supporting the roll body so as to be movable up and down with respect to the molding plate;
A molding apparatus characterized by. The molding apparatus according to claim 2 or 3,
A roll plate support unit for supporting the roll plate so as to be movable up and down with respect to the substrate;
A molding apparatus characterized by. The molding apparatus according to claim 1,
The molding plate conveyance unit has a guide unit for regulating the inclination of the molding plate in the conveyance direction of the molding plate;
A molding apparatus characterized by. The molding apparatus according to claim 2 or 3,
The substrate transport section has a guide section for regulating the tilt of the substrate in the transport direction of the substrate;
A molding apparatus characterized by. The molding apparatus according to claim 3,
Comprising a slit portion for regulating the irradiation width of ultraviolet rays in the transport direction of the substrate;
A molding apparatus characterized by. The molding apparatus according to claim 2 or 3,
Including a nitrogen gas supply unit that blows nitrogen gas onto the ultraviolet curable resin irradiated with ultraviolet rays,
A molding apparatus characterized by. A molding plate in which a substrate having optical transparency is disposed on a molding pattern with an uncured ultraviolet curable resin interposed therebetween is conveyed in a fixed direction, and the substrate is placed on the molding plate by a cylindrically formed roll body. A molding method of pressing and irradiating the ultraviolet curable resin with ultraviolet rays from the side of the substrate being conveyed after pressing.   A substrate coated with an uncured ultraviolet curable resin is conveyed in a certain direction, the ultraviolet curable resin is irradiated with ultraviolet rays for preliminary curing, and the substrate is formed by a roll plate having a molding pattern formed on the peripheral side surface after irradiation. A molding method in which the ultraviolet curable resin is pressed and the ultraviolet curable resin being conveyed is irradiated with ultraviolet rays for main curing after being pressed.   The substrate coated with the uncured ultraviolet curable resin is conveyed in a certain direction, the ultraviolet curable resin on the substrate is pressed by a roll plate having a molding pattern formed on the peripheral side surface, and the ultraviolet rays being pressed and conveyed A molding method for irradiating a cured resin with ultraviolet rays.

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