JP5293318B2 - Intermittent film forming method and intermittent film forming apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a film molding method and a film molding apparatus by which a continuous film is supplied to the film molding apparatus while being successively rewound and a fine rugged shape can be intermittently press-formed on a film surface and further foreign matter adhesion and transportation scratch on a molded surface can be suppressed at a film transportation process after molding. <P>SOLUTION: The intermittent film molding method at least includes: a supply process for intermittently supplying a molding film near a metallic mold surface; a molding process for molding a shape corresponding to the shape of the metallic mold surface on one surface of the molding film by bringing the molding film into contact with the metallic mold and pressing it; and a mold releasing process for releasing the molding film stuck to the metallic mold surface after molding and transporting it. In the mold releasing process, the molding film is released from the metallic mold while being held, and then a first protective film is laminated on the one surface without bringing anything into contact with the one surface of the molding film. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention provides, for example, a molding method for intermittently press-molding fine irregularities on the surface of the molding film by supplying a continuous molding film in a roll shape to a molding apparatus while sequentially rewinding the film. And a molding apparatus.

  In particular, the present invention relates to an intermittent film forming method and an intermittent film forming apparatus for laminating a protective film for the purpose of preventing scratches and foreign matter adhesion to a forming film released from a mold after press forming.

  As a means for producing an optical film such as a light guide plate, a light diffusing plate, and a lens, a method of transferring a fine uneven pattern on the surface of the film has been conventionally known.For example, for a roll-like long film, An apparatus and a method for intermittently forming fine concavo-convex patterns have been proposed (Patent Document 1, Patent Document 2).

  In these apparatuses and methods, the concavo-convex pattern is formed on the film surface by press-transferring the film supplied from the unwinding roll into the press apparatus to a die having a fine concavo-convex pattern. When press-transferring, the mold is heated to a temperature equal to or higher than the glass transition point of the film. After the transfer is completed, the mold is cooled under a certain condition while continuing the press. When the cooling proceeds to below the glass transition point of the film, the press pressure is released and the film is released from the mold only by applying a certain tension to the film. Thereafter, the film is sent downstream, the film forming surface to be formed next is supplied to the mold surface, and press transfer is repeated.

  Moreover, as a method of releasing the film from the mold and supplying it, the peeling roll and the auxiliary roll arranged in parallel are rotated on the surface of the mold after the transfer while the film is held and held downstream. Have been proposed (Patent Document 3 and Patent Document 4).

JP 2005-199455 A Japanese Patent Laying-Open No. 2005-310286 JP 2008-105407 A JP 2008-105409 A

  However, when intermittent film formation and release conveyance are performed by these methods, foreign matters may adhere to the film forming surface during the conveyance process after molding, or scratches may occur, which is a factor in reducing the yield. It was. Moreover, when a base material with low rigidity, such as a thin film, is applied, the film often wrinkles during the conveyance process after molding, which has been a factor in reducing the yield. In order to solve these problems, it is easy to laminate a protective film before winding or to remove foreign matter on the film surface with a cleaner device. However, it has not been possible to completely eliminate foreign matter adhesion, conveyance scratches, wrinkles and the like that may occur until the film released from the mold is introduced into the laminating apparatus or the cleaner apparatus.

  The present invention was obtained as a result of diligent studies to solve the above-mentioned problems, and was obtained by supplying a continuous film to a molding apparatus while sequentially rewinding, thereby forming a fine uneven shape on the film surface. The present invention relates to a molding method and a molding apparatus that intermittently perform press molding, and aims to suppress foreign matter adhesion and conveyance scratches on a molding surface in a film conveyance process after molding.

The intermittent film forming method of the present invention that solves the above problems includes a supply step of intermittently supplying a forming film in the vicinity of the mold surface, and contacting and pressing the forming film against the mold, A molding step for molding a shape corresponding to the shape of the mold surface on one surface of the molding film, and a mold release for releasing and transporting the molding film after molding attached to the mold surface An intermittent film forming method including at least a step,
In the mold release step, after the mold is released from the mold while holding the mold film, the first surface is not contacted with the first surface of the mold film, and the first surface is then contacted with the first surface. It is characterized by laminating a protective film.

In addition, the intermittent film forming apparatus of the present invention that solves the above-described problems is a mold, a press device that presses the forming film against the surface of the mold, and the forming film is released from the surface of the mold. At the same time, the first protective film is laminated on the surface of the molded film that has been released, and then the mold supply device for supplying the molding film to be molded to the mold surface, and the molding film is conveyed. An intermittent film forming apparatus including at least a conveying device for
The release supply device sandwiches a peeling roll for peeling the molding film, a peeling roll driving means for rotationally driving the peeling roll, a molding film pass line and a first protective film pass line. An auxiliary roll arranged in parallel with the peeling roll, auxiliary roll biasing means for biasing the auxiliary roll so as to hold the molding film to the peeling roll, the molding film pass line and the first roll A laminating roll disposed in parallel with the peeling roll across the protective film pass line, protective film unwinding means for sending the protective film to the first protective film pass line, and a molding film on the peeling roll While maintaining the relative positional relationship for embracing, the peeling roll, the auxiliary roll, and the laminating roll are moved in the vicinity of the mold surface in parallel to the surface. With guides and which, at least,
The first protective film pass line is formed between the molding film pass line and the laminating roll.

  According to the intermittent film forming apparatus and the forming method of the present invention, when the protective film is released from the mold, it can be laminated almost at the same time, so that flaws on the transfer roll after release and adhesion of foreign matters in the transfer process can be suppressed. . Moreover, since rigidity improves by laminating | stacking a protective film, the conveyance wrinkle which was remarkable with the film for thin shaping | molding can be suppressed.

FIG. 1 is a schematic view of an embodiment of the intermittent film forming apparatus of the present invention viewed from the film width direction for forming. FIG. 2 is a schematic perspective view of a mold release supply device in an embodiment of the intermittent film forming apparatus of the present invention. FIG. 3 is a schematic view of a state in which a protective film is laminated on one surface of a molding film as viewed from the molding film width direction in an embodiment of the intermittent film molding apparatus of the present invention. FIG. 3 is a schematic view of a state in which protective films are laminated on both surfaces of the molding film as viewed from the molding film width direction in one embodiment of the intermittent film molding apparatus of the present invention. FIG. 5 is a schematic view of the operation of the press part in the molding process as seen from the film width direction for molding in one embodiment of the intermittent film forming method of the present invention. FIG. 6 is a schematic view of the operation of the press section in the mold release step as viewed from the film width direction for molding in one embodiment of the intermittent film forming method of the present invention. FIG. 7 is a schematic view of the operation of the press section in the supplying step as viewed from the width direction of the forming film in one embodiment of the intermittent film forming method of the present invention.

  A preferred embodiment of the present invention will be described in detail with reference to the drawings.

The intermittent film forming apparatus of the present invention includes a mold, a pressing device that presses the forming film against the surface of the mold, and the forming film is released from the surface of the mold and is released from the mold. A mold release supply device for laminating a first protective film on the surface of the molding film, and supplying a molding film to be molded next to the mold surface; and a conveying device for conveying the molding film; In an intermittent film forming apparatus including at least
The release supply device sandwiches a peeling roll for peeling the molding film, a peeling roll driving means for rotationally driving the peeling roll, a molding film pass line and a first protective film pass line. An auxiliary roll arranged in parallel with the peeling roll, auxiliary roll biasing means for biasing the auxiliary roll so as to hold the molding film to the peeling roll, the molding film pass line and the first roll A laminating roll disposed in parallel with the peeling roll across the protective film pass line, protective film unwinding means for sending the protective film to the first protective film pass line, and a molding film on the peeling roll While maintaining the relative positional relationship for embracing, the peeling roll, the auxiliary roll, and the laminating roll are moved in the vicinity of the mold surface in parallel to the surface. With guides and which, at least,
The first protective film pass line is configured between the molding film pass line and the laminating roll.

  FIG. 1 shows a schematic cross-sectional view of the intermittent film forming apparatus 1 of the present invention as viewed from the film width direction for forming. In the following, the case where the fine uneven shape is processed on the surface 3a of the mold 3 will be described, but the same applies to the case where other shapes are processed.

  As shown in FIG. 1, a first intermittent film forming apparatus 1 according to the present invention includes a press device 10 as the press device, an unwind unit 50 and a take-up unit 60 as the transport device, and a fine surface. The mold supply device 20 for releasing the molding film that is in close contact with the mold 3 on which the concavo-convex shape is formed and supplying the molding film to be molded next, and the heater unit for heating and cooling the mold 30 and a cooling unit 40.

  As an operation of the intermittent film forming apparatus 1, the surface 3 a on which the forming film 2 wound up in a roll shape by the unwinding unit 50 is unwound and the fine uneven shape of the mold 3 is processed by the pressing apparatus 10. , The shape corresponding to the shape of the surface of the mold 3, that is, the fine concavo-convex shape opposite to the fine concavo-convex shape of the mold 3 is transferred and molded to the molding surface 2 a of the molding film. Then, the molding film 2 to be transferred and molded next is unwound from the unwinding unit 50 while being wound into a roll. This operation is defined as one cycle, and unwinding, transfer molding, and winding are intermittently and sequentially repeated. The molding process is not limited to the heat molding method, and can be performed by a molding method using light, for example. In the case of not using the heat forming method, the heating unit 30 and the cooling unit 40 which are temperature control devices are not necessary in the apparatus and method of the present invention.

  An example of a mold release supply apparatus 20 having a protective film laminating mechanism, which is a characteristic part of the present invention, will be described with reference to the drawings.

  FIG. 2 shows a schematic perspective view of the entire mold release supply apparatus 20, and FIG. 3 shows a schematic view of the mold release supply apparatus 20 as seen from the film width direction for molding.

  The mold release supply device 20 includes a mold release moving unit 210 that reciprocates in the transport direction while gripping the mold surface so as to hold the film for molding, and a protective film supply unit 230 that supplies the first protective film 200. Composed. The release moving unit 210 includes a peeling roll 211, an auxiliary roll 212, a molding film path line through which the molding film 2 passes through the peeling roll, and a first protective film path through which the first protective film 200 passes. A laminating roll 213 and a guide roll 214 that are separated from each other across the line are connected via a frame 220 so that the unit linearly moving means 219 can reciprocate in the conveying direction (arrows A and B). On the other hand, the protective film supply unit 230 includes a protective film unwinding roll 231 and a guide roll 232.

  A peeling roll rotating means 215 is connected to the peeling roll 211. And it is comprised so that it can operate | move with the designated rotation speed to the direction of both forward rotation / reverse rotation by the command from the high-order controller which is not illustrated. For example, a configuration in which a servo motor is combined as the peeling roll rotating means and a servo amplifier is combined as the rotation controller is preferable. Further, the rotation of the peeling roll 211 is guided by a linear motion guide (not shown) so that it can smoothly move substantially parallel to the surface of the mold 3.

  The forming film contact portion of the peeling roll 211 is arranged so that the fine pattern shape on the mold surface is not damaged even if the forming film is supplied while contacting or pressing the mold surface. You may comprise the foamed sponge which has a silicone type resin or a fluororesin as a main component so that the roll surface may not deteriorate. As another configuration, a rubber material having a certain elasticity and adhesiveness may be used. In this case, for example, the rubber hardness (JIS K6253) is preferably 40 to 70, more preferably 50 to 60, and the surface center line average roughness (JIS B0601) is preferably 0.01 μm to 1.0 μm. More preferably, the thickness is in the range of 0.01 μm to 0.5 μm. Suitable materials include EPDM, silicone rubber, fluororubber and the like. If each roll has a rubber hardness greater than 70 or a centerline average roughness greater than 1 μm, the adhesion between the molding film and the roll may not be sufficient. When the slippage occurs and the peeling force decreases due to a decrease in the film tension for molding. On the other hand, when the rubber hardness is less than 40, the release operation becomes unstable due to large rubber deformation during the release operation. There is a possibility that a mold release mark may be generated on the surface of the molding film, so care must be taken. In addition, it is difficult in production that the center line average roughness is smaller than 0.01 μm.

  Further, when the molding film 2 is released, the peeling roll 211 and the mold surface may be in contact with each other. At this time, an elastic member such as an air cylinder or a spring is provided in the vicinity of both ends in the film width direction of the peeling roll 211 so that the pressing force on the mold surface of the peeling roll 211 can be controlled. It is preferable to use a biasing means. A high mold release effect can be obtained by contacting or pressing the mold surface.

  In the laminating roll 213, an air cylinder 221 is attached to the end in the roll longitudinal direction so that the laminating roll 213 can be separated from and attached to the peeling roll 211 with the molding film pass line and the first protective film pass line interposed therebetween. When releasing the mold while laminating the first protective film 200, the laminating roll is brought close to the peeling roll so as to nip the forming film. The nip pressure to the peeling roll is controlled by the air supply pressure to the air cylinder 221. The laminating roll 213 may hold the shaft end so that it can freely rotate around the roll axis, or may be configured to rotate at the same peripheral speed in synchronism with the peeling roll rotating means 215. good. As a means for synchronizing, it is preferable to mechanically connect using a gear, a belt, or the like, or to connect the servo motor to the end of each rotating shaft and perform synchronous control so that the rotation amount is the same.

  In addition, the protective film contact portion of the laminate roll 213 is made of a foamed sponge mainly composed of a silicone resin or a fluorine resin so that the roll surface does not deteriorate with respect to the high-temperature molding film immediately after peeling from the mold. good. In addition, if a rubber material having a certain elasticity and adhesiveness is applied, the effect of uniformly laminating the first protective film 200 over the entire width while excluding air or the like is further enhanced, and further, the first protection It is possible to suppress the surface of the film 200 from being damaged. For example, the rubber hardness (JIS K6253) is preferably 50 to 90, more preferably 60 to 80, and the surface center line average roughness (JIS B0601) is preferably in the range of 0.01 μm to 1.0 μm, more preferably. Is preferably in the range of 0.01 μm to 0.5 μm. Suitable materials include EPDM, silicone rubber, fluororubber and the like. When the rubber hardness of each roll is greater than 90 or the center line average roughness is greater than 1 μm, the adhesiveness between the protective film and the roll is not sufficient, and therefore, between the base film and the protective film as the molding film. Air may be caught in the air and uniform lamination is difficult. On the other hand, when the rubber hardness is less than 50, since the rubber deformation during the laminating operation is large, the protective film is not laminated with sufficient force, which may cause a problem in that the adhesion force is lowered. In addition, although the lamination linear pressure per unit length in the film width direction for molding depends on the base material and the protective film to be used, the range of about 1 to 50 N / cm is generally in order to obtain appropriate adhesion and appearance uniformity. preferable.

  The auxiliary roll 212 is attached at its shaft end so that it can freely rotate around the roll axis. The material of the outer surface of the auxiliary roll 212 that comes into contact with the protective film may be the same surface material as that of the above-described peeling roll. In particular, when the frictional resistance with the molding film to be used is high, wrinkles are induced on the roll surface. Therefore, it is preferable to apply a fluororesin or metal having a highly slippery surface.

  The guide roll 214 is held by the frame 220 so as to freely rotate about the roll axis. The guide roll 214 plays a role of introducing the first protective film 200 into the laminating roll 213 at a constant angle and without any problem, and the outer surface in contact with the first protective film 200 is the roll being conveyed. In order to prevent the above wrinkles, a material having good sliding properties with the protective film, such as fluorine resin and metal, is preferable.

  The peeling roll 211, the auxiliary roll 212, the laminating roll 213, and the guide roll 214 described above are connected to the frame 220 to constitute the mold release moving unit 210, and the unit linear movement means 219 makes the unit near the mold surface. Are reciprocated in the transport direction (arrows A and B).

  Unit release means 219 such as a linear drive motor is connected to the release moving unit 210. For the unit linear motion means 219, it is preferable to synchronize the operation so that the rotational movement amount and the linear motion movement amount are the same as those of the peeling roll rotation drive means, so that a smooth operation can be obtained, and a servo motor drive is suitable. However, an electromagnetic actuator or a pneumatic actuator may be used. In the case of peeling the molding film 2, the unit roll is driven while the peeling roll 211 is rotated, and the first roll is moved by the laminating roll 213 while moving the release unit to the unwinding side. The protective film 200 is laminated. In addition, when the frictional force between the forming film 2 and the peeling roll 211 is sufficiently high, the linear force of the release unit can be obtained only by the frictional force and the forming film tension. good.

  Furthermore, when the surface unevenness pattern of the mold is very fine and is easily damaged by contact with the peeling roll, the distance (clearance) between the peeling roll 211 and the mold surface shown in FIG. 5 mm is good, more preferably 0.1 mm to 1 mm.

  Moreover, a cooling water circulation mechanism etc. may be added to the peeling roll 211, the laminate roll 213, and the auxiliary roll 212, and each roll may be temperature-controlled to fixed temperature. Since the temperature of the molding film 2 is high immediately after release, it is preferable to keep the temperature of the peeling roll 211 and the auxiliary roll 212 that are in contact immediately after the mold release. Further, it has an effect of lowering the temperature of the molding film 2 at the time of mold release and immediately after the mold release, and is also effective for stable conveyance and winding after press molding.

  On the other hand, the unwinding driving means 233 is connected to the protective film unwinding roll 231 so that the first protective film 200 can be unwound while applying a constant tension during the laminating operation. A configuration in which torque control is performed based on data obtained by the means is preferable. Further, the guide roll 232 is held so as to freely rotate around the roll axis, and the outer surface in contact with the first protective film 200 is for preventing wrinkles on the roll during conveyance. A material having good sliding properties with the first protective film 200, such as fluorine resin or metal, is preferable.

  With the configuration described above, after the molding film 2 is released from the mold 3, the molding surface of the molding film 2 does not come in contact with any members of the molding apparatus, and the first protective film is brought into contact with the molding surface. 200 can be laminated, that is, when the molding film 2 is released from the mold, the first protective film 200 can be laminated almost at the same time. Can be suppressed. Moreover, since rigidity improves by laminating | stacking a protective film, the conveyance wrinkle which was remarkable with the film for thin shaping | molding can be suppressed.

  Further, the laminate of the protective film is not limited to only one side. The protective film laminating mechanism may include a plurality of protective film unwinding means so that the pass line of the second protective film 201 passes between the molding film pass line and the peeling roll 211. By comprising in this way, a protective film can be laminated on both surfaces of the film 2 for shaping | molding. FIG. 4 shows a schematic view of the mold release apparatus viewed from the molding film width direction when protective films are laminated on both surfaces of the molding film 2.

  The protective film unwinding roll 241 and the guide roll 242 are arranged on the outer surface of the peeling roll 211 so that the second protective film 201 is laminated on the opposite side of the first protective film 200 with the molding film 2 interposed therebetween. To do. The protective film unwinding roll 241 is torqued based on the winding diameter or data obtained by a tension detecting means (not shown) so that the film can be unwound while applying a constant tension to the second protective film 201 during the laminating operation. A drive configuration for controlling and controlling is preferable. On the other hand, the guide roll 242 is held by the frame 220 so as to freely rotate around the roll axis, and is incorporated in the mold release moving unit 210 so as to reciprocate in the conveyance direction (arrows A and B). To do. The outer surface that contacts the second protective film so as to be introduced at a constant angle with respect to the laminating roll 213 is made of a fluorine-based resin or the like in order to prevent wrinkles on the roll during transportation. A material such as metal that has good sliding properties with the protective film is preferable.

  Since the protective film can be laminated on both surfaces of the molding film 2 at substantially the same time as the molding film 2 is released from the mold 3 by the above apparatus configuration, the rigidity can be further improved as compared with the single-sided lamination. The effect of suppressing conveyance wrinkles can be enhanced.

  Below, apparatus structures other than a mold release supply apparatus are demonstrated using FIG.

  The press device 10 is connected to the press cylinder 12 so that the pressure plate (upper) 14a can be moved up and down using the column 11 as a guide. The support column 11 is disposed so as to be sandwiched between the frame (upper) 16a and the frame (lower) 16b. A temperature control plate (upper) 15a is attached to the lower surface of the pressure plate (upper) 14a. On the other hand, a temperature control plate (lower) 15b is attached to the upper surface of the pressure plate (lower) 14b. A heating unit 30 and a cooling unit 40 are connected to each temperature control plate via piping, wiring, and the like. And the metal mold | die 3 is attached to the upper surface of the temperature control plate (lower) 15b, and heating and cooling control are carried out via the lower temperature control plate. In addition, the metal mold | die 3 may be attached to the lower surface of the temperature control plate (upper) 15a.

  The press cylinder is connected to a hydraulic pump (not shown) and an oil tank, and the hydraulic pump controls the raising / lowering operation of the pressure plate (upper) 14a and the pressurizing force. In this embodiment, a hydraulic press cylinder is applied, but any mechanism can be used as long as it can control the applied pressure.

  The pressure range is preferably controllable in the range of 0.1 MPa to 20 MPa, more preferably 1 MPa and in the range of 10 MPa. If the pressure is 20 MPa or more, the mold may be damaged or deformed. If the pressure is 0.1 MPa or less, the resin does not flow sufficiently, and there is a possibility that shaping according to the pattern shape cannot be performed.

  The pressurization speed of the press cylinder is preferably controllable in the range of 0.01 MPa / s to 10 MPa / s, more preferably in the range of 0.05 MPa / s to 5 MPa / s. At the time of high pressure increase of 10 MPa / s or more, the deformation of the resin does not follow, and there is a possibility that shaping according to the pattern shape cannot be performed. Further, if the pressure is increased slowly at 0.01 Pa / s or less, molding takes time, and productivity is extremely reduced.

  In addition, when a temperature control plate is used so that even if there is a certain amount of thickness unevenness in the molding film, the temperature control plate (upper) 15a and the molding film 2 are 130 ° C. or higher. It is preferable to install an elastic plate 17 having a heat resistant temperature of. As the elastic plate 17, for example, ethylene / propylene / diene rubber (EPDM) having a thickness of 0.3 mm to 1.0 mm, silicone rubber, fluorine rubber, or the like can be preferably used. The thing which gave is good. Here, the heat resistant temperature refers to a temperature at which the rate of change in tensile strength when left at that temperature for 24 hours exceeds 10%.

  The mold 3 used in the present invention will be described. The transfer surface of the mold has a fine pattern, and methods for forming the pattern on the mold include machining, laser processing, photolithography, and electron beam drawing. Here, the fine concavo-convex shape formed on the mold is a convex shape that is periodically repeated with a height of 10 nm to 1 mm and a period of 10 nm to 1 mm. The height of the convex shape is more preferably 1 μm to 100 μm, and the period is more preferably 1 μm to 100 μm. As examples of convex shapes, protrusions of any shape typified by triangular pyramids, cones, quadrangular prisms, lens shapes, etc. are arranged in a discrete or dot shape, and the cross section is triangular, square, trapezoidal , Projections having an arbitrary shape typified by a semicircle, an ellipse and the like are arranged in a stripe shape. As a material of the mold, any material can be used as long as desired pressing strength, pattern processing accuracy, mold film releasability can be obtained. For example, metal materials including stainless steel, nickel, copper, etc., silicone, Glass, ceramics, resins, or those whose surfaces are coated with an organic film for improving mold release properties are preferably used. The fine pattern of the mold is formed corresponding to a fine uneven pattern desired to be imparted to the surface of the molding film.

  Next, the heating unit 30 will be described. The heating unit 30 is preferably a temperature control plate (upper), (lower) 15a, 15b made of an aluminum alloy and controlled by an electric heater cast in the plate. Further, the heating control may be performed by flowing a temperature-controlled heat medium into a copper or stainless steel pipe cast in the temperature control plate or a hole processed by machining. Furthermore, the apparatus structure which combined both may be sufficient.

As the heat medium, Barrel Therm (Matsumura Oil Co., Ltd.), NeoSK-OIL (Soken Techniques Co., Ltd.) or the like may be used, and water heated to 100 ° C. or higher may be circulated. And it is preferable that the number of lay nozzles in the pipe is in the range of 1.0 × 10 ^{4 to} 12 × 10 ⁴ so that heat can be transferred efficiently.

  Moreover, when using a cast heater, a cartridge heater, etc., it is preferable that the temperature control plate can be divided and controlled.

  It is preferable that the temperature control plate falls within a temperature distribution within 10 ° C., more preferably within 5 ° C., in the range during temperature increase, temperature decrease, and constant temperature control.

  Alternatively, the heat medium piping line may be processed directly on the mold to directly control the temperature of the mold.

  Next, the cooling unit 40 will be described. The cooling unit performs cooling control by flowing a temperature-controlled refrigerant body into copper or stainless steel pipes cast into temperature control plates (upper) (lower) 15a and 15b, or holes machined.

As the coolant, water is optimal, but an ethylene glycol solution or the like may be used. The temperature is preferably in the range of 10 ° C. to 50 ° C., and the number of lay nozzles in the pipe is preferably in the range of 1.0 × 10 ^{4 to} 12 × 10 ⁴ so that heat can be transferred efficiently.

  The unwinding unit 50 and the winding unit 60, which are the above-mentioned film forming apparatus for forming, will be described. The unwinding unit 50 includes an unwinding roll rotating means 51, transport rolls 52 a to 52 d, a drawing buffer unit 53, and a forming film fixing unit 54. The winding unit 60 includes a winding roll rotating means 61, conveyance rolls 62 a to 62 d, a winding buffer unit 63, a conveyance driving roll 64, and a forming film fixing unit 65.

  The drawer buffer unit 53 and the take-up buffer unit 63 are respectively composed of boxes 55 and 66 and suction / exhaust means 56 and 67 connected thereto. The suction / exhaust means 56, 67 may be any device that can suck and exhaust air, such as a vacuum pump. By exhausting the air in the box, a pressure difference is given between the front and back surfaces of the molding film inserted in the box. Thus, a certain tension is applied and the molding film is loosened and held in the box. The length of the forming film inserted into the box is appropriately the length of the forming film that is intermittently conveyed before and after forming the forming film. Further, sensors 57a, 57b, 68a, 68b are mounted in the boxes 55, 66. The sensor may be any sensor that can detect the molding film at a predetermined position. When the molding film is released and conveyed by the above-described release unit and the molding film is removed from the sensor detection position in the box, the upstream and downstream unwinding roll rotating means 51 or the winding roll rotating means 61 Is driven to unwind or wind up the molding film, and the molding film can always be loosened at a predetermined position in the box.

  In addition, the molding film fixing portions 54 and 65 are preferably flat plates having suction holes formed on the surface thereof, but may further have a mechanism for sandwiching the molding film with clips, or a combination thereof.

  The molding film fixing portions 54 and 65 are both operated when performing the pressing operation. And when releasing a molding film, it is preferable to operate the molding film fixing | fixed part 54, to fix a molding film, and to open the molding film fixing | fixed part 65. FIG. Further, when the forming film is sent from upstream to downstream, both the forming film fixing portions 54 and 65 are opened.

  Although not shown, the conveyance drive roll 64 is connected to a rotation driving means such as a motor, and when conveying the forming film, the nip roll 64a is close to the conveyance drive roll 64, sandwiches the forming film, and the conveyance drive roll 64 controls the torque. While performing, the film for forming is conveyed under a constant tension.

Next, the intermittent film forming method of the present invention will be described.
The intermittent film forming method of the present invention includes a supplying step of supplying a forming film intermittently in the vicinity of the mold surface, and contacting and pressing the forming film against the mold, At least a molding step for molding a shape corresponding to the shape of the mold surface on one surface, and a mold release step for releasing and transporting the molding film after molding adhered to the mold surface Including an intermittent film forming method comprising:
In the mold release step, after the mold is released from the mold while holding the mold film, the first surface is not contacted with the first surface of the mold film, and the first surface is then contacted with the first surface. This is a method of laminating a protective film.

  An embodiment in which the film forming operation is performed using the intermittent film forming apparatus 1 will be described with reference to FIGS. 5 to 7 are schematic cross-sectional views of only the operation of the press unit including the mold release supply device as seen from the width direction of the formed film. FIG. 5 shows the molding process, FIG. 6 shows the mold release process, and FIG. Shown in The series of molding operations is performed by the following processes (A) to (E). In addition, after setting the metal mold 3 in the press device 10 in advance, the molding film 2 is set in the unwinding unit 50, the unwinding part of the molding film 2 is pulled out, and the guide roller is used to place the inside of the pressing device. Along with the surface of the mold, the winding unit 60 is in a state of being wound up via a mold release supply device. Further, the heating unit is operated to raise both the temperature control plate (upper) 15a and the temperature control plate (lower) 15b to the molding temperature. In addition, following (A)-(C) is a shaping | molding process, (D) is a mold release process, (E) is a supply process.

  (A) The operation of the press section is shown in FIG. The press device 10 is operated to lower the temperature control plate (upper) 15a, and press is started so that the molding film is sandwiched between the surface of the mold 3 and the temperature control plate (upper). Conditions such as temperature, press pressure, pressurization speed, and pressurization time depend on the material of the forming film, the transfer shape, particularly the aspect ratio of the unevenness. In general, the molding temperature is set to 100 to 180 ° C., the press pressure is set to 1 to 10 MPa, the molding time is set to 1 second to 60 seconds, and the pressurization speed is set in the range of 0.05 MPa / s to 1 MPa / s.

  (B) The operation of the next press section is shown in FIG. During press molding, the cooling unit is operated to lower the temperature of the temperature control plate (upper) 15a and the temperature control plate (lower) 15b. In addition, it is preferable that pressurization is continued during cooling. The cooling temperature is set so that the mold surface temperature is sufficiently cooled to release the molding film. For example, the surface temperature of the mold 3 may be cooled to the glass transition point of the molding film or less. During this time, the holding of the molding film is continued.

  (C) The operation of the next press section is shown in FIG. After the cooling is completed, the press pressure is released, and the temperature control plate (upper) 15a is raised so that a sufficient space can be secured for the release moving unit 210 to move horizontally in the press apparatus.

  (D) Operations of the next press section are shown in FIGS. 6 (d) and 6 (e). The release moving unit 210 is moved upstream (in the direction of arrow A) by the unit linear motion means 219. At the same time, the peeling roll 211 is rotated by the peeling roll rotating means to release the molding film 2 from the mold 3, and further, the first film fed out from the released molding film 2 and the protective film unwinding roll 231. The protective film 200 is sandwiched between the peeling roll 211 and the laminating roll 213, and the first protective film 200 is laminated on the molding surface of the molding film 2. At this time, it is preferable to synchronize so that the peripheral speed of the peeling roll, the peripheral speed of the laminating roll, and the linear motion speed are the same so that the molding film 2 does not slip on the surface of the peeling roll 211.

  (E) The operation of the next press section is shown in FIGS. In order to prevent the peeling roll 211 and the laminating roll 213 from rotating, a brake is applied to the peeling roll rotating means 215 and the unit linear motion means 219 is moved downstream in the conveyance direction with a constant tension applied by the conveyance driving roll 64 on the downstream side ( Move by the length set in advance in the arrow B). By this operation, a molding film in a region to be molded next can be supplied to the mold surface. At this time, since the surface of the mold is high temperature, when a film under high tension is locally contacted, the film suddenly becomes high temperature and the strength is lowered at the contacted location. May occur and cause in-plane swells. Therefore, in order to prevent this in-plane undulation, it is preferable that the film supplied to the mold surface is in a state where tension is not applied as much as possible. Further, if wrinkles are present in the film supplied to the mold surface, the wrinkles may be formed without being sufficiently stretched in the subsequent pressurizing process, and linear wrinkle marks may remain on the molding surface. Therefore, it is preferable to supply the film without wrinkles on the mold surface. Alternatively, it is preferable to stretch the wrinkles simultaneously with the supply of the film or immediately after the supply.

  After the molding film 2 is released from the mold 3 by the above-described series of molding film molding operations, the molding surface does not come into contact with the molding surface of the molding film 2 without any contact of the molding apparatus members or the like. Since the first protective film 200 can be laminated, that is, the first protective film 200 can be laminated almost at the same time as the molding film 2 is released from the mold. Of foreign matter can be suppressed. Moreover, since rigidity improves by laminating | stacking a protective film, the conveyance wrinkle which was remarkable with the film for thin shaping | molding can be suppressed.

  In the above, the first protective film 200 is laminated only on one surface of the molding film 2 formed by the mold 2, but the second protective film 201 is the surface opposite to the molding surface of the molding film 2. Alternatively, the protective film may be laminated on both surfaces of the molding film 2. Both surfaces of the molding film 2 can be reliably protected from scratches and the like, and the effect of suppressing conveyance wrinkles is high. Note that the lamination of the protective films on both sides can be realized by the steps shown in (A) to (E) above by applying the mold release supply device shown in FIG.

  Further, when the laminating operation is stopped, the apparatus is adjusted or the operation is controlled so that the molding surface and the intermittent portion of the molding surface exist in the portion sandwiched between the laminating roll 213 and the peeling roll 211. Is preferred. This is because when the laminating operation stops intermittently, a stop mark that tends to occur in the width direction at the stop position is prevented.

  The film for molding applied to the method and apparatus of the present invention preferably has a glass transition temperature Tg of 40 to 180 ° C, more preferably 50 to 160 ° C, and most preferably 50 to 120 ° C. It is a film containing a certain thermoplastic resin as a main component. When the glass transition temperature Tg is lower than 40 ° C., the heat resistance of the molded product is lowered, and the shape changes with time. Also, if Tg exceeds 180 ° C, the molding temperature must be increased, resulting in inefficiency in energy, and volume fluctuation during heating and cooling of the sheet becomes large, and the film bites into the imprint mold. However, even if it can be released, it is not preferable because the transfer accuracy of the pattern may be reduced or the pattern may be partially broken to cause a defect.

  Specifically, the molding film mainly composed of the thermoplastic resin applied to the present invention is preferably a polyester resin such as polyethylene terephthalate, polyethylene-2, 6-naphthalate, polypropylene terephthalate, polybutylene terephthalate, polyethylene, Polyolefin resins such as polystyrene, polypropylene, polyisobutylene, polybutene, and polymethylpentene, polyamide resins, polyimide resins, polyether resins, polyester amide resins, polyether ester resins, acrylic resins, polyurethane resins, polycarbonates It is made of a base resin or a polyvinyl chloride resin. Among these, there are various types of monomers to be copolymerized, and it is particularly easy to adjust material properties, so that polyester resins, polyolefin resins, polyamide resins, acrylic resins, or mixtures thereof are used. It is preferable that the thermoplastic resin is mainly formed from the selected thermoplastic resin, and it is more preferable that the above-mentioned thermoplastic resin is 50% by weight or more.

  The film for molding applied to the present invention may be a film composed of the above-mentioned resin alone or a laminate composed of a plurality of resin layers. In this case, compared with a single film, surface characteristics such as slipperiness and friction resistance, mechanical strength, and heat resistance can be imparted. Thus, when it is a laminate composed of a plurality of resin layers, it is preferable that the entire film satisfies the above-mentioned requirements, but the layer as a whole satisfies at least the above-mentioned requirements even if it does not satisfy the above-mentioned requirements. If it is formed on the surface layer, the surface can be easily formed.

  Moreover, it is preferable that it is the range of 0.01-1 mm as preferable thickness (thickness, film thickness) of the film for shaping | molding applied to this invention. If the thickness is less than 0.01 mm, the thickness is not sufficient for molding, and if it exceeds 1 mm, the conveyance is generally difficult due to the rigidity of the film. In addition, in a molding film having a thickness of 0.05 mm or less, wrinkles are likely to occur due to insufficient film rigidity in the mold release conveyance process. Therefore, the apparatus and method of the present invention described above improve the rigidity by the laminated laminate structure, so that wrinkles are suppressed. It is effective for.

  In the above description, the molding film has been described as a thermoplastic resin, but the present invention can also be applied to a known intermittent molding apparatus and method in which a photocurable resin is used as a base material.

  Moreover, the protective film applied to this invention has a preferable thing which laminates | stacks with the film for shaping | molding, protects a shaping | molding surface pattern shape, and improves a conveyance property. For example, for a molding surface on which a fine uneven shape is formed, a two-layer laminate of an adhesive layer and a base material layer configured such that an adhesive layer is laminated on the molding film surface side can be mentioned. In addition to the two-layer laminate, other layers may be included.

Examples of the base material layer include polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyethylene film, polypropylene film, cellophane, diacetyl cellulose film, triacetyl cellulose film, acetyl cellulose butyrate film, polyvinyl chloride film, and polychlorinated chloride. Vinylidene film, polyvinyl alcohol film, ethylene-vinyl acetate copolymer film, polystyrene film, polycarbonate film, polymethylpentene film, polysulfone film, polyetheretherketone film, polyethersulfone film, polyetherimide film, polyimide film, fluorine Resin film, nylon film, acrylic resin film, etc. Rukoto can.
As such an adhesive layer, an acrylic, rubber-based, or silicone-based adhesive resin can be used.

  The protective film applied to the present invention may be a self-adhesive type. In particular, it is suitable as a protective film for non-molded surfaces and relatively smooth surfaces. For example, polyester-based resins such as polyethylene terephthalate and polybutylene terephthalate, polyolefin, polyamide, polycarbonate, acrylic resin, polyvinyl chloride, paper, etc. Examples thereof include a system (linear low density polyethylene) or the like formed on the surface as an adhesive layer.

  Moreover, as thickness of the protective film applied to this invention, the range of 20 micrometers-500 micrometers is preferable. When it is thinner than 20 μm, it is difficult to handle the protective film, and the effect of improving the rigidity when laminated with the molding film is small. On the other hand, when the thickness is larger than 500 μm, handling is difficult, and an increase in material cost becomes a problem.

1: intermittent film forming apparatus 2 of the present invention 2: film for molding 3: mold 10: press apparatus 20: release supply apparatus 30: heater unit 40: cooling unit 50: unwinding unit 60: winding unit 200: first 1 protective film 201: second protective film 210: mold release moving unit 211: peeling roll 212: auxiliary roll 213: laminating roll 231: first protective film unwinding roll 241: second protective film unwinding roll A : Unwinding direction B: Winding side direction

Claims (7)

A supply step of intermittently supplying a molding film in the vicinity of the mold surface;
A molding step of molding the shape corresponding to the shape of the mold surface on one surface of the molding film by bringing the molding film into contact with and pressing the mold; and
A mold release step of releasing and transporting the molded film after molding adhered to the mold surface, and an intermittent film molding method comprising at least
In the mold release step, after the mold is released from the mold while holding the mold film, the first surface is not contacted with the first surface of the mold film, and the first surface is then contacted with the first surface. An intermittent film forming method for laminating a protective film.   In the state in which the mold release step is held in both the peeling roll and the auxiliary roll while rotating both rolls of the peeling roll and the auxiliary roll arranged in parallel with the peeling roll. This is performed by moving the molding film from the downstream side to the upstream side in the vicinity of the mold surface in parallel with the mold surface, and the one surface of the molding film is in contact with the auxiliary roll. The intermittent film forming method according to claim 1, wherein the first protective film is laminated on the one surface before.   By sandwiching the molding film and the first protective film between the peeling roll and a laminating roll arranged in parallel with the peeling roll, the first film is formed on the one surface of the molding film. The intermittent film forming method according to claim 2, wherein one protective film is laminated.   The intermittent film-forming method according to any one of claims 1 to 3, wherein a second protective film is laminated on a surface opposite to the one surface of the molding film. Mold,
A pressing device for pressing a molding film against the surface of the mold;
In order to release the molding film from the surface of the mold, laminate the first protective film on the surface of the released molding film, and supply the molding film to be molded next to the mold surface A mold release supply device,
In an intermittent film forming apparatus including at least a conveying device for conveying a forming film,
The release supply device is
A peeling roll for peeling the molding film;
A peeling roll driving means for rotationally driving the peeling roll;
An auxiliary roll disposed in parallel with the peeling roll across the molding film pass line and the first protective film pass line;
An auxiliary roll biasing means for biasing the auxiliary roll so as to hold the film for molding on the peeling roll;
A laminating roll disposed in parallel with the peeling roll across the molding film pass line and the first protective film pass line;
Protective film unwinding means for delivering the protective film to the first protective film pass line;
A guide for moving the peeling roll, the auxiliary roll, and the laminating roll in the vicinity of the mold surface in parallel to the surface while maintaining a relative positional relationship for embracing the forming film to the peeling roll;
And an intermittent film forming apparatus configured such that the first protective film pass line is provided between the forming film pass line and the laminating roll.   6. The intermittent film forming apparatus according to claim 5, further comprising driving means for moving the peeling roll, the auxiliary roll, and the laminating roll in the vicinity of the mold surface in parallel with the surface.   The said mold release supply apparatus is provided with several protective film unwinding means, It is comprised so that there may be a 2nd protective film pass line between the said film pass line for shaping | molding and the said peeling roll. 6. The intermittent film forming apparatus according to 6.