JP4688031B2 - Method and apparatus for manufacturing uneven sheet - Google Patents

Description

  The present invention relates to a method and apparatus for producing a concavo-convex sheet, in particular, a sheet-like material such as an embossed sheet having an antireflection effect in which a regular fine concavo-convex pattern is formed on the surface, with high quality without defects, In addition, the present invention relates to a method and apparatus for manufacturing a concavo-convex sheet suitable for manufacturing with high line speed and high productivity.

  In recent years, an embossed sheet having an antireflection effect has been adopted for use in electronic displays such as liquid crystals. In addition, flat lenses such as lenticular lenses and fly-eye lenses, embossed sheets such as light diffusion sheets, brightness enhancement sheets, optical waveguide sheets, and prism sheets are used. As such an embossed sheet, a sheet having a regular fine concavo-convex pattern formed on the surface has been conventionally known. As a method for forming such a regular fine concavo-convex pattern, various methods are conventionally known (see Patent Documents 1 and 2, etc.).

  For example, in an apparatus having a configuration as shown in FIG. 7, a resin is applied to the surface of the stamper roller 1 having a regular uneven pattern formed on the surface by the applying means 2, and the continuously running sheet 3 is applied to the stamper roller. 1 and the nip roller 4, the resin of the stamper roller 1 is in contact with the sheet 3, the resin is irradiated with ionizing radiation and cured, and then the sheet 3 is wound around the release roller 5 and peeled off from the stamper roller 1. The contents to be disclosed are disclosed.

Further, in the apparatus configured as shown in FIG. 8, a resin is applied in advance to the surface of the continuously running sheet 3, and this sheet 3 is connected to the stamper roller 1 on which a regular uneven pattern is formed. Content that is sandwiched between the nip rollers 4 and the uneven pattern of the stamper roller 1 is transferred to the resin, and is cured by irradiating the resin with ionizing radiation, and then the sheet 3 is wound around the release roller 5 and peeled off from the stamper roller 1 Is disclosed.
JP-A-11-300768 JP 2001-62853 A

One of the serious problems in the above process is that when the speed of the production line is increased in order to increase productivity, air is caught between the cured resin film on the surface of the sheet 3 and the pattern roller 1. This means that defects due to bubbles occur on the surface of the sheet 3. As countermeasures, the patent documents 1 and 2 described above employ the following countermeasures. However, a complete solution has not been obtained,
For example, in Patent Document 1, a staying part (hypertrophic peed part) that is pushed out in the width direction while the resin stays in the meeting part of the roller is formed, but there is a concern that film formation may become unstable, There was a problem that the condition setting became more difficult as the speed was increased.

  In Patent Document 2, the first cured resin is applied to the roller surface in the form of a fine mist, and then the base material coated with the second cured resin is pressure-bonded to the roller. However, a separate coating device is required. In addition, there is a problem that a material capable of forming a fine mist is necessary (that is, there is no degree of freedom in material selection).

  The present invention has been made in view of such circumstances, and is used to manufacture a concavo-convex sheet having a regular fine concavo-convex pattern formed on the surface with high quality and high productivity without defects. It is an object of the present invention to provide a method and apparatus for producing a concavo-convex sheet suitable for the above.

  In order to achieve the above-mentioned object, the present invention provides a method for producing a concavo-convex sheet in which the concavo-convex surface of the concavo-convex roller is transferred and formed on the surface of the sheet-like body. The formed belt-like flexible sheet-like body is continuously run, and the sheet-like body is sandwiched between the concavo-convex roller and at least one nip roller disposed opposite to the concavo-convex roller, and the concavo-convex roller and the sheet. The surface of the concavo-convex roller is transferred to the concavo-convex shape of the concavo-convex roller while sucking air between the concavo-convex body, and the resin liquid layer is cured while the sheet-like body is wound around the concavo-convex roller. A method for producing a concavo-convex sheet is provided.

  For this purpose, the present invention provides a sheet-like body supply means for feeding out a belt-like flexible sheet-like body, an application means for applying a resin liquid to the surface of the sheet-like body, and the sheet-like body that runs continuously. And a transfer means for transferring and forming the unevenness of the surface of the uneven roller onto the surface of the sheet-like body, while being wound around the rotating uneven roller while being pressed with at least one nip roller disposed opposite to the uneven roller, A resin liquid curing means for curing the resin liquid in a state where the sheet-like body is wound around the uneven roller; and an air between the uneven roller and the sheet-like body provided on the upstream side of the uneven roller. An apparatus for producing a concavo-convex sheet, characterized by comprising a suction means for sucking water.

  According to the present invention, in the manufacture of a concavo-convex sheet in which the concavo-convex surface of the concavo-convex roller is transferred and formed on the surface of the sheet-form body, the concavo-convex surface of the concavo-convex roller surface is sucked while sucking air between the concavo-convex roller and the sheet-form body. The shape is transferred to the resin liquid layer, and the resin liquid layer is cured in this state. As described above, since the concave / convex shape is transferred while sucking the air between the concave / convex roller and the sheet-like body, the problem of the occurrence of bubble defects due to the entrainment of air is solved.

  Therefore, according to the present invention, a concavo-convex sheet having a regular fine concavo-convex pattern formed on the surface can be manufactured with high quality without defects and with high line speed and high productivity.

  In this specification, the term “concave / convex roller” refers to a concave / convex pattern (embossed pattern on the surface of a belt-shaped body such as an endless belt as well as a concave / convex pattern on the surface of a cylindrical roller. In this case, even such a belt-like body acts in the same manner as a cylindrical embossing roller, and the same effect can be obtained.

  In addition, in order to achieve the above object, the present invention provides a method for producing a concavo-convex sheet in which the concavo-convex surface of the concavo-convex roller is transferred and formed on the surface of the sheet-like body. A belt-like flexible sheet-like body on which a layer is formed is continuously run, and the sheet-like body is sandwiched between the concavo-convex roller and at least one nip roller disposed opposite to the concavo-convex roller, A wind shielding member is arranged on the upstream side, and the uneven shape on the surface of the uneven roller is transferred to the resin liquid layer while preventing air from being caught between the uneven roller and the sheet-like body, and the sheet shape Provided is a method for producing a concavo-convex sheet, wherein the resin liquid layer is cured while a body is wound around the concavo-convex roller.

  For this purpose, the present invention provides a sheet-like body supply means for feeding out a belt-like flexible sheet-like body, an application means for applying a resin liquid to the surface of the sheet-like body, and the sheet-like body that runs continuously. And a transfer means for transferring and forming the unevenness of the surface of the uneven roller onto the surface of the sheet-like body, while being wound around the rotating uneven roller while being pressed with at least one nip roller disposed opposite to the uneven roller, Resin liquid curing means for curing the resin liquid in a state where the sheet-like body is wound around the uneven roller, and provided upstream of the uneven roller, between the uneven roller and the sheet-like body There is provided a manufacturing apparatus for a concavo-convex sheet, comprising: a wind-shielding means for preventing air entrainment.

  According to the present invention, in the manufacture of a concavo-convex sheet in which the concavo-convex surface of the concavo-convex roller is transferred and formed on the surface of the sheet-like body, a wind shielding member is disposed on the upstream side of the concavo-convex roller. While preventing air from being caught in between, the uneven shape on the surface of the uneven roller is transferred to the resin liquid layer, and the resin liquid layer is cured in that state. As described above, since the concavo-convex shape is transferred while preventing air from being caught between the concavo-convex roller and the sheet-like body, the problem of occurrence of bubble defects due to air being entangled is solved.

  Therefore, according to the present invention, a concavo-convex sheet having a regular fine concavo-convex pattern formed on the surface can be manufactured with high quality without defects and with high line speed and high productivity.

  In the present invention, it is preferable that the resin liquid is a radiation curable resin liquid and the resin liquid layer is cured by irradiating the resin liquid layer with radiation. By using such a radiation curable resin liquid, curing of the resin is facilitated.

  In the present invention, it is preferable that the pitch of the concavo-convex pattern transferred and formed on the sheet-like body is 100 μm or less. In the present invention, the uneven sheet is preferably used as an optical film.

  As described above, according to the present invention, a concavo-convex sheet having a regular fine concavo-convex pattern formed on the surface can be produced with high quality and high productivity without defects and with high line speed.

  Hereinafter, an embodiment of the present invention (first embodiment) will be described with reference to the accompanying drawings. FIG. 1 is a configuration diagram showing a configuration of an embossed sheet manufacturing apparatus 10 to which the present invention is applied. The embossed sheet manufacturing apparatus 10 includes a sheet-like material supply unit 11, a coating unit 12, a drying unit 19, an embossing roller 13 that is a concavo-convex roller, a nip roller 14, an embossing roller 13, and a resin material F (FIG. 2). A suction means 22 for sucking air between the air and the resin, a resin curing means 15, a peeling roller 16, a protective film supply means 17, a sheet winding means 18, and the like.

  The sheet supply means 11 which is a sheet-like body supply means is for sending out the sheet W which is a sheet-like body, and includes a delivery roll on which the sheet W is wound.

  The coating means 12 is a device that applies a radiation curable resin liquid to the surface of the sheet W, and includes a liquid supply source 12A that supplies the radiation curable resin liquid, a liquid supply device (liquid feed pump) 12B, a coating head 12C, It comprises a support roller 12D that wraps and supports the sheet W at the time of application, a pipe for supplying a radiation curable resin liquid from the liquid supply source 12A to the application head 12C, and the like. As the coating head 12C, a coating head of a die coater (extrusion type coater) is employed.

  As the drying means 19, various known systems can be adopted as long as the coating liquid applied to the sheet W can be uniformly dried, such as a tunnel-shaped drying apparatus shown in FIG. 1. . For example, a radiant heating method using a heater, a hot air circulation method, a far infrared method, a vacuum method, or the like can be employed.

  The embossing roller 13 is required to have an uneven pattern accuracy, mechanical strength, roundness, and the like that can transfer and form unevenness on the surface of the sheet W. Such an embossing roller 13 is preferably a metal roller.

  As shown in a sectional view in FIG. 3, a regular fine uneven pattern is formed on the outer peripheral surface of the embossing roller 13. Such a regular fine concavo-convex pattern is required to have a shape obtained by inverting the fine concavo-convex pattern on the surface of an embossed sheet as a product.

  As an embossed sheet as a product, for example, a lenticular lens in which fine concavo-convex patterns are arranged two-dimensionally, or a fine cone such as a fly-eye lens, cone, or pyramid in which fine concavo-convex patterns are arranged three-dimensionally in the XY direction A flat lens or the like laid on the surface is an object, and a regular fine uneven pattern on the outer peripheral surface of the embossing roller 13 is made to correspond to this.

  As a method for forming a regular fine concavo-convex pattern on the outer peripheral surface of the embossing roller 13, a method of cutting the surface of the embossing roller 13 with a diamond bit (single point), photo-etching, electron beam drawing on the surface of the embossing roller 13, The method of forming irregularities directly by laser processing etc. can be adopted, and irregularities are formed on the surface of thin metal plate by photo etching, electron beam drawing, laser processing, stereolithography, etc. Can be wound around and fixed to the embossing roller 13.

  In addition, uneven surfaces are formed on the surface of materials that are easier to process than metal by photo-etching, electron beam drawing, laser processing, stereolithography, etc., and a reversal of this shape is formed by electroforming etc. to make a thin metal plate It is also possible to adopt a method in which an embossing roller 13 is formed by creating a body and winding and fixing the plate-like body around the roller. In particular, when the inversion mold is formed by electroforming or the like, there is a feature that a plurality of plate-like bodies having the same shape can be obtained from one master (mother).

  It is preferable to perform a mold release process on the surface of the embossing roller 13. Thus, the shape of the fine concavo-convex pattern can be satisfactorily maintained by performing the mold release process on the surface of the embossing roller 13. As the mold release treatment, various known methods such as coating treatment with a fluororesin can be employed. The embossing roller 13 is preferably provided with driving means. The embossing roller 13 rotates counterclockwise (CCW) as shown in the figure.

  The nip roller 14 forms a roller while pressing the sheet W while being paired with the embossing roller 13, and is required to have predetermined mechanical strength, roundness, and the like. The longitudinal elastic modulus (Young's modulus) on the surface of the nip roller 14 is set to an appropriate value because roller molding is insufficient when it is too small, and when it is too large, it reacts sensitively to the inclusion of foreign substances such as dust and tends to cause defects. It is preferable. The nip roller 14 is preferably provided with driving means. The nip roller 14 rotates in the clockwise direction (CW) as shown in the figure.

  In order to apply a predetermined pressing force between the embossing roller 13 and the nip roller 14, it is preferable to provide a pressing means on either the embossing roller 13 or the nip roller 14. Similarly, it is preferable to provide fine adjustment means on either the embossing roller 13 or the nip roller 14 so that the gap (clearance) between the embossing roller 13 and the nip roller 14 can be accurately controlled.

  The suction means 22 sucks air between the embossing roller 13 and the resin material F, and the sheet W is peeled off from the nip roller 14 and delivered to the embossing roller 13 as shown in a side view of FIG. It is provided in the vicinity of the peeling point P. In FIG. 2, only the embossing roller 13 and the nip roller 14 are shown as rollers, and the peeling roller 16 is omitted.

  As shown in FIG. 2, the suction means 22 mainly communicates a suction chamber 30 having a substantially square box shape in which a suction port 28 is opened on the surface of the embossing roller 13, and a suction pump 30 and a vacuum pump (not shown). And an air tube 32 to be configured. The suction port 28 of the suction means 22 is formed in an arc shape that follows the circumferential shape of the embossing roller 13.

  That is, the suction chamber 30 has a pair of a front plate 30A and a back plate 30B formed in substantially the same length as the embossing roller 13 in the width direction of the embossing roller 13, and a pair of the front plate 30A and the back plate 30B. It is composed of side plates 30C and 30D and an upper plate 30E.

  Further, the lower edge a of the pair of side plates 30C and 30D is formed in an arc shape that follows the circumferential shape of the embossing roller 13, and the lower edge b of the side plates 30C and 30D follows the circumferential shape of the nip roller 14. It is formed in an arc shape.

  By forming the suction chamber 30 in this way, the suction port 28 can be brought close to the limit where it does not come into contact with the surfaces of the embossing roller 13 and the nip roller 14, and the air leak when sucked can be minimized. Therefore, the air between the embossing roller 13 and the resin material F can be efficiently sucked, and the uneven shape of the embossing roller 13 can be transferred to the resin material F with high accuracy.

  An example of the uneven shape of the embossing roller 13 is a groove having a triangular cross section and a pitch of 50 μm in the roller axial direction. The cross-sectional shape of the groove is a triangular shape with an apex angle of 90 degrees, and the bottom of the groove has a triangular shape of 90 degrees with no flat portion. That is, the groove width is 50 μm and the groove depth is about 25 μm. Since the groove is endless without a seam in the circumferential direction of the roller, the embossing roller 13 can form a lenticular lens (prism sheet) having a triangular cross section on the sheet W.

  In addition, when the uneven shape of the embossing roller 13 is relatively rough, for example, when the pitch or step of the uneven shape is on the order of mm, the lower end edge of the back plate 30B of the suction port 28 is formed on the surface of the embossing roller 13. By forming the concave / convex shape following the concave / convex shape, the suction port 28 can be brought close to the limit where it does not come into contact with the surface of the embossing roller 13, and the air leak when sucked can be minimized.

  The resin curing means 15 is a light irradiation means provided facing the embossing roller 13 on the downstream side of the nip roller 14. The resin curing means 15 transmits the sheet W by light irradiation and cures the resin liquid layer. The resin curing means 15 can irradiate light (radiation) having a wavelength corresponding to the curing characteristics of the resin, and according to the conveyance speed of the sheet W. It is preferable that a sufficient amount of radiation can be irradiated. As the resin curing means 15, for example, a columnar irradiation lamp having substantially the same length as the width of the sheet W can be adopted. Further, a plurality of the cylindrical irradiation lamps can be provided in parallel, and a reflector can be provided on the back surface of the cylindrical irradiation lamp.

  The peeling roller 16 is paired with the embossing roller 13 to peel the sheet W from the embossing roller 13 and is required to have predetermined mechanical strength, roundness, and the like. The sheet W is peeled off from the embossing roller 13 and wound around the peeling roller 16 while being sandwiched between the rotating embossing roller 13 and the peeling roller 16 at the peeling portion. In order to ensure this operation, the peeling roller 16 is preferably provided with a driving means. The peeling roller 16 rotates in the clockwise direction (CW) as shown in the figure.

  In addition, when the temperature of resin etc. rises by hardening, the structure which provides a cooling means to the peeling roller 16 can also be employ | adopted in order to cool the sheet | seat W at the time of peeling, and to ensure peeling.

  Although not shown, a plurality of backup rollers are provided to face each other between the pressing location (9 o'clock position) of the embossing roller 13 and the peeling location (3 o'clock position). A configuration in which the curing process is performed while pressing the sheet W with the roller 13 can also be adopted.

  The sheet winding means 18 stores the peeled sheet W, and includes a winding roll that winds the sheet W or the like. In this sheet winding means 18, the protective film H supplied from the adjacent protective film supply means 17 is supplied to the surface of the sheet W, and is stored in the sheet winding means 18 in a state where both films overlap. The

  In the embossed sheet manufacturing apparatus 10, a guide roller or the like that forms a conveyance path of the sheet W may be provided between the coating unit 12 and the embossing roller 13, between the peeling roller 16 and the sheet winding unit 18, and the like. In addition, a tension roller or the like can be provided as needed to absorb slack during conveyance of the sheet W.

  Next, each material applied to the present invention will be described. As the sheet W, a resin film, paper (resin coated paper, synthetic paper, etc.), metal foil (aluminum web, etc.) and the like can be used. As the material of the resin fill, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyester, polyolefin, acrylic, polystyrene, polycarbonate, polyamide, PET (polyethylene terephthalate), biaxially stretched polyethylene terephthalate, Known materials such as polyethylene naphthalate, polyamideimide, polyimide, aromatic polyamide, cellulose acylate, cellulose triacetate, cellulose acetate propionate, and cellulose diacetate can be used. Of these, polyester, cellulose acylate, acrylic, polycarbonate, and polyolefin can be preferably used.

  The sheet W generally has a width of 0.1 to 3 m, the sheet W has a length of 1000 to 100,000 m, and the sheet W has a thickness of 1 to 300 μm. However, application of other sizes is not impeded.

  These sheets W may be previously subjected to corona discharge, plasma treatment, easy adhesion treatment, heat treatment, dust removal treatment and the like. The surface roughness Ra of the sheet W is preferably 3 to 10 nm at a cutoff value of 0.25 mm.

  The sheet W may be a sheet W provided with a base layer such as an adhesive layer in advance and dried and cured, or a sheet having another functional layer formed in advance on the back surface. Similarly, as the sheet W, not only a one-layer structure but also a structure having two or more layers can be adopted. Moreover, it is preferable that the sheet | seat W is a transparent body and translucent body which can permeate | transmit light.

  Resins that can be used in the present invention include a reactive group-containing compound such as a (meth) acryloyl group, a vinyl group, or an epoxy group, and a radical or cation that can react with the reactive group-containing compound by irradiation with ultraviolet rays or the like. Those containing compounds that generate active species can be used.

  In particular, from the viewpoint of curing speed, a combination of a reactive group-containing compound (monomer) containing an unsaturated group such as a (meth) acryloyl group or a vinyl group and a radical photopolymerization initiator that generates a radical by light is preferable. . Of these, (meth) acryloyl group-containing compounds such as (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, and polyester (meth) acrylate are preferable.

  As the (meth) acryloyl group-containing compound, a compound containing one or more (meth) acryloyl groups can be used. Moreover, the reactive group containing compound (monomer) containing unsaturated groups, such as said acryloyl group and a vinyl group, may be used independently or may be used in mixture of multiple types as needed.

  Examples of such (meth) acryloyl group-containing compounds include, for example, isobornyl (meth) acrylate, bornyl (meth) acrylate, tricyclodecanyl as monofunctional monomers containing only one (meth) acryloyl group-containing compound. (Meth) acrylate, dicyclopentanyl (meth) acrylate, dicyclopentenyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, 4-butylcyclohexyl (meth) acrylate, acryloylmorpholine, 2-hydroxyethyl (Meth) acrylate, 2-hydroxypropyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, Propyl (meth) acrylate, butyl (meth) acrylate, amyl (meth) acrylate, isobutyl (meth) acrylate, t-butyl (meth) acrylate, pentyl (meth) acrylate, isoamyl (meth) acrylate, hexyl (meth) acrylate , Heptyl (meth) acrylate, octyl (meth) acrylate, isooctyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, nonyl (meth) acrylate, decyl (meth) acrylate, isodecyl (meth) acrylate, undecyl (meth) acrylate , Dodecyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, isostearyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate , Butoxyethyl (meth) acrylate, ethoxydiethylene glycol (meth) acrylate, polyethylene glycol mono (meth) acrylate, polypropylene glycol mono (meth) acrylate, methoxyethylene glycol (meth) acrylate, ethoxyethyl (meth) acrylate, methoxypolyethylene glycol ( Examples include meth) acrylate and methoxypolypropylene glycol (meth) acrylate.

  Furthermore, as a monofunctional monomer having an aromatic ring, phenoxyethyl (meth) acrylate, phenoxy-2-methylethyl (meth) acrylate, phenoxyethoxyethyl (meth) acrylate, 3-phenoxy-2-hydroxypropyl (meth) acrylate, 2-phenylphenoxyethyl (meth) acrylate, 4-phenylphenoxyethyl (meth) acrylate, 3- (2-phenylphenyl) -2-hydroxypropyl (meth) acrylate, and p-cumylphenol reacted with ethylene oxide ( (Meth) acrylate, 2-bromophenoxyethyl (meth) acrylate, 4-bromophenoxyethyl (meth) acrylate, 2,4-dibromophenoxyethyl (meth) acrylate, 2,6-dibromophenoxyethyl (meth) ) Acrylate, 2,4,6-bromophenyl (meth) acrylate, 2,4,6-tribromophenoxyethyl (meth) acrylate.

  Examples of such commercially available aromatic monocyclic monocyclic monomers include Aronix M113, M110, M101, M102, M5700, TO-1317 (above, manufactured by Toagosei Co., Ltd.), Biscote # 192, # 193, # 220, 3BM (Osaka Organic Chemical Co., Ltd.), NK Ester AMP-10G, AMP-20G (Shin Nakamura Chemical Co., Ltd.), Light Acrylate PO-A, P-200A, Epoxy Ester M-600A, light ester PO (above, manufactured by Kyoeisha Chemical Co., Ltd.), New Frontier PHE, CEA, PHE-2, BR-30, BR-31, BR-31M, BR-32 (above, Daiichi Kogyo) Pharmaceutical Co., Ltd.).

  Examples of unsaturated monomers having two (meth) acryloyl groups in the molecule include alkyl diols such as 1,4-butanediol diacrylate, 1,6-hexanediol diacrylate, and 1,9-nonanediol diacrylate. Examples include polyalkylene glycol diacrylates such as diacrylate, ethylene glycol di (meth) acrylate, tetraethylene glycol diacrylate, and tripropylene glycol diacrylate, neopentyl glycol di (meth) acrylate, and tricyclodecane methanol diacrylate.

  As unsaturated monomers having a bisphenol skeleton, ethylene oxide-added bisphenol A (meth) acrylic acid ester, ethylene oxide-added tetrabromobisphenol A (meth) acrylic acid ester, propylene oxide-added bisphenol A (meth) acrylic acid ester, propylene oxide-added Tetrabromobisphenol A (meth) acrylic acid ester, bisphenol A epoxy (meth) acrylate obtained by epoxy ring-opening reaction of bisphenol A diglycidyl ether and (meth) acrylic acid, tetrabromobisphenol A diglycidyl ether and (meth) Tetrabromobisphenol A epoxy (meth) acrylate, bisphenol F diglycidyl ether and (meth) obtained by epoxy ring-opening reaction with acrylic acid Bisphenol F epoxy (meth) acrylate obtained by epoxy ring-opening reaction with crylic acid, tetrabromobisphenol F epoxy (meth) acrylate obtained by epoxy ring-opening reaction of tetrabromobisphenol F diglycidyl ether and (meth) acrylic acid Etc.

  Commercially available unsaturated monomers having such a structure include Biscote # 700 and # 540 (above, manufactured by Osaka Organic Chemical Industry Co., Ltd.), Aronix M-208, M-210 (above, Toagosei Co., Ltd.) ), NK ester BPE-100, BPE-200, BPE-500, A-BPE-4 (above, Shin-Nakamura Chemical Co., Ltd.), light ester BP-4EA, BP-4PA, epoxy ester 3002M, 3002A 3000M, 3000A (above, manufactured by Kyoeisha Chemical Co., Ltd.), KAYARAD R-551, R-712 (above, manufactured by Nippon Kayaku Co., Ltd.), BPE-4, BPE-10, BR-42M (above, No. 1) Manufactured by Ichi Kogyo Seiyaku Co., Ltd.), Lipoxy VR-77, VR-60, VR-90, SP-1506, SP-1506, SP-1507, SP-1509, SP 1563 (manufactured by Showa High Polymer Co., Ltd.), NEOPOL V779, NEOPOL V779MA (manufactured by Japan U-PICA Co., Ltd.), and the like.

  Furthermore, as a trifunctional or higher functional (meth) acrylate unsaturated monomer, a trihydric or higher polyhydric alcohol (meth) acrylate such as trimethylolpropane litho (meth) acrylate, pentaerythritol tri (meth) acrylate or trimethylol. Propane trioxyethyl (meth) acrylate, tris (2-acryloyloxyethyl) isocyanurate, etc. are listed, and commercially available products include Aronix M305, M309, M310, M315, M320, M350, M360, M408 (and above, Toagosei) Made by Co., Ltd., Biscoat # 295, # 300, # 360, GPT, 3PA, # 400 (Osaka Organic Chemical Co., Ltd.), NK ester TMPT, A-TMPT, A-TMM-3, A- TMM-3L, A-TMMT (above, Shinnaka Chemical Co., Ltd.), Light Acrylate TMP-A, TMP-6EO-3A, PE-3A, PE-4A, DPE-6A (above, Kyoeisha Chemical Co., Ltd., KAYARAD PET-30, GPO-303, TMPTA) , TPA-320, DPHA, D-310, DPCA-20, DPCA-60 (manufactured by Nippon Kayaku Co., Ltd.) and the like.

  In addition, a urethane (meth) acrylate oligomer may be blended. Examples of urethane (meth) acrylates include polyether polyols such as polyethylene glycol and polytetramethyl glycol; succinic acid, adipic acid, azelaic acid, sebacic acid, phthalic acid, tetrahydro (anhydrous) phthalic acid, hexahydro (anhydrous) phthalic acid Obtained by reaction of a dibasic acid such as ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, etc. Polyester polyol, polyε-caprolactone-modified polyol; polymethylvalerolactone-modified polyol; ethylene glycol, propylene glycol, 1,4-butanediol, Alkyl polyols such as 1,6-hexanediol and neopentyl glycol; bisphenol A skeleton alkylene oxide modified polyols such as ethylene oxide-added bisphenol A and propylene oxide-added bisphenol A; bisphenol F skeleton alkylene such as ethylene oxide-added bisphenol F and propylene oxide-added bisphenol F Oxide-modified polyols or mixtures thereof and organic polyisocyanates such as tolylene diisocyanate, isophorone diisocyanate, hexamethylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, etc. Manufactured from hydroxy group-containing (meth) acrylate And urethane (meth) acrylate oligomers. A urethane (meth) acrylate oligomer is preferable for maintaining the viscosity of the curable composition of the present invention moderately.

  As commercially available monomers of these urethane (meth) acrylates, for example, Aronix M120, M-150, M-156, M-215, M-220, M-225, M-240, M-245, M-270 ( As mentioned above, manufactured by Toagosei Co., Ltd.), AIB, TBA, LA, LTA, STA, Viscoat # 155, IBXA, Viscoat # 158, # 190, # 150, # 320, HEA, HPA, Viscoat # 2000, # 2100, DMA, biscort # 195, # 230, # 260, # 215, # 335HP, # 310HP, # 310HG, # 312 (above, manufactured by Osaka Organic Chemical Industry Co., Ltd.), Light Acrylate IAA, LA, SA , BO-A, EC-A, MTG-A, DMP-A, THF-A, IB-XA, HOA, HOP-A, HOA-M L, HOA-MPE, light acrylate 3EG-A, 4EG-A, 9EG-A, NP-A, 1,6HX-A, DCP-A (manufactured by Kyoeisha Chemical Co., Ltd.), KAYARADTC-110S, HDDA, NPGDA, TPGDA, PEG400DA, MANDA, HX-220, HX-620 (Nippon Kayaku Co., Ltd.), FA-511A, 512A, 513A (Hitachi Chemical Co., Ltd.), VP (BASF) ACMO, DMAA, DMAPAA (manufactured by Kojin Co., Ltd.) and the like.

  The urethane (meth) acrylate oligomer is obtained as a reaction product of (a) hydroxy group-containing (meth) acrylate, (b) organic polyisocyanate and (c) polyol, but (a) hydroxy group-containing (meth). A reaction product obtained by reacting an acrylate with (b) an organic polyisocyanate and then (c) a polyol is preferable.

  The above unsaturated monomers may be used alone, or a plurality of types may be mixed as necessary.

  Examples of photo radical polymerization initiators include acetophenone, acetophenone benzyl ketal, 1-hydroxycyclohexyl phenyl ketone, 2,2-dimethoxy-2-phenylacetophenone, xanthone, fluorenone, benzaldehyde, fluorene, anthraquinone, triphenylamine, carbazole 3-methylacetophenone, 4-chlorobenzophenone, 4,4′-dimethoxybenzophenone, 4,4′-diaminobenzophenone, Michler's ketone, benzoin propyl ether, benzoin ethyl ether, benzyldimethyl ketal, 1- (4-isopropylphenyl)- 2-hydroxy-2-methylpropan-1-one, 2-hydroxy-2-methyl-1-phenylpropan-1-one, thioxanthone, diethyl Oxanthone, 2-isopropylthioxanthone, 2-chlorothioxanthone, 2-methyl-1- [4- (methylthio) phenyl] -2-morpholino-propan-1-one, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, Examples thereof include bis- (2,6-dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxide, ethyl-2,4,6-trimethylbenzoylethoxyphenylphosphine oxide, and the like.

  Commercially available radical photopolymerization initiators include, for example, Irgacure 184, 369, 651, 500, 819, 907, 784, 2959, CGI 1700, CGI 1750, CGI 11850, CG 24-61, Darocurl 116, 1173 (above, Ciba Specialty Chemicals ( Co., Ltd.), Lucirin LR8728, 8893X (manufactured by BASF), Ubekrill P36 (manufactured by UCB), KIP150 (manufactured by Lamberti), and the like. Among these, Lucirin LR8883X is preferable from the viewpoint of being liquid and easily dissolved and having high sensitivity.

  The radical photopolymerization initiator is preferably blended in the total composition in an amount of 0.01 to 10% by weight, particularly 0.5 to 7% by weight. The upper limit of the blending amount is preferably in this range from the viewpoints of the curing characteristics of the composition, the mechanical properties and optical characteristics of the cured product, handling, and the like, and the lower limit of the blending amount is preferably in the range of preventing a decrease in the curing rate.

  The composition of the present invention may further contain a photosensitizer. Examples of the photosensitizer include triethylamine, diethylamine, N-methyldiethanolamine, ethanolamine, 4-dimethylaminobenzoic acid, 4-dimethyl Examples include methyl aminobenzoate, ethyl 4-dimethylaminobenzoate, isoamyl 4-dimethylaminobenzoate and the like, and examples of commercially available products include Ubekryl P102, 103, 104, 105 (manufactured by UCB). .

  Further, in addition to the above components, various additives as necessary include, for example, antioxidants, ultraviolet absorbers, light stabilizers, silane coupling agents, coating surface improvers, thermal polymerization inhibitors, leveling agents, surfactants. Colorants, storage stabilizers, plasticizers, lubricants, solvents, fillers, anti-aging agents, wettability improvers, mold release agents, and the like can be blended as necessary.

  Here, examples of the antioxidant include Irganox 1010, 1035, 1076, 1222 (manufactured by Ciba Specialty Chemicals Co., Ltd.), Antigen P, 3C, FR, GA-80 (manufactured by Sumitomo Chemical Co., Ltd.). Examples of the ultraviolet absorber include Tinuvin P, 234, 320, 326, 327, 328, 329, 213 (manufactured by Ciba Specialty Chemicals Co., Ltd.), Seesorb 102, 103, 110, 501; 202, 712, 704 (above, manufactured by Sipro Kasei Co., Ltd.) and the like. Examples of the light stabilizer include Tinuvin 292, 144, 622LD (above, manufactured by Ciba Specialty Chemicals Co., Ltd.), Sanol LS770 ( Sankyo Co., Ltd.), Sumisorb TM-0 1 (manufactured by Sumitomo Chemical Co., Ltd.) and the like. Examples of the silane coupling agent include γ-aminopropyltriethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, commercially available Examples of the product include SH6062, 6030 (above, manufactured by Toray Dow Corning Silicone Co., Ltd.), KBE903, 603, 403 (above, manufactured by Shin-Etsu Chemical Co., Ltd.) and the like. Examples include silicone additives such as dimethylsiloxane polyether and nonionic fluorosurfactants, and commercially available silicone additives include DC-57, DC-190 (above, manufactured by Dow Corning), SH-28PA, SH-29PA, SH-30PA, SH-190 (above, Toray Dow Corning Silicone Co., Ltd.), KF351, KF352, KF353, KF354 (above, manufactured by Shin-Etsu Chemical Co., Ltd.), L-700, L-7002, L-7500, FK-024-90 (above, Nihon Unicar Co., Ltd.) )), Non-ionic fluorosurfactants commercially available as FC-430, FC-171 (above 3M Co., Ltd.), MegaFuck F-176, F-177, R-08, F780 (above Dainippon) Ink Co., Ltd.) and the like, and the release agent includes Prisurf A208F (Daiichi Kogyo Seiyaku Co., Ltd.).

  The organic solvent for adjusting the viscosity of the resin liquid of the present invention may be any organic solvent that can be mixed without unevenness such as precipitates, phase separation, and cloudiness when mixed with the resin liquid. For example, acetone, methyl ethyl ketone, Examples thereof include methyl isobutyl ketone, ethanol, propanol, butanol, 2-methoxyethanol, cyclohexanol, cyclohexane, cyclohexanone, toluene, and the like.

  When an organic solvent is added, it is necessary to dry and evaporate the organic solvent during the manufacturing process of the product. However, if a large amount of residual solvent remains in the product, the mechanical properties of crystallization deteriorate. There is also a concern that the organic solvent evaporates and diffuses during use as a product, causing bad odor and adverse health effects. For this reason, organic solvents having a high boiling point are not preferable because the amount of residual solvent increases.

  However, if the boiling point is too low, it will evaporate violently, resulting in rough surface, condensation water adhering to the surface of the composition due to the heat of vaporization during drying, resulting in surface defects and vapor concentration. It becomes higher and the risk of ignition etc. increases.

  Therefore, the boiling point of the organic solvent is preferably 50 ° C. or higher and 150 ° C. or lower, and more preferably 70 ° C. or higher and 120 ° C. or lower. From the viewpoint of the solubility of the material and the boiling point, the organic solvent is preferably methyl ethyl ketone (bp. 79.6 ° C), 1-propanol (bp. 97.2 ° C) or the like.

  The amount of the organic solvent added to the resin solution of the present invention depends on the type of the solvent and the viscosity of the resin solution before the addition of the solvent. , 40% by weight or less, preferably 15% by weight or more and 30% by weight or less. If the amount of the organic solvent added is too small, the effect of reducing the viscosity and the effect of increasing the coating amount are small, and the coating property is not sufficiently improved.

  However, if the resin liquid is diluted too much, the viscosity is too low and the liquid flows on the sheet-like body to cause unevenness, or the liquid turns around the back surface of the sheet-like body. In addition, the drying process may not be sufficient, and a large amount of organic solvent may remain in the product, resulting in deterioration of product function, volatilization during product use, generation of bad odors, and adverse health effects. Occurs.

  The resin liquid of the present invention can be produced by mixing the above-mentioned components by a conventional method, and can be produced by heating and dissolving as necessary. The viscosity of the resin liquid thus prepared is usually 10 to 50000 mPa · s / 25 ° C.

  When the resin liquid is supplied to the sheet W or the embossing roller 13, if the viscosity is too high, it is difficult to supply the composition uniformly. When manufacturing a lens, uneven coating, undulation, and air bubbles are generated. For this reason, it becomes difficult to obtain the target lens thickness, and the lens performance cannot be fully exhibited.

  This tendency is particularly noticeable when the line speed is increased. Accordingly, in this case, the liquid viscosity is preferably low, preferably 10 to 100 mPa · s, and more preferably 10 to 50 mPa · s. Such a low viscosity can be adjusted by adding an appropriate amount of an organic solvent. Further, the viscosity can be adjusted by setting the temperature of the coating solution to be kept warm.

  On the other hand, if the viscosity after evaporation of the solvent is too low, it may be difficult to control the lens thickness when embossing with the embossing roller 13, and a uniform lens with a certain thickness may not be formed. A preferred viscosity is 10 to 3000 mPa · s. When an organic solvent is mixed, by providing a step of evaporating the organic solvent by heat drying or the like between the steps of supplying the resin solution and embossing with the embossing roller 13, the viscosity is low when the resin solution is supplied. Thus, when the embossing roller 13 is used for embossing, the organic solvent is dried and the embossing roller 13 can be uniformly embossed with a resin solution having a higher viscosity.

  In the case of a prism lens sheet, the cured product obtained by curing the resin liquid of the present invention with radiation particularly preferably has the following physical properties (refractive index, softening point).

  The refractive index is preferably 1.55 or more and more preferably 1.56 or more at 25 ° C. of the cured product. This is because when the refractive index at 25 ° C. of the cured product is less than 1.55, when a prism lens sheet is formed using this composition, sufficient front luminance may not be ensured.

  As a softening point, 40 degreeC or more is preferable and 50 degreeC or more is more preferable. This is because if the softening point is less than 40 ° C., the heat resistance may not be sufficient.

  Next, returning to FIG. 1, the operation of the embossed sheet manufacturing apparatus 10 will be described. The sheet W is sent out from the sheet-like body supply means 11 at a constant speed. The sheet W is fed into the application unit 12 and a resin liquid (resin material F) is applied to the surface of the sheet W. After the application, the resin liquid applied to the sheet W is dried by the drying means 19 and the solvent is evaporated.

  Next, the sheet W is fed into a forming unit composed of an embossing roller 13 and a nip roller 14. As a result, roller forming is performed while the continuously running sheet W is pressed by the rotating embossing roller 13 and the nip roller 14 at the 9 o'clock position of the embossing roller 13. That is, the sheet W is wound around the rotating embossing roller 13, and the unevenness on the surface of the embossing roller 13 is transferred to the resin material F while the air between the embossing roller 13 and the resin material F is sucked by the suction means 22.

  Thereby, the air that has entered between the embossing roller 13 and the resin material F is removed, and the resin material F adheres to the uneven shape on the surface of the embossing roller 13. Can transfer well.

  Next, in a state where the sheet W is wound around the embossing roller 13, the resin curing unit 15 transmits the sheet W and irradiates the resin liquid layer with radiation, thereby curing the resin liquid layer. Thereafter, the sheet W is peeled off from the embossing roller 13 by winding the sheet W around the peeling roller 16 at the 3 o'clock position of the embossing roller 13.

  In addition, although not shown in FIG. 1, in order to further accelerate hardening after peeling the sheet | seat W, radiation irradiation can also be performed again.

  The peeled sheet W is conveyed to the sheet take-up means 18 and the protective film H supplied from the protective film supply means 17 is supplied to the surface of the sheet W. It is wound up and stored by a winding roll.

  In this way, the resin layer is formed on the surface of the sheet W without unevenness, and further, the embossing by the embossing roller 13 is made stable and uniform. Thereby, the uneven | corrugated sheet | seat in which the regular fine uneven | corrugated pattern was formed in the surface can be manufactured with high quality without a defect. FIG. 4 shows a schematic cross-sectional shape of the sheet W (concavo-convex sheet).

  Next, other embodiment (2nd Embodiment) of the manufacturing method of the uneven | corrugated sheet | seat based on this invention is described. The basic configuration of the embossed sheet manufacturing apparatus 10 of this embodiment is substantially the same as that of the first embodiment described above. Therefore, only the differences will be described in detail.

  FIG. 5 is a configuration diagram illustrating a main part of the resin sheet manufacturing apparatus 10 according to the present invention, and corresponds to FIG. 2 of the first embodiment. In addition, the same code | symbol is attached | subjected about the same and similar member as 1st Embodiment shown by FIG.1 and FIG.2, and the description is abbreviate | omitted.

  In FIG. 5, instead of the suction means 22 of the first embodiment, a wind shield plate 34 as a wind shield member is provided. The wind shield plate 34 is a plate-like member formed in the width direction of the embossing roller 13 so as to have substantially the same length as the embossing roller 13. The windshield plate 34 has a base end supported by an apparatus main body (not shown), and is arranged so as to maintain a predetermined clearance (for example, 0.1 mm) between the surface of the embossing roller 13. .

  By configuring the wind shielding plate 34 in this manner, the air entrainment due to the rotation of the embossing roller 13 can be minimized. Therefore, air can be efficiently prevented from being caught between the embossing roller 13 and the resin material F, and the uneven shape of the embossing roller 13 can be accurately transferred to the resin material F.

  When the uneven shape of the embossing roller 13 is relatively rough, for example, when the pitch or step of the uneven shape is on the order of mm, the planar shape of the tip portion of the wind shield plate 34 is formed on the surface of the embossing roller 13. By forming the concavo-convex shape following the shape, the tip of the wind shield plate 34 can be brought close to the limit where it does not come into contact with the surface of the embossing roller 13, and air entrainment can be minimized.

  Next, still another embodiment (third embodiment) of the method for producing an uneven sheet according to the present invention will be described. The basic configuration of the embossed sheet manufacturing apparatus 10 of this embodiment is substantially the same as that of the first embodiment described above. Therefore, only the differences will be described in detail.

  FIG. 6 is a configuration diagram showing a main part of the resin sheet manufacturing apparatus 10 according to the present invention, and corresponds to FIG. 2 and the second embodiment (FIG. 5) of the first embodiment. In addition, the same code | symbol is attached | subjected about the same and similar member as 1st Embodiment shown by FIG.1 and FIG.2, and the description is abbreviate | omitted.

  In FIG. 6, instead of the suction means 22 of the first embodiment, a wind shielding roller 36 as a wind shielding member is provided. The wind shield roller 36 is a roller member formed in the width direction of the embossing roller 13 so as to have substantially the same length as the embossing roller 13. The wind shield roller 36 is supported by an apparatus main body (not shown), and is arranged so as to maintain a predetermined clearance (for example, 0.1 mm) between the surface of the embossing roller 13.

  By configuring the wind-shielding roller 36 in this way, air entrainment due to the rotation of the embossing roller 13 can be minimized. Therefore, air can be efficiently prevented from being caught between the embossing roller 13 and the resin material F, and the uneven shape of the embossing roller 13 can be accurately transferred to the resin material F.

  When the uneven shape of the embossing roller 13 is relatively rough, for example, when the pitch or step of the uneven shape is on the order of mm, the peripheral surface shape of the wind shielding roller 36 is changed to the uneven shape formed on the surface of the embossing roller 13. By forming the concavo-convex shape, the tip of the wind-shielding roller 36 can be brought close to the limit where it does not come into contact with the surface of the embossing roller 13, and air entrainment can be minimized.

  The wind shield roller 36 can exhibit a predetermined effect even if it is configured to be rotatable or a simple bar-like member that does not rotate. Further, in the case of a structure that can rotate, it may be a driven type that can simply rotate even if there is a drive mechanism.

  As mentioned above, although the example of embodiment of the manufacturing method of the uneven | corrugated sheet | seat which concerns on this invention was demonstrated, this invention is not limited to the example of the said embodiment, Various aspects can be taken.

  For example, in the example of the present embodiment, the suction means 22 and two types of wind shielding members (the wind shielding plate 34 and the wind shielding roller 36) are employed, but other similar configurations may be employed.

  Moreover, in the example of this embodiment, the aspect which uses the roller-shaped embossing roller 13 was employ | adopted, However, the aspect using the uneven | corrugated pattern (embossed shape) formed in the surface of belt-like bodies, such as an endless belt, is also used. Can be adopted. This is because even such a belt-like body acts in the same manner as a cylindrical roller, and the same effect can be obtained.

The block diagram which shows the structure of the manufacturing apparatus of the embossed sheet | seat with which this invention is applied The side view explaining the suction means provided in the manufacturing apparatus of the resin sheet of this invention Sectional view showing the outline of the embossing roller Sectional view showing the outline of the embossed sheet The side view explaining the windshield provided in the manufacturing apparatus of the resin sheet of this invention The side view explaining the wind-shielding roller provided in the manufacturing apparatus of the resin sheet of this invention The conceptual diagram which shows the structure of the manufacturing apparatus of the embossed sheet of a prior art example The conceptual diagram which shows the other structure of the manufacturing apparatus of the embossed sheet | seat of a prior art example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Embossed sheet manufacturing apparatus, 11 ... Sheet supply means, 12 ... Application means, 13 ... Embossing roller, 14 ... Nip roller, 15 ... Resin curing means, 16 ... Release roller, 17 ... Protective film supply means, 18 ... Sheet winding Removing means, 22 ... suction means, 34 ... wind shield plate, 36 ... wind shield roller, H ... protective film, W ... sheet

Claims (6)

In the method for producing a concavo-convex sheet by transferring the concavo-convex on the surface of the concavo-convex roller to the surface of the sheet-like body,
The belt-like flexible sheet-like body in which the resin liquid layer is formed on the surface by applying the resin liquid is continuously run,
The sheet-like body is pinched by the uneven roller and at least one nip roller disposed opposite to the uneven roller, and a wind shielding member is disposed on the upstream side of the uneven roller, and the uneven roller, the sheet-like body, Transferring the uneven shape of the uneven roller surface to the resin liquid layer while preventing air from being caught between
The method for producing a concavo-convex sheet, comprising curing the resin liquid layer in a state where the sheet-like body is wound around the concavo-convex roller. The resin solution is a radiation curable resin solution, the manufacturing method of the indented sheet according to claim 1 Symbol placement curing of the resin solution layer is characterized by being made by subjecting the radiation to the resin solution layer. The method for producing a concavo-convex sheet according to claim 1 or 2 , wherein a pitch of the concavo-convex pattern transferred and formed on the sheet-like body is 100 µm or less. The said uneven | corrugated sheet | seat is used as an optical film, The manufacturing method of the uneven | corrugated sheet | seat of any one of Claims 1-3 characterized by the above-mentioned. Sheet-like body supply means for feeding out a belt-like flexible sheet-like body;
Application means for applying a resin liquid to the surface of the sheet-like body;
The continuous sheet-like body is wound around a rotating concavo-convex roller and sandwiched between at least one nip roller disposed opposite to the concavo-convex roller, and the concavo-convex surface of the concavo-convex roller is transferred to the surface of the sheet-like body. Transfer means to form;
A resin liquid curing means for curing the resin liquid in a state where the sheet-like body is wound around the uneven roller;
A wind-shielding means provided on the upstream side of the concavo-convex roller to prevent air from being caught between the concavo-convex roller and the sheet-like body;
An apparatus for producing an uneven sheet, comprising: 6. The apparatus for producing a concavo-convex sheet according to claim 5 , wherein the resin liquid curing means is radiation irradiation means provided in the vicinity of the concavo-convex roller.

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