JP5929207B2 - Manufacturing method of optical film - Google Patents

Description

  The present invention relates to various optical stop films used for flat panel displays and the like, and relates to a method for producing an antireflection film having a fine concavo-convex shape on the surface, for example, a moth-eye structure.

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

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

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

  By the way, it is desired that the manufacturing mold used for this type of molding be prevented from being scratched as much as possible, and therefore, it is generally manufactured using a hard material that is hardly scratched. However, the manufacturing mold according to the moth-eye structure must be made of a soft material that is easily damaged by producing a fine concavo-convex shape using anodization of aluminum. As a result, the manufacturing mold according to the moth-eye structure has a drawback of being easily damaged.

  In addition, the manufacturing mold according to the moth-eye structure has a remarkably fine structure related to the repetition period below the wavelength of visible light, and this also has a drawback that it is easily damaged as compared with the conventional molding mold. . Further, the allowable amount of scratches is much smaller than that of conventional molds for molding, and the optical properties of the optical film produced due to slight scratches are remarkably deteriorated.

  As a result, the metal mold related to the moth-eye structure has a problem that it needs to be handled while being markedly damaged when being stored and transported.

  In the roll plate, the substrate surface or the like may rub against the mold surface when the rotation is started at the start of production and when the rotation is stopped at the end of production. As described above, the mold according to the moth-eye structure is easily damaged, and thus may be damaged even when the substrate is rubbed on the surface at the start of production or at the end of production.

  As a result, it is necessary to handle molds related to the moth-eye structure with much greater attention not only at the time of storage and transport, but also at the start of production and at the end of production. was there.

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

  The present invention has been made in view of such a situation, and an optical film manufacturing method capable of significantly preventing scratches as compared with the related art with respect to a mold of an optical film related to a moth-eye structure or the like. The purpose is to provide.

  The present inventor repeated earnest research in order to solve the above-mentioned problems, and at the time of start-up or the like, in a state where the conveyance speed of the base material and the peripheral speed of the roll plate coincide with each other, a protective material such as a protective film is disposed, Or, by removing the protective material that has been arranged so far, except for the period when the conveyance speed of the base material and the peripheral speed of the roll plate coincide, the protective material protects the fine uneven shape. As a result, the present invention has been completed.

    Specifically, the present invention provides the following.

(1) Manufacture of an optical film that forms an optical film by shaping the uneven shape formed on the peripheral side surface to the base material by pressing the base material on the peripheral side surface of the roll plate while conveying the base material. In the method
Starting the rotation of the roll plate and the conveyance of the base material, starting the rotation of the roll plate and the conveyance of the base material to a steady state;
Producing the optical film in the steady state,
The starting step includes
In a state where a protective material for protecting the uneven shape of the peripheral side surface is arranged on the peripheral side surface of the roll plate, the rotation of the roll plate and the conveyance of the base material are started,
When the rotation of the roll plate and the conveyance of the base material rise to a steady state, a protective material removing step of removing the protective material is provided.

  According to (1), as represented by the first embodiment and the fourth embodiment, at the start of production, the roll plate is protected by a protective material, and the peripheral side surface of the roll plate is directly rubbed with a substrate or the like. This can prevent the roll plate from being damaged.

(2) In (1),
The protective material is an adhesive film wound around the peripheral side surface, the peripheral side surface side being an adhesive layer,
The protective material removing step includes
The protective material is attached to the base material and removed.

  According to (2), as represented by the first embodiment, for example, the protective material can be removed by conveying the base material 2 simply by folding the end portion and sticking it to the base material. The protective material can be removed.

(3) Manufacture of an optical film in which an optical film is produced by pressing the base material on the peripheral side surface of a roll plate while shaping the concave and convex shape formed on the peripheral side surface to the base material while conveying the base material. In the method
A step of producing the optical film while maintaining the rotation of the roll plate and the conveyance of the base material in a steady state;
A rotation step of stopping the rotation of the roll plate and the conveyance of the base material,
The stopping step includes
In the steady state, on the peripheral side surface of the roll plate, a protective material arranging step of arranging a protective material that protects the uneven shape of the peripheral side surface,
When the protective material is arranged in the protective material arranging step, the rotation of the roll plate and the conveyance of the base material are stopped.

  According to (3), as represented by the second, third, and fifth embodiments, at the end of production, the roll plate is protected by a protective material, and the peripheral side surface of the roll plate is directly covered by a substrate or the like. After avoiding rubbing, the rotation of the roll plate and the conveyance of the base material can be stopped, whereby the roll plate can be prevented from being damaged.

(4) In (3),
The protective material is an adhesive film in which the peripheral side surface is an adhesive layer;
The protective material arranging step includes
One end of the protective material is attached to the roll plate and wound around the roll plate by rotation of the roll plate.

  According to (4), as represented by the second embodiment, the protective material can be arranged by simply rotating the roll plate simply by sticking the end portion to the roll plate, and the protective material can be arranged easily and reliably. can do.

(5) In (3),
The protective material is an adhesive film in which the peripheral side surface is an adhesive layer;
The protective material arranging step includes
One end of the protective material is attached to the base material, and the protective material is wound around the roll plate by conveying the base material.

  According to (5), as represented by the third embodiment, the protective material can be wound around the roll plate and disposed by simply transporting the base material simply by sticking the end portion to the base material. A protective material can be disposed on the surface.

(6) In (1) or (3),
The protective material is a protective resin layer made of an ultraviolet curable resin.

  According to (6), as represented by the fourth to seventh embodiments, a protective material is simply arranged by applying a coating method, and further, the manufacturing process of the optical film is effectively used for protection. The material can be removed.

(7) In (1),
The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective material is
It is a protective resin layer made of UV curable resin,
The protective material removing step includes
The protective resin layer is attached to the substrate to remove the protective material.

  According to (7), as represented by the fourth embodiment, the protective material can be removed by effectively using the manufacturing process of the optical film.

(8) In (3),
The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective material is
It is a protective resin layer made of UV curable resin,
The protective material arranging step includes
The protective material is disposed by applying the material of the protective resin layer to the roll plate.

  According to (8), as represented by the fifth embodiment, the protective material can be provided by effectively using the optical film manufacturing material.

(9) In (3),
The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective resin layer is
It is a protective resin layer made of UV curable resin,
The protective material arranging step includes
The protective material is arranged on the roll plate through the base material by applying the material of the protective resin layer to the base material.

  According to (9), as represented by the sixth embodiment, the protective material can be provided by effectively using the optical film manufacturing material.

(10) In (3),
The substrate is
The lower layer and the upper layer UV curable resin are sequentially provided, and by forming the resin layer with the UV curable resin, the uneven shape formed on the peripheral side surface is formed,
The protective material arranging step includes
By stopping the application of the lower layer UV curable resin to the substrate and applying only the upper layer UV curable resin to the substrate, the upper layer UV curable resin through the substrate. Is applied to the roll plate, and the protective material is disposed on the roll plate.

  According to (10), as represented by the seventh embodiment, the protective material can be provided by effectively using the optical film manufacturing material.

(11) In (1), (2), (3), (4), (5), (6), (7), (8), (9), or (10),
The optical film is
It is an antireflection film having a moth-eye structure.

  According to (11), with respect to the mold of the antireflection film according to the moth-eye structure, it is possible to significantly prevent damage as compared with the conventional one.

  With respect to the mold of the optical film related to the moth-eye structure or the like, it is possible to prevent the damage significantly.

It is a figure which shows the antireflection film which concerns on 1st Embodiment of this invention. It is a figure which shows the manufacturing process of the antireflection film of FIG. It is a figure which shows the roll plate which concerns on the antireflection film of FIG. It is a figure where it uses for description of the roll plate of FIG. It is a figure where it uses for description of the surface shape of an antireflection film by contrast with the roll plate of FIG. It is a figure where it uses for description of protection of a roll plate. It is a figure with which it uses for description of roll plate protection at the time of starting. It is a figure which shows the continuation of FIG. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of roll plate protection which concerns on 2nd Embodiment. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of roll plate protection which concerns on 3rd Embodiment. It is a figure where it uses for description of roll plate protection which concerns on 4th Embodiment. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of roll plate protection which concerns on 5th Embodiment. It is a figure where it uses for description of roll plate protection which concerns on 6th Embodiment. It is a figure which shows the antireflection film which concerns on 7th Embodiment. It is a figure which shows the manufacturing process of the antireflection film of FIG.

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

  FIG. 2 is a diagram showing a manufacturing process of the antireflection film 1. In the manufacturing process 10, the ultraviolet curable resin 4 is applied to the substrate 2 by the die 12 in the resin supply process. In addition, about application | coating of the ultraviolet curable resin 4, not only the case by the die | dye 12 but various methods are applicable. Subsequently, in the molding process by the molding apparatus, the manufacturing process 10 presses and presses the substrate 2 against the peripheral side surface of the roll plate 13 which is an antireflection film manufacturing mold by the pressing roller 14. The ultraviolet curable resin 4 is brought into close contact with 2 and the ultraviolet curable resin 4 is sufficiently filled in the fine recesses formed on the peripheral side surface of the roll plate 13. In this manufacturing process, the ultraviolet curable resin 4 is cured by irradiating ultraviolet rays in this state, and thereby the uneven film 3 is produced. In this manufacturing process, the substrate 2 is subsequently peeled from the roll plate 13 via the peeling roller 15. In the production process 10, an anti-reflection film 1 is produced by producing an adhesive layer or the like on the substrate 2 as necessary and then cutting it into a desired size. As a result, the antireflection film 1 is mass-produced efficiently by sequentially molding the fine shape produced on the peripheral side surface of the roll plate 13 which is a mold for manufacturing the antireflection film, onto the long base material 2 made of a roll material. Is done.

  FIG. 3 is a perspective view showing the configuration of the roll plate 13. The roll plate 13 is formed on the peripheral side surface of the base metal, which is a cylindrical metal material, by using anodization of aluminum with a fine uneven shape with a repetition period equal to or less than the wavelength of visible light. Is molded into the substrate 2 as described above. For this reason, the base plate itself of the roll plate 13 is made of aluminum, or an aluminum layer is provided directly on the surface of the base material of copper or the like or through various intermediate layers. The roll plate 13 is manufactured by densely producing fine holes on the surface of the base material by repeating anodizing treatment and etching treatment, digging up the fine holes, and gradually increasing the diameter of the fine holes. Is done. Thereby, as shown in FIG. 4, the roll plate 13 is closely formed with fine holes whose hole diameter gradually decreases in the depth direction, and as shown in FIG. 5 by comparison with FIG. 4, the antireflection film 1. Then, a fine uneven shape corresponding to this fine hole is produced. In FIG. 4, the horizontal axis represents the circumferential direction θ and the rotation axis direction Y of the roll plate 13, and the vertical axis represents the radial direction r of the roll plate 13. In FIG. 5, the horizontal axis represents the in-plane directions X and Y of the antireflection film 1, and the vertical axis represents the thickness T.

[Protection of roll plate]
By the way, as described above, the roll plate produced in this way and used for shaping is markedly damaged compared to the conventional case not only during storage and conveyance, but also at the start of production and at the end of production. It is necessary to handle with care. FIG. 6 is a diagram for explaining roll plate protection according to this embodiment. In this 1st Embodiment, the protective film 21 is applied to the protective material of the roll plate 13, and this protective film 21 prevents the roll plate 13 from being damaged during storage and conveyance and at the start of production.

  Here, when the roll plate 13 is removed from the roll plate 13 manufacturing apparatus, the roll plate 13 is mounted on a rotating carriage. Here, the rotating carriage is a carriage that supports the roll plate 13 in a state where the roll plate 13 is rotatably supported by the rotation shafts at both ends and the peripheral side surface is floated. The roll plate 13 is mounted on the rotating carriage and transported and stored.

[Protection of Roll Plate in First Embodiment]
The roll plate 13 is such that the protective film 21 is wound around the peripheral side surface of the rotating carriage. Here, the protective film 21 is a variety of films such as PP (polypropylene), PE (polyethylene), PET, etc., and those that are difficult to wrinkle and have few irregularities that cause damage can be widely applied. Moreover, thickness can be selected as needed, for example in the range of 10 micrometers or more and 500 micrometers or less.

  In this embodiment, the protective film 21 is a single-sided adhesive film whose inner side surface (side surface of the roll plate 13) is an adhesive surface. In addition, the adhesive force of this adhesive surface can be set so that it may become larger than the adhesive force of the base material 2 with respect to the roll plate 13, and the convenience at the time of removing the protective film 21 mentioned later can be aimed at. In addition, by using the protective film 21 as an adhesive film, it is possible to improve the effect of preventing peeling during storage and the like, and further preventing the adhesion of foreign substances. Specifically, for example, Hitachi Chemical (registered trademark) manufactured by Hitachi Chemical Co., Ltd. can be applied to the protective film 21.

  The protective film 21 is wider than the width of the peripheral side surface of the roll plate 13 (the length of the peripheral side surface in the direction along the axis) and is longer than the length of the roll plate 13 that is wound once, and at the time of molding The roll plate 13 is rotated in the reverse direction, and one end is attached to the roll plate 13 and wound around the roll plate 13, and the winding end side end is arranged to overlap the winding start side end by a certain distance. Thereby, in this embodiment, when the roll plate 13 is transported and stored, the protective film 21 prevents damage to the roll plate 13 and adhesion of foreign matter or the like.

  FIG. 7 is a diagram for explaining a method for protecting the roll plate 13 at the time of activation by the protective film 21. In this step, the roll plate 13 is set in the shaping apparatus with the protective film 21 wound. At this time, in the shaping apparatus, the pressing roller 14 and the peeling roller 15 are held at positions away from the roll plate 13 as compared with the shaping time. In this state, the manufacturing process starts the conveyance of the base material 2, thereby starting the conveyance of the base material 2 by so-called paper threading and starting the rotation of the roll plate 13. Here, since the pressing roller 14 and the peeling roller 15 are held at separated positions, the substrate 2 is not pressed against the roll plate 13 around which the protective film 21 is wound in this paper threading state. The substrate 2 may partially come into contact with the protective film 21 in the process up to and through the paper threading. However, in this embodiment, even in such a case, the protective film 21 can prevent contact with the peripheral side surface of the roll plate 13. Thus, in this embodiment, the roll plate 13 is damaged by the protective film 21 until the paper is threaded, and foreign matter is prevented from being attached.

  As shown in FIG. 8, when the peripheral speed V13 of the roll plate 13 and the transport speed V2 of the base material 2 are equal to each other and become the speed at the time of molding (so-called steady state) as shown in FIG. In this manufacturing process, the pressing roller 14 and the peeling roller 15 are moved to the positions at the time of molding, thereby pressing the substrate 2 against the roll plate 13. At this time, since the circumferential speed V13 of the roll plate 13 and the transport speed V2 of the base material 2 are equal, the protective film 21 is simply pressed against the roll plate 13 by the base material 2 and has the same circumference as the roll plate 13. It will rotate by the speed V21, and the behavior which rubs the peripheral side surface of the roll plate 13 can be avoided effectively.

  This manufacturing process peels off the protective film 21 from the roll plate 13 as shown in FIG. At this time, in the protective film 21, the end portion of the winding end that overlaps at the beginning of the winding is folded back, and the protective film 21 is attached to the base material 2 by the adhesive force of the protective film 21 at this end portion. Is peeled off from the roll plate 13. Then, this manufacturing process moves to a production process, starts application of an ultraviolet curable resin, and starts a shaping process. It should be noted that the application of the ultraviolet curable resin may already be started at the time when the peeling of the protective film 21 is started. Further, the protective film 21 may be peeled off without being attached to the substrate 2. Accordingly, in this embodiment, the roll plate 13 is prevented from being scratched after paper threading and until the start of shaping, and as a result, it is significantly damaged compared to the conventional case at the time of storage and conveyance and at the start of production. Can be prevented.

  In this embodiment, the process management is performed so that one roll plate 13 processes the base material 2 for one roll, and at the end of production, the roll plate 13 is gradually damaged without considering any damage. The rotation speed of the roll plate 13 is reduced and the production is finished.

  In addition, when holding the protective film 21 on the roll plate 13 with an adhesive as described above, it is predicted that a residue of the adhesive remains on the peripheral side surface of the roll plate 13 after the protective film 21 is peeled off. There is a risk of adversely affecting the product. Therefore, in the case of an adhesive, by selecting a material that has good binding properties to the ultraviolet curable resin 4 applied to the base material 2, the residue is removed by the ultraviolet curable resin 4, and the adverse effect due to the residue is effective. Can be avoided. Specifically, the material having the same composition as the ultraviolet curable resin 4 can be applied to the adhesive to effectively avoid the influence of the residue.

  Here, in order to confirm the effect of the present embodiment, the protective film 21 was set on a roll plate without any scratches, and started without applying an ultraviolet curable resin, and a paper threading process was executed. Here, four of the five experiments were found to have scratches on the roll plate. The scratch was a scratch that gently curved. As a result, it was confirmed that the roll plate 13 was damaged at the time of startup. However, according to this embodiment, it has been found that such damage can be prevented.

  According to this embodiment, the protective material is disposed on the peripheral side surface of the roll plate for storage and conveyance, and at the start of production, the rotation of the roll plate and the conveyance of the substrate are started up in a steady state to remove the protective material. As a result, it is possible to significantly prevent the roll plate from being damaged as compared with the prior art.

  More specifically, by applying a protective film to the protective material, it is possible to easily and reliably prevent the roll plate from being damaged.

  Furthermore, the roll plate can be protected more reliably by sticking and protecting the protective film on the roll plate with the adhesive surface.

  As a result, it is possible to provide an optical film having a fine structure excellent in optical characteristics with no scratches on appearance. In addition, the yield can be improved and the handling of the roll plate can be simplified.

[Second Embodiment]
By the way, when the production amount of the antireflection film is small as compared with the life of the roll plate, the shaping process is stopped during the production and the rotation of the roll plate 13 is stopped. In this case, the peripheral side surface of the roll plate 13 may be rubbed with the base material 2, thereby damaging the roll plate 13. Therefore, in this embodiment, the roll plate 13 is prevented from being damaged even at the end of production. In this embodiment, the configuration is the same as that in the first embodiment except that the configuration at the end of production is different.

  FIG. 10 is a diagram for explaining the manufacturing process according to the second embodiment. Here, in this manufacturing process, one end of the protective film 21 made of the same single-sided adhesive film as in the first embodiment is attached to the roll plate 13 at a location where the production is not covered with the base material 2. In this state, this process makes the roll plate 13 go around and winds the protective film 21 around the roll plate 13 (see FIG. 11). In this case, after the application of the ultraviolet curable resin is finished, the end of the protective film 21 is attached to the roll plate 13, thereby preventing the outer surface of the protective film 21 from being soiled. Although the protective film 21 can be applied with the same configuration as that of the first embodiment, the fine unevenness formed on the peripheral side surface of the roll plate 13 by being pressed against the roll plate 13 by the rollers 14 and 15. A material having an adhesive layer with an adhesive strength that does not damage the shape and having a hardness that does not damage the shape can be applied. Further, a separator may be provided on the side opposite to the side surface of the adhesive layer so that the substrate 2 can be easily peeled off on the side of the peeling roller 15. Specifically, for example, Hitachi Chemical (registered trademark) manufactured by Hitachi Chemical Co., Ltd. can be applied to the protective film 21.

  In this way, when the protective film 21 is attached to the roll plate 13 and wound, the protective film 21 is applied to the roll plate 13 in a state in which the conveyance speed V2 of the substrate 2 and the peripheral speed V13 of the roll plate 13 coincide. By being wound, the protective film 21 is transported at the same transport speed V <b> 21 as the transport speed V <b> 2 of the substrate 2 and is wound around the roll plate 13. As a result, it is possible to effectively avoid the damage caused by winding the protective film 21 and winding the protective film 21 without applying any circumferential stress to the peripheral side surface of the roll plate 13.

  When the protective film 21 is wound around the roll plate 13 in this way, as shown in FIG. 11, the manufacturing process separates the rollers 14 and 15 from the roll plate 13 to stop the rotation of the roll plate 13 and the base material. 2 transport is stopped. Thereafter, the roll plate 13 is removed from the apparatus and placed on the rotating carriage. At this time, the end portion of the protective film 21 is peeled off, and the upper and lower relations at the beginning and end of winding of the protective film 21 are switched. As a result, at the start of subsequent production, the protective film 21 is removed as described above for the first embodiment. Make it peelable. Note that the switching of the vertical relationship between the start and end of winding may be performed when production is resumed.

  Here, in order to confirm the effect of the present embodiment, according to an experiment in which the protective film 21 is not placed and placed on a roll plate without scratches, and an ultraviolet curable resin is applied and subjected to a shaping process, the produced reflection In the prevention film, scratches corresponding to scratches that draw a gentle curve were found at the circumferential pitch of the roll plate 13. In this case, a region where many scratches (linear scratches having a length of about several mm) due to a mode different from this occurred was discovered. As a result, it was found that scratches occurred at the end of production. As for the roll plate, in addition to the fact that it was confirmed with the antireflection film, a large number of scratched areas were found along the entire width. Here, in the experiment described above with respect to the first embodiment, since such a flaw area was not found, it can be seen that such a flaw area occurred when production was stopped. However, in this embodiment, it has been found that such damage during production stop can be reliably prevented.

  According to the second embodiment, when the production is further stopped, the protective plate is arranged to stop the rotation of the roll plate. It is possible to prevent damage and adhesion of foreign matter.

  Moreover, when this protective material is a protective film, the roll plate can be reliably protected.

[Third Embodiment]
FIG. 12 is a diagram for explaining a manufacturing process according to the third embodiment of the present invention. Here, in this manufacturing process, the protective film 21 is attached to the substrate 2 and winding of the protective film 21 around the roll plate 13 is started. This embodiment has the same configuration as that of the second embodiment except for the configuration related to the start of winding.

  In this way, in order to start the winding by being attached to the base material 2, the protective film 21 is locally provided with an adhesive on the end on the side where the start of the winding starts and the base material 2 side. Here, this adhesive has an adhesive force between the substrate 2 and the protective film 21 so that the protective film 21 is wound around the roll plate 13 side when the substrate 2 is discharged on the peeling roller 15 side. The pressure is selected to be smaller than the adhesive strength of the roll plate 13 and the protective film 21 on the roll plate side. Instead of locally providing an adhesive layer on the protective film 21 as described above, an adhesive layer may be provided on the substrate 2. In addition, this protective film 21 can apply the structure similar to what was mentioned above in 2nd Embodiment except the structure regarding this adhesion layer.

  As a result, the protective film 21 is wound around the roll plate 13 by the rotation of the roll plate 13 (see FIG. 10). After the production process is stopped in the same manner as in the second embodiment (see FIG. 11), the roll is rolled. Place the plate on a rotating carriage.

  In this embodiment, the same effect as that of the first embodiment can be obtained even if the protective film is wound around the roll plate 13 by being attached to the substrate 2 side.

[Fourth Embodiment]
In this embodiment, instead of winding the protective film on the rotating carriage in the first embodiment, a protective resin layer is provided on the peripheral side surface of the roll plate by applying a protective resin. Prevents scratches and adhesion of foreign matter. In addition, the protective resin layer prevents the roll plate from being damaged at the start of production.

  For this reason, when the roll plate 13 is removed from the roll plate manufacturing apparatus, it is mounted on a rotating carriage, and a protective resin is applied to the peripheral side surface. As a result, as shown in FIG. 13, the roll plate 13 is formed with the protective resin layer 31 on the peripheral side surface. Here, as will be described later, the protective resin layer 31 is attached to the shaping resin material applied to the base material 2 at the start of production, and removed from the roll plate 13 to increase the adhesion strength to the roll plate. In comparison, a material having a high adhesion strength to the shaping resin is applied. More specifically, in this embodiment, the resin material is applied to the roll plate 13 and then cured by drying to produce the protective resin layer 31. If it can be sufficiently removed at the start of production, it may be cured by irradiation with ultraviolet rays.

  As this protective resin, for example, Metal Coat FC-121 manufactured by Fine Chemical Japan can be applied. Thereby, in this embodiment, when the roll plate 13 is transported and stored, the protective plate 31 prevents the roll plate 13 from being scratched and adhering to foreign matters.

  FIG. 14 is a diagram for explaining a method for protecting the roll plate 13 at the time of activation by the protective resin layer 31. In this step, the roll plate 13 is set in the shaping apparatus in the same manner as described above for the first embodiment, and then the conveyance of the base material 2 is started by paper threading and the rotation of the roll plate 13 is started. Here, in this embodiment, since the protective resin layer 31 is formed on the peripheral side surface of the roll plate 13, the roll plate 13 is damaged by the protective resin layer 31 and foreign matter adheres until the paper is threaded. Is prevented.

  When the peripheral speed of the roll plate 13 and the conveying speed of the base material 2 are equal to each other and the speed at the time of molding is set (in a so-called steady state), the manufacturing process includes the pressing roller 14 and The peeling roller 15 is moved to the position at the time of molding, thereby pressing the substrate 2 against the roll plate 13. At this time, since the peripheral speed of the roll plate 13 and the conveying speed of the base material 2 are equal, the protective resin layer 31 is simply pressed against the roll plate 13 by the base material 2 and has the same peripheral speed as the roll plate 13. Therefore, the behavior of rubbing the peripheral side surface of the roll plate 13 can be effectively avoided.

  In this state, the manufacturing process starts application of the ultraviolet curable resin and starts irradiation with ultraviolet rays. Here, the protective resin layer 31 is integrated with the ultraviolet curable resin applied to the substrate 2 by irradiation of ultraviolet rays due to its strong adhesion strength to the shaping resin, and is peeled off from the roll plate 13 together with the substrate 2. It will be. As a result, in this embodiment, the roll plate 13 is prevented from being damaged after the paper is passed through until the start of shaping, and as a result, it is significantly damaged at the time of storage and conveyance and at the start of production compared to the conventional case. Can be prevented.

  In this embodiment, as in the first embodiment, the process management is performed so that one roll plate 13 processes the base material 2 for one roll. Without considering the sticking, the rotational speed of the roll plate 13 is gradually reduced to finish the production.

  According to this embodiment, even if the roll plate is protected by the protective resin layer instead of the protective film, the same effect as that of the first embodiment can be obtained.

[Fifth Embodiment]
FIG. 15 is a diagram for explaining a manufacturing process according to the fifth embodiment of the present invention. Here, in this manufacturing process, the protective resin layer 31 is formed on the peripheral side surface of the roll plate 13 and the drive of the roll plate 13 is stopped. This embodiment has the same configuration as that of the fourth embodiment except for the configuration related to the production of the protective resin layer 31.

  In the manufacturing process of this embodiment, a protective resin for the protective resin layer 31 is applied to the peripheral side surface of the roll plate 13 by the die 34. As in the fourth embodiment, the protective resin is made of a material having a stronger adhesion strength to the shaping resin than the adhesion strength to the roll plate. For example, the same protective resin as the ultraviolet curable resin for shaping is used. Resin is applied. In this step, at the end of production, the application of the ultraviolet curable resin for shaping is completed and the irradiation of ultraviolet rays is stopped, thereby completing the shaping process. Subsequently, the application of the resin for the protective resin layer 31 is started by the die 34, and when the application to the entire circumference of the roll plate 13 is completed, the rollers 14 and 15 are separated and the conveyance of the base material 2 is stopped. Further, the rotation of the roll plate 13 is stopped. In this case as well, as described above with respect to the fourth embodiment, if it can be sufficiently removed at the start of production, it may be cured by irradiation with ultraviolet rays.

  According to this embodiment, even when the roll plate is protected by the protective resin layer instead of the protective film, the same effect as that of the second embodiment can be obtained.

[Sixth Embodiment]
FIG. 16 is a diagram for explaining a manufacturing process according to the sixth embodiment of the present invention. Here, this manufacturing process is the same as that of the fifth embodiment except that the protective resin layer 31 is produced by applying a protective resin to the base 2 side instead of the roll plate 13.

  According to this embodiment, the same effect as that of the fifth embodiment can be obtained even when the protective resin is applied to the base material side to produce the protective resin layer on the roll plate.

[Seventh Embodiment]
FIG. 17 is a view showing an antireflection film according to the seventh embodiment of the present invention. Here, the ultraviolet curable resin 4 used for shaping is required to be able to transfer the fine structure produced on the roll plate with high accuracy and efficiency, and on the other hand, it is required to adhere to the substrate 2 sufficiently firmly. . Therefore, in this embodiment, the ultraviolet curable resin 4 has a two-layer structure composed of the lower layer ultraviolet curable resin 4A and the upper layer ultraviolet curable resin 4B, and satisfies these functions required for the ultraviolet curable resin 4. .

  For this reason, the lower UV curable resin 4A has good adhesion to the substrate 2, and a resin having good adhesion to the resin layer of the upper UV curable resin 4B is applied. Further, as the upper layer UV curable resin 4B, a resin having excellent shaping characteristics is applied. Thereby, in this embodiment, the performance and productivity of the antireflection film 41 are improved. The ultraviolet curable resins 4A and 4B can be prepared by applying, for example, acrylic resins so as to have desired characteristics.

  FIG. 18 is a diagram illustrating a manufacturing process of the antireflection film 41. This manufacturing process 50 corresponds to the two-layer structure of the ultraviolet curable resin layer 4, the die 12 </ b> A for sequentially applying the lower ultraviolet curable resin 4 </ b> A in the transport direction of the substrate 2, and the upper ultraviolet curable resin 4 </ b> B. The die 12B for applying the resin is disposed, and the ultraviolet curable resins 4A and 4B are sequentially applied by the dies 12A and 12B. Except for the configuration related to the dies 12A and 12B, the manufacturing process is the same as the manufacturing process 10 described above with reference to FIG.

  In this embodiment, when it is removed from the roll plate manufacturing apparatus, it is mounted on a rotating carriage, and a protective resin is applied to the peripheral side surface by an upper UV curable resin 4B, and a protective resin layer 31 by this upper UV curable resin 4B. Is produced. The roll plate 13 is prevented from being scratched by the protective resin layer 31 and further prevented from adhering foreign matter until it rises to a steady state at the start of production.

  Further, when standing up to a steady state, only the lower layer UV curable resin 4A is applied to the base material 2 for a certain period of time and irradiated with UV rays, thereby protecting the base material 2 using the adhesion of the lower layer UV curable resin 4A. The resin layer 31 is removed. In this case, if the protective resin layer 31 can be removed practically enough, the protective resin layer may be removed by applying the UV curable resins 4A and 4B of the lower and upper layers as in the production. good.

  On the other hand, at the end of production, the application of the lower layer UV curable resin 4A is stopped for a certain period, and only the upper layer UV curable resin 4B is applied to the substrate 2 and conveyed. Here, the upper layer UV curable resin 4B has a weak adhesion with the base material 2, and in this case, the upper layer UV curable resin 4B is peeled off from the base material 2 and remains around the roll plate 13. Will be produced. Thereby, in this embodiment, when the protective resin layer 31 is produced on the roll plate 13, the application of the ultraviolet curable resin 4B is stopped, and the rotation of the roll plate 13 is further stopped.

  According to the seventh embodiment, the anti-reflection film is made by forming the ultraviolet curable resin used for forming into a two-layer structure and forming the protective resin layer with the upper-layer ultraviolet curable resin according to the two-layer structure. The same effects as those of the above-described embodiment can be obtained by effectively using the two-layer structure and equipment related to the above structure.

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

  That is, in the above-described embodiment, the case where the protective film and the protective resin layer are provided has been described. However, the present invention is not limited thereto, and the protective film may be provided on the protective resin layer.

  Further, in the above-described embodiment, the case where the protective layer is provided by the ultraviolet curable resin has been described. However, the present invention is not limited to this, and a resin curable by an electron beam other than ultraviolet rays may be applied, and further, thermosetting A functional resin may be applied.

  Moreover, although the case where the resin for shaping | molding was apply | coated to the base material side was described in the above-mentioned embodiment, this invention is not limited to this, It can apply widely also when apply | coating to the roll plate side.

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

  In the above-described embodiment, the case where the fine uneven shape related to the moth-eye structure is formed has been described. However, the present invention is not limited to this, and the optical film is formed by forming various uneven shapes formed on the mold. It can be widely applied to the case of manufacturing.

DESCRIPTION OF SYMBOLS 1,41 Antireflection film 2 Base material 3 Uneven film 4, 4A, 4B UV curable resin 10 Manufacturing process 12, 50, 12A, 12B, 34 Die 13 Roll plate 14, 15 Roller 21 Protective film 31 Protective resin layer

Claims (11)

In the method for producing an optical film, while conveying the substrate, press the substrate against the circumferential side surface of the roll plate and mold the uneven shape formed on the circumferential side surface into the substrate to produce an optical film,
Starting the rotation of the roll plate and the conveyance of the base material, starting the rotation of the roll plate and the conveyance of the base material to a steady state;
Producing the optical film in the steady state ;
A rotation step of stopping the rotation of the roll plate and the conveyance of the base material,
The starting step includes
In a state where a protective material for protecting the uneven shape of the peripheral side surface is arranged on the peripheral side surface of the roll plate, the rotation of the roll plate and the conveyance of the base material are started,
When the rotation and conveyance of the base material of the roll plate rises to a steady state, it has a protective material removing step of removing the protective material,
The stopping step includes
In the steady state, it has a protective material arrangement step of arranging the protective material on the peripheral side surface of the roll plate,
The method for producing an optical film, wherein when the protective material is arranged in the protective material arranging step, rotation of the roll plate and conveyance of the base material are stopped . The protective material is an adhesive film wound around the peripheral side surface, the peripheral side surface side being an adhesive layer,
The protective material removing step includes
The method for producing an optical film according to claim 1, wherein the protective material is attached to the substrate and removed. In the method for producing an optical film, while conveying the substrate, press the substrate against the circumferential side surface of the roll plate and mold the uneven shape formed on the circumferential side surface into the substrate to produce an optical film,
A step of producing the optical film while maintaining the rotation of the roll plate and the conveyance of the base material in a steady state;
A rotation step of stopping the rotation of the roll plate and the conveyance of the base material,
The stopping step includes
In the steady state, on the peripheral side surface of the roll plate, a protective material arranging step of arranging a protective material that protects the uneven shape of the peripheral side surface,
When the protective material is arranged in the protective material arranging step, rotation of the roll plate and conveyance of the base material are stopped. The protective material is an adhesive film in which the peripheral side surface is an adhesive layer;
The protective material arranging step includes
The method for producing an optical film according to claim 3, wherein one end of the protective material is attached to the roll plate and wound around the roll plate by rotation of the roll plate. The protective material is an adhesive film in which the peripheral side surface is an adhesive layer;
The protective material arranging step includes
The method for producing an optical film according to claim 3, wherein one end of the protective material is attached to the base material, and the protective material is wound around the roll plate by conveyance of the base material. The method for producing an optical film according to claim 1, wherein the protective material is a protective resin layer made of an ultraviolet curable resin. The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective material is
It is a protective resin layer made of UV curable resin,
The protective material removing step includes
The manufacturing method of the optical film of Claim 1. The said protective resin layer is made to adhere to the said base material, and the said protective material is removed. The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective material is
It is a protective resin layer made of UV curable resin,
The protective material arranging step includes
The manufacturing method of the optical film of Claim 3. The said protective material is arrange | positioned by application | coating of the material of the said protective resin layer to the said roll plate. The substrate is
By forming the ultraviolet curable resin layer provided on the base material, the uneven shape formed on the peripheral side surface is formed,
The protective material is
It is a protective resin layer made of UV curable resin,
The protective material arranging step includes
The manufacturing method of the optical film of Claim 3. The said protective material is arrange | positioned to the said roll plate through the said base material by application | coating of the material of the said protective resin layer to the said base material. The substrate is
The lower layer and the upper layer UV curable resin are sequentially provided, and by forming the resin layer with the UV curable resin, the uneven shape formed on the peripheral side surface is formed,
The protective material arranging step includes
By stopping the application of the lower layer UV curable resin to the substrate and applying only the upper layer UV curable resin to the substrate, the upper layer UV curable resin through the substrate. The method for producing an optical film according to claim 3, wherein the protective material is disposed on the roll plate. The optical film is
An antireflection film having a moth-eye structure. Any one of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 . the method for producing an optical film according to.

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