JP6003654B2 - Transfer roll, transfer roll manufacturing method, and article manufacturing method - Google Patents

Description

The present invention relates to a transfer roll, and more specifically, a transfer roll formed of an anodized alumina having a body portion and a shaft portion and having a plurality of pores on the outer peripheral surface of the body portion, a manufacturing method thereof, and the method The present invention relates to a method for manufacturing an article using a transfer roll.
This invention claims priority based on Japanese Patent Application No. 2011-221842 for which it applied to Japan on October 6, 2011, and uses the content here.

  An optical film having a fine concavo-convex structure with a period of less than or equal to the wavelength of visible light on the surface exhibits an antireflection function and the like, and thus its usefulness has attracted attention. In particular, it is known that a fine concavo-convex structure called a moth-eye structure exhibits an effective antireflection function by continuously increasing from a refractive index of air to a refractive index of a material.

  Examples of the method for producing an optical film having a fine concavo-convex structure on the surface include an imprint method in which the fine concavo-convex structure formed on the surface of the mold is transferred to the surface of the base film (transfer object). As the imprint method, for example, the following method is known (Patent Document 1).

  Patent Document 1 discloses a method of forming fine irregularities in a self-organized manner on the surface of aluminum by anodizing high-purity aluminum as a method for producing a mold having a plurality of pores. In this state, ultraviolet rays are applied to the ultraviolet curable resin in a state where the ultraviolet curable resin is interposed between the transfer roll on which the anodized alumina having fine irregularities is formed on the outer peripheral surface and the transparent base film. Irradiated and cured to form a cured resin layer having a plurality of convex portions on the surface where the pores of the anodized alumina are inverted. Then, the antireflective film which has a fine uneven structure on the surface can be manufactured by peeling a base film from a transfer roll with the said cured resin layer.

The transfer roll is usually made of high-purity aluminum, but since high-purity aluminum is very soft, the shaft portion required when mounting the transfer roll to the antireflection film manufacturing apparatus is integrated with the transfer roll. It was difficult to form. Further, since high-purity aluminum is very soft, it is difficult to perform threading and the like, and it is difficult to screw other members. In addition, in order to form fine irregularities on the surface of high-purity aluminum, anodization is performed in the electrolytic solution, and the aluminum base material generates heat during the anodization. Therefore, in order to heat the aluminum substrate gradually, the aluminum substrate is made into a hollow cylindrical shape, and the electrolytic solution is circulated in a state where the contact area between the aluminum substrate and the electrolytic solution is increased. Has been done. Therefore, it has been common to anodic oxidation by immersing a hollow cylindrical aluminum base material in an electrolytic solution.
Moreover, when producing an antireflection film by transferring the uneven shape to an ultraviolet curable resin or the like, it was difficult to integrally form high-purity aluminum and a shaft, so the outer periphery of a hollow cylindrical aluminum substrate In general, a sleeve in which an anodized alumina having a plurality of pores on the surface is mounted on the outer periphery of a cylindrical mandrel (axial core) has been used. The advantage of using the mandrel is that the transfer roll is completed when the mandrel is inserted into the sleeve, so that the detaching operation of the bearing does not occur unlike the transfer roll with a shaft. Thereby, the film thickness unevenness of the antireflection film due to poor bearing mounting accuracy can be reduced. In addition, even when the fine uneven surface has deteriorated, it is one of the advantages that the transfer roll can be renewed by removing only the sleeve and re-processing the sleeve, or by replacing with a new sleeve.

  In the transfer roll, methods such as Patent Document 2 and Patent Document 3 are known as methods for attaching a sleeve to a mandrel.

  However, in recent years, there has been an increasing demand for wider widths of molded articles produced using transfer rolls. In order to increase the width of the molded body, it is necessary to increase the width of the transfer roll. In the methods of Patent Document 2 and Patent Document 3, widening the transfer roll means widening the sleeve. In the methods described in Patent Document 2 and Patent Document 3, when the sleeve is widened to exceed 1 m, the cutting tool processes the entire inner diameter portion by one-time cutting when the sleeve inner diameter portion is processed. However, it is necessary to finish the inner diameter part by changing the chuck and carrying out mid-rolling from the opposite side. Once the chuck is changed, there is a problem that the shaft centers at both ends are displaced, and the processing accuracy on the entire inner diameter surface of the sleeve is lowered. In particular, the sleeve is made of high-purity aluminum with a purity of 99% or more. However, since high-purity aluminum is a material that is difficult to cut, it is extremely difficult to accurately process the inner diameter of the sleeve if the center of the shaft is displaced at both ends. It becomes.

  In the method described in Patent Document 2, it is necessary to fit both end faces of the sleeve to the mandrel when the mandrel is mounted. However, when the processing accuracy of the inner diameter of the sleeve is not good, It becomes difficult to match the fitting portion with the fitting portion of the mandrel. This is due to the deflection of the mandrel and the sleeve body and the deterioration of the fitting part accuracy due to the shift of the axial center of both ends of the sleeve, the transfer roll becomes wide, and the fitting part on the sleeve side and the fitting part of the mandrel The longer the distance, the more difficult it is to install the mandrel.

  In the method described in Patent Document 3, there is no problem in mounting the mandrel, but in order to apply pressure evenly by the elastic membrane, the processing accuracy of the sleeve inner diameter surface is necessary, and the way of applying pressure to the sleeve inner diameter portion is If it is not uniform, there is a problem that film thickness unevenness occurs during transfer of the fine concavo-convex structure.

  Further, in the methods of Patent Document 2 and Patent Document 3 in which the sleeve is mounted on the mandrel, when the sleeve is widened, it is necessary to increase the mounting equipment and the mounting space. The mandrel to which the sleeve is attached is attached with one end fixed, but the sleeve cannot be attached or detached unless there is a space more than twice the length of the sleeve.

  Other than the method of mounting the sleeve on the mandrel, there is a method of using a transfer roll with a shaft as described in Patent Document 4. However, when the shaft-equipped transfer roll described in Patent Document 4 is made of high-purity aluminum, there arises a problem that the strength at the bearing portion cannot be maintained. Furthermore, there is a problem that screw hole machining for connecting a rotary joint for flowing temperature-controlled water from the shaft end cannot be performed. Moreover, since the aluminum base material which consists of high-purity aluminum is very soft, the process of the complicated temperature control water flow path using a welding process like the patent document 4 inside can be performed. Can not.

JP 2009-174007 A JP 2011-131424 A International Publication No. 2009/107294 JP 2002-67057 A

  The present invention has been made in order to solve the above-described problems, and even when a transfer roll made of high-purity aluminum and having a fine concavo-convex structure on the surface becomes wide, it is possible to perform the intermediate-feed processing and the inner diameter processing. There is no problem of accuracy, the strength of the shaft portion can be maintained, a member such as a rotary joint can be easily attached, and a temperature control medium flow path inside the transfer roll can be easily formed, and a manufacturing method thereof, and The manufacturing method of the articles | goods using the said transfer roll is provided.

  As a means for solving the above problems, a transfer roll according to the present invention is a transfer roll comprising a body part and a shaft part, wherein the body part is made of high-purity aluminum, and a plurality of pores are formed on the surface of the body part. Anodized alumina is formed, and the body portion is subjected to hole processing for a temperature control medium flow path. A shaft member of a member different from the body portion is fixed and connected to both end surfaces of the body portion from both sides. In this case, the temperature control medium flows into the body portion through the shaft member.

  Further, in the transfer roll according to the present invention, both end surfaces of the body portion and one end surface of the shaft member have flange portions, and the body portion and the shaft member are fixed by connecting the flange portions. The shaft part is removable.

  The transfer roll according to the present invention is characterized in that shaft members are connected to both end surfaces of the body portion from both sides by fitting.

The present invention has the following aspects.
The transfer roll according to the present invention is a transfer roll including a body portion and a shaft portion that can be detached from the body portion, and the body portion is made of high-purity aluminum, and a plurality of fine particles are formed on the surface of the body portion. Anodized alumina having holes is formed, and the body is subjected to hole processing for a temperature control medium flow path, and both end surfaces of the body are made of a material having rigidity higher than that of the body. When the shaft portion is fixed and connected from both sides, the temperature control medium flows into the body portion via the shaft portion.
Further, in the transfer roll according to the present invention, both end surfaces of the body portion and one end surface of the shaft portion have flange portions, and the body portion and the shaft portion are fixed by connecting with the flange portions, The trunk portion and the shaft portion are detachable.
The transfer roll according to the present invention is characterized in that the shaft portion is connected to both end surfaces of the body portion by fitting from both sides.

The present invention further has the following aspects.
<1> A transfer roll composed of a cylindrical body having a fine irregular shape on at least a part of an outer peripheral surface and a shaft, wherein the body is made of high-purity aluminum, and the shaft is The body is made of a material having higher rigidity than the material constituting the body, and is disposed on both sides of the body in the columnar axial direction so as to sandwich the body in the axial direction. Characteristic transfer roll;
<2> Both end surfaces of the body portion and one end surface of the shaft portion have flange portions, and the body portion and the shaft portion are fastened by fastening means at the flange portion. The transfer roll according to <1>;
<3> Both end surfaces of the body part and one end surface of the shaft part have fitting parts, and the body part and the shaft part are fitted in the fitting parts. The transfer roll according to <1>;
<4> The transfer roll according to any one of <1> to <3>, wherein a temperature control medium flow path is formed in the body portion;
<5> The transfer roll according to <4>, wherein the temperature control medium flow path is a through hole penetrating the body portion along a cylindrical axial direction;
<6> A method for producing a transfer roll, wherein a high-purity aluminum is formed into a cylindrical shape, and a high-purity aluminum formed into the cylindrical shape is anodized to form at least a part of the outer peripheral surface. A method for producing a transfer roll, comprising: an anodizing step for obtaining a body portion having a fine irregular shape; and a connecting step for connecting the shaft portion to both ends of the cylindrical axial direction of the body portion;
<7> The forming step further includes a flow path forming step of forming a temperature control medium flow path on the high-purity aluminum molded in the columnar shape, and the anodizing process is performed on the temperature control medium flow path. The method for producing a transfer roll according to <6>, comprising anodizing the high-purity aluminum while supplying a temperature control medium;
<8> The transfer according to <7>, wherein the flow path forming step is a step of forming a through hole in the high-purity aluminum along a cylindrical axial direction of the high-purity aluminum. Roll manufacturing method;
<9> Using the transfer roll according to any one of <1> to <3> or the transfer roll manufactured by the method according to <6>, an article having fine irregularities transferred to the surface is obtained. A method for producing an article, characterized in that
<10> Using the transfer roll according to <4> or the transfer roll manufactured by the method according to any one of <7> to <8>, an article having a fine relief structure transferred to the surface. A method for producing an article, comprising: producing the article while supplying the temperature control medium to the temperature control medium flow path when obtaining the article.

  According to the present invention, it is possible to fasten from both sides a shaft portion made of a material different from the body portion on both sides of the body portion made of high-purity aluminum having anodized alumina having a plurality of pores on the surface. By configuring in this way, a transfer roll that does not require the intermediate processing of an aluminum base material such as a sleeve or mandrel structure can be obtained. Further, according to the transfer roll manufacturing method of the present invention, the screw hole for attaching the rotary joint to the shaft end portion can be obtained by using the shaft portion made of a material having higher rigidity than that of high-purity aluminum so that the strength of the bearing portion is maintained. There is no problem even if it is processed. Furthermore, it is also possible to create a flow path through which the temperature control medium flows to the trunk portion via the shaft portion. Further, when the transfer roll is widened, it is possible to obtain a transfer roll that can maintain the strength of the bearing portion and can easily form the temperature control medium flow path inside the transfer roll.

It is sectional drawing of the transfer roll which concerns on embodiment of this invention. It is sectional drawing which follows the AA line of the transfer roll of FIG. It is sectional drawing which follows the BB line of the transfer roll of FIG. It is sectional drawing which follows the CC line of the transfer roll of FIG. It is sectional drawing of the transfer roll which concerns on another embodiment of this invention. It is sectional drawing which shows the formation process of the pore of an anodized alumina. It is a schematic diagram of the apparatus which manufactures articles | goods using the transfer roll which concerns on this invention.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

<Transfer roll>
First, the structure of the transfer roll based on this invention is demonstrated.
FIG. 1 is a view showing an example of a transfer roll according to the present invention. The transfer roll of the present invention is made of a high-purity aluminum and has a cylindrical body portion 10 formed with anodized alumina having a plurality of pores on the surface, and is disposed on both end surfaces of the body portion 10 in the columnar axial direction. The shaft portion 40 sandwiches the cylindrical body portion 10 in the axial direction.
The purity of the high-purity aluminum constituting the body part 10 is preferably 99% or more, more preferably 99.5% or more, and further preferably 99.8% or more. When the purity of aluminum is lower than 99%, when anodizing, an uneven structure having a size that scatters visible light due to segregation of impurities is formed, or when the barrel 10 is anodized, the surface of the barrel 10 There is a risk that the regularity of the pores formed in this will be reduced.
The diameter of the cylindrical body 10 is preferably 150 to 600 mm, and more preferably 200 to 550 mm. If the diameter of the cylindrical body portion 10 is 150 mm or more, an article having the fine uneven shape of the body portion 10 transferred thereon can be efficiently manufactured without excessively increasing the rotational speed of the transfer roll. Moreover, if the diameter of the cylindrical trunk | drum 10 is 600 mm or less, it can suppress that the weight of the trunk | drum 10 becomes larger than necessary.
Moreover, it is preferable that the length (length from the AA cross section to CC cross section in FIG. 1) of the trunk | drum 10 is 600-2000 mm, and it is more preferable that it is 720-1800 mm.

The shaft portions 40 arranged at both ends of the body portion 10 are made of a material different from that of the body portion 10 and made of a material having higher rigidity than the body portion 10.
In the present invention, a highly rigid material refers to a material having no problem in strength when the shaft portion 40 is connected and fixed to the body portion 10 or when a bearing is attached to the shaft portion 40. Specifically, a material having a Brinell hardness (HB) of 30 or more is preferable, and a material of 35 or more is more preferable. If the Brinell hardness of the material constituting the shaft portion 40 is 30 or more, the shaft portion may be deformed or damaged when the shaft portion 40 is connected to and fixed to the body portion 10 or when a bearing is attached to the shaft portion 40. It is preferable because the strength can be sufficient.
Although the upper limit of the Brinell hardness of the material which comprises the axial part 40 is not specifically limited, From a viewpoint that it is not necessary to use special materials, such as rhenium, it is preferable that it is 3000 or less.
Here, Brinell hardness refers to a value measured by applying a pressure of 500 kgf using a cemented carbide having a diameter of 10 mm in accordance with a method defined in JIS (Japanese Industrial Standard) Z 2243.
Furthermore, the shaft portion 40 is more preferably made of a material having corrosion resistance. Specifically, the shaft portion 40 is more preferably made of a material such as titanium or stainless steel. Further, the shaft portion 40 may be subjected to a surface treatment such as quenching or coating for giving strength.

Both end surfaces of the body portion 10 and one end surface of the shaft portion 40 have a flange portion 11 and a flange portion 41, and the body portion 10 and the shaft portion 40 are preferably fastened by these flange portions.
As means for fastening the body portion 10 and the shaft portion 40 with the flange portion, the connecting hole 50 provided in the flange portion 41 on one end surface of the shaft portion 40 and the flange portion 11 of the body portion 10 are bolts and nuts. Connection and fixing methods. When the flange portion 11 and the connecting hole 50 are connected by bolts and nuts, it is preferable to provide a bolt or nut mounting gap 12 in the body portion 10. When the mounting gap 12 is provided in the body portion 10, the distance of the mounting gap 12 is preferably 2 to 10 cm from the viewpoint of ease of connection using bolts and nuts.
Moreover, it is preferable that the diameter of the connection hole 50 is 0.2-3 cm, and it is more preferable that it is 0.5-2 cm.

The flange portion 11 and the flange portion 41 have a disk shape and are configured so that the body portion 10 and the shaft portion 40 can be fastened. 1-10 cm is preferable and, as for the thickness of the flange part 11, 1.5-5 cm is more preferable. If the thickness of the flange part 11 is 1-10 cm, since the trunk | drum 10 can be hold | maintained in the state which fixed the axial part 40 and the trunk | drum 10, it is preferable. Moreover, 1-10 cm is preferable and, as for the thickness of the flange part 41, 1.5-8 cm is more preferable.
If the flange portion 41 has a thickness of 1 to 10 cm, sufficient strength of the flange portion 41 can be ensured, and the trunk portion 10 can be held in a state where the shaft portion 40 and the trunk portion 10 are securely fixed. preferable.
The diameter of the flange portion 11 can be appropriately adjusted according to the diameter of the body portion 10. In the transfer roll of the present invention, since the preferable diameter of the body portion 10 is 150 to 600 mm, the diameter of the flange portion 11 is also preferably 150 to 600 mm. Similarly, the diameter of the flange portion 41 is also preferably 150 to 600 m.

  It is preferable that both end surfaces of the body portion 10 and one end surface of the shaft portion 40 have a fitting portion 51, and the body portion 10 and the shaft portion 40 are fitted in the fitting portion. Since the barrel portion 10 and the shaft portion 40 have the fitting portion, positioning can be performed when the shaft portion 40 is fastened to the barrel portion 10 with the connecting hole 50, so that the axes of the barrel portion 10 and the shaft portion 40 are shifted. You can prevent things.

Moreover, it is preferable that the temperature control medium flow path 20 is formed in the trunk | drum 10, and it is preferable that the temperature control medium flow path 30 is formed in the axial part 40. FIG.
The temperature control medium flow path 30 is formed so as to penetrate from one end surface of the shaft portion 40 to the flange portion 41, and is connected to a groove-shaped flow passage 32 formed on the connection surface between the flange portion 41 and the body portion 10. It is preferable. Moreover, it is preferable that the temperature control medium flow path 20 is formed so as to penetrate the trunk portion 10. Since the temperature control medium flow path 20 is formed so as to penetrate the body portion 10, the formation of the temperature control medium flow path 20 can be facilitated.
The temperature control medium flow path 20 is preferably formed at a position of 2 to 7 cm from the surface of the body portion 10 and more preferably formed at a position of 3 to 6 cm. If the distance from the surface of the trunk | drum 10 to the temperature control medium flow path 20 is 2-7 cm, since the temperature of the surface of the trunk | drum 10 can be controlled more precisely, it is preferable.
The detail of the temperature control medium flow path provided in the transfer roll of the present invention will be described as follows with reference to FIGS. 2A to 2C.

2A, FIG. 2B, and FIG. 2C are views respectively showing an AA cross section, a BB cross section, and a CC cross section of the transfer roll of FIG.
As shown in FIGS. 2A and 2C, groove-like flow paths 32 a and 32 d for flowing the temperature control medium flowing in from the temperature control medium flow path 30 to the body section 10 are formed in the flange portion 41 of the shaft portion 40. Is formed. These flow paths 32 a and 32 d are formed so as to be connected to the temperature control medium flow path 20 of the body portion 10 at their ends.
The depth of the grooves of the groove-like flow paths 32a and 32d may be appropriately designed according to the flow rate of the temperature control medium supplied to the flow paths, but is preferably 0.2 to 3 cm, more preferably 0.5 to 2 cm. preferable. If the depth of the grooves of the groove-like flow paths 32a and 32d is 0.2 to 3 cm, it is preferable because a deep groove is formed in the flange portion 41 and the strength can be suppressed from decreasing. Moreover, 0.5-5 cm is preferable and, as for the horizontal width of the groove-shaped flow paths 32a and 32d, 1-4 cm is more preferable.
The flange portion 41 is formed with a plurality of groove-like flow paths 32C and 32b for circulating the temperature control medium flowing from the temperature control medium flow path 20. The number of the groove-like flow paths 32 formed in the flange portion 41 can be appropriately adjusted according to the number of the temperature control medium flow paths 20 formed in the body portion 10.
The depth of the grooves of the groove-like flow paths 32C and 32b is preferably 0.2 to 3 cm, and more preferably 0.5 to 2 cm. If the groove depth of the groove-like flow paths 32C and 32b is 0.2 to 3 cm, it is preferable because a deep groove can be prevented from being formed in the flange portion 41 and the strength can be suppressed. Moreover, 0.2-3 cm is preferable and, as for the horizontal width of the groove-shaped flow paths 32C and 32b, 0.5-2 cm is more preferable.
The diameter of the temperature control medium flow path 30 provided in the shaft portion 40 and the flange portion 41 may be appropriately adjusted to a size that can maintain the strength of the shaft portion 40 and supply a desired amount of the temperature control medium.

As shown in FIG. 2B, a plurality of temperature control medium flow paths 20 are formed in the body portion 10.
The number of temperature control medium flow paths 20 formed in the body part 10 is preferably 2 or more, more preferably 4 to 16, and more preferably 6 to 12. Moreover, 0.2-3 cm is preferable and, as for the diameter of the hole of the temperature control medium flow path 20, it is more preferable that it is 0.5-2 cm. If the diameter of the hole of the temperature control medium flow path 20 is 0.2 to 3 cm and the number of the temperature control medium flow paths 20 is 4 to 16, the strength of the body portion 10 is prevented from greatly decreasing. Meanwhile, the temperature of the surface of the trunk portion 10 can be controlled within a desired range.

As the temperature control medium, it is preferable to use water, oil, or a fluorine-based heat medium, and it is most preferable to use water. If the temperature control medium is water, it is preferable because the temperature control medium can be procured at low cost.
In the transfer roll of the present invention, it is preferable to supply the temperature control medium to the temperature control medium flow path 20 using a conventionally known method such as a pump.

  A bearing unit may be attached to the shaft portion 40. By attaching the bearing unit to the shaft portion 40, the step of inserting the shaft portion 40 into the bearing after the shaft portion 40 is fastened to both ends of the body portion 10 to form a transfer roll can be omitted.

  FIG. 3 is a view showing another embodiment of the transfer roll according to the present invention. In the transfer roll according to the present embodiment, as shown in FIG. 3, both end surfaces of the body portion 10 and one end surface of the shaft portion 42 have fitting portions, and the body portion 10 and the shaft portion 42 are fitted. It is preferable that the mating portion 51 is fastened. The fitting portion 51 of FIG. 3 has a concave body 10 and a convex shaft portion 42. However, the cylindrical portion 10 may be convex and the concave shaft portion 42 may be concave. The fitting is not limited to the concavo-convex shape as shown in FIG. 3, and the body portion 10 or the insertion portion of the shaft portion 42 may have a tapered shape.

In the example of FIG. 3, the structure for flowing the temperature control medium is preferably the same as in FIG. 1. That is, the temperature control medium flow path 30 of the shaft part 42, the groove-shaped flow path 32 formed on the end face of the shaft part 42, and the temperature control medium flow path 20 formed in the body part 10 are also the same as in FIG. Preferably it is formed.
Also in the example of FIG. 3, a bearing unit may be attached to the shaft portion 40.

  In the example of FIG. 1 or FIG. 3, when the temperature control medium flows, leakage of the temperature control medium from the fastening portion between the body portion 10 and the shaft portion 40 (or the shaft portion 42) or other temperature control medium flow path In order to prevent liquid from entering, it is preferable to use a water stop component (not shown) such as packing or O-ring for the fastening portion.

The shape of the temperature control medium flow path 20 in the trunk | drum 10 is not limited to the shape shown in FIG. 1 or FIG. 3, It can change variously. Further, the groove-like flow path 32 is not limited to the shape shown in FIG. 1 or 3, and may be any structure as long as the temperature control medium circulates in the body portion 10.
In FIG. 1, the groove-like flow path 32 is not provided in the flange portion 41 of the shaft portion 40 but can be provided on the end face of the body portion 10 so that the temperature control medium flows in a reciprocating manner. However, since the trunk portion 10 is made of high-purity aluminum and precise cutting is difficult, it is preferable to provide the flow path 32 on the shaft portion 40 side.

Next, the operation of the transfer roll of the present invention will be described.
In the example of FIG. 1, the shaft portion 40 can connect a rotary joint for temperature control water to the connection surface with the body portion 10 and the end surface opposite to the connection surface. Temperature-controlled water flows through the temperature-control medium flow path 30 inside.
As shown in FIG. 1, the temperature control medium flowing from the flow path 30 of the shaft portion 40 first flows into the groove-shaped flow path 32 a and communicates with the flow path 20 of the trunk portion 10 at the end portion. And the temperature control medium flows. The temperature control medium that has passed through the body portion 10 moves to the flow path 32b of the shaft 40 on the opposite side, and the temperature control medium flows through the flow path 32b and flows in the body section 10 that is in communication with the end of the flow path 32b. The temperature control medium flows through the path 20 so as to be folded back. The temperature control medium that has been turned back passes through the flow path 32C and similarly flows into the body 10, finally gathers in the flow path 32d, and the shaft on the opposite side to the side on which the temperature control medium is first supplied. It flows to the flow path 30 of the part. In this way, by allowing the temperature control medium to reciprocate and circulate in the body part 10, the temperature of the body part 10 can be uniformly controlled.

The structure through which the temperature control medium flows, that is, the structure of the groove-shaped flow paths 32a to 32d and the temperature control medium flow path 20 is not limited to the above. For example, the temperature control medium supplied from the shaft portion 40 is A two-pass method may be used in which it flows into the body portion 10 and returns to the finally supplied shaft portion 40. The number of times the temperature control medium reciprocates in the body 10 is not limited to the above description, and the temperature control medium does not reciprocate in the body 10, and the shaft 40 It may flow in one pass to the other. However, when the body 10 is wide, it is preferable that the temperature control medium reciprocates within the body 10 at least once from the viewpoint of uniformizing the temperature of the body 10.
Here, the two-pass method refers to a method in which there are two flow paths in which the shaft section 40 has flow paths for supply and drainage, and the temperature control medium is supplied from both shafts. Similarly, one pass is a system in which a temperature control medium is supplied from one shaft portion and the temperature control medium is discharged from the other shaft portion. Point to.

<Method for producing transfer roll>
Next, a method for producing a transfer roll composed of a cylindrical body having a fine unevenness and a shaft on at least a part of the outer peripheral surface will be described.
The method for producing a transfer roll of the present invention comprises forming a high-purity aluminum into a cylindrical shape, performing a molding step, anodizing the high-purity aluminum formed into the cylindrical shape, and forming fine irregularities on at least a part of the outer peripheral surface. The method includes an anodizing step for obtaining a body having a shape, and a connecting step for connecting the shaft to both ends of the cylindrical axial direction of the body.

  The body portion 10 is formed through a molding process of molding an aluminum base material made of high-purity aluminum into a columnar shape and an anodizing process of anodizing the aluminum base material molded into a columnar shape.

(Molding process)
Conventionally known methods such as cutting and casting can be used for forming the high purity aluminum into a cylindrical shape. In the present invention, the body portion 10 may be provided with flange portions 11 at both end portions in the axial direction, or may be formed with recesses into which the shaft portion 42 is fitted. The shape is also referred to as a cylindrical shape or a substantially cylindrical shape. The flange part 11 and the recessed part provided in the both ends of an axial direction can be formed by conventionally well-known methods, such as cutting an aluminum base material.

Moreover, in the manufacturing method of the transfer roll of this invention, it is preferable that the said formation process includes the flow path formation process which forms a temperature control medium flow path in the high purity aluminum formed in the column shape.
When forming the flow path of the temperature control medium in the body part 10, it is preferable to form it using a deep hole machining tool. Specifically, it is preferable to form the temperature control medium flow path 20 using a gun drill or the like.
Furthermore, it is preferable that the flow path forming step is a step of forming a through hole along the cylindrical axial direction of high purity aluminum formed in a cylindrical shape using the deep hole machining tool.
When forming the temperature control medium flow path 20 using a deep hole machining tool such as a gun drill, if the temperature control medium flow path 20 cannot be formed by a single process, a hole is made from one end surface of the body portion 10 in the axial direction. Then, processing may be performed from the other end surface of the body portion 10. The temperature control medium channel 20 is a channel through which the temperature control medium flows, and therefore does not require special processing accuracy. Therefore, unlike the inner peripheral surface of the sleeve-structured transfer roll, there is no problem with respect to misalignment of the axis.

  Moreover, it is preferable that the outer peripheral surface of the trunk | drum 10 is mirror-finished. Conventionally known methods such as buffing, cutting, and chemical polishing can be used as a method of mirror-finishing the outer peripheral surface of the body portion 10. The mirror surface processing is preferably performed after the flange portion 11, the concave portions provided at both end portions in the axial direction, or the temperature control medium flow path 20 is formed.

(Anodizing process)
Next, referring to FIG. 4, an anodizing process in which the body 10 made of high purity aluminum is anodized to form a fine uneven structure on the surface of the body 10 will be described.
First, when the body portion 10 is placed in the electrolytic solution and anodic oxidation is performed, an oxide film 54 having pores 52 is formed as shown in FIG. 4B from the state shown in FIG.
As an electrolytic solution used for anodization, oxalic acid, sulfuric acid, or the like can be used.
When oxalic acid is used as the electrolytic solution, the concentration of oxalic acid is preferably 0.7 M (where “M” means “mol / l”) or less. When the concentration of oxalic acid exceeds 0.7M, the current value becomes too high, and the surface of the oxide film may become rough.
On the other hand, when sulfuric acid is used as the electrolytic solution used for anodic oxidation, the concentration of sulfuric acid is preferably 0.7 M or less. If the concentration of sulfuric acid exceeds 0.7M, the current value may become too high to maintain a constant voltage.

In the anodic oxidation of high-purity aluminum, in order to obtain anodized alumina having highly regular pores at a predetermined cycle, it is necessary to apply a conversion voltage that matches the predetermined cycle. For example, when obtaining anodized alumina having a pore period of 100 nm, the formation voltage is preferably 30 to 60V. In addition, when obtaining anodized alumina having a pore period of 63 nm, the formation voltage is preferably 25 to 30V. When the formation voltage suitable for the predetermined cycle is not applied, the regularity tends to be lowered.
In the transfer roll of the present invention, it is preferable that the period of the fine pores of the fine concavo-convex structure formed on the outer peripheral surface of the body portion 10 is 25 to 400 nm. The chemical conversion voltage at the time of anodizing is preferably 20 to 160V, and more preferably 30 to 80V.
Here, the period of the pores (hereinafter sometimes referred to as the average period of the pores) refers to the average distance between the recesses of the pores.

  In one aspect of the method for producing a transfer roll of the present invention, the temperature of the electrolytic solution is preferably 60 ° C. or lower, more preferably 45 ° C. or lower, still more preferably 30 ° C. or lower, and particularly preferably 20 ° C. or lower. When the temperature of the electrolytic solution exceeds 60 ° C., a so-called “burn” phenomenon occurs, and the pores may be broken, or the surface may melt and the regularity of the pores may be disturbed.

As the anodic oxidation reaction proceeds, the body 10 generates heat, and the temperature of the electrolyte rises due to this, resulting in unevenness in the degree of anodic oxidation. As a result, the depth of the pores varies. May occur. In the transfer roll manufacturing method of the present invention, the anodizing step is performed while supplying the temperature adjusting medium to the temperature adjusting medium flow path 20 formed in the body portion 10 and adjusting the temperature of the body portion 10. It is preferable that
Moreover, in the transfer roll based on this invention, since the trunk | drum 10 has a substantially columnar shape, compared with the conventionally used hollow cylindrical transfer roll, a contact area with electrolyte solution is small. Therefore, it is possible to reduce the amount of heat generated when the body portion 10 is anodized as compared with a hollow cylindrical transfer roll having the same size. Further, even when the overall calorific value is increased due to the widening of the body 10, by supplying the temperature control medium to the temperature control medium flow path 20, the heat generation of the body 10 and the electrolyte solution It is possible to control the temperature, that is, to control the temperature rise of the electrolytic solution due to the heat generation of the body 10.
Here, the calorific value (heat flow rate Q) of the body portion 10 is a value obtained from the following formulas (1) and (2).
Heat flow rate Q [J / s] = Voltage E × Current I (1)
Heat flow rate Q [Kcal / h] = {(initial temperature t1−change temperature t2) × flow rate V × specific gravity w × specific heat c} / time H (2)
Moreover, the voltage E is calculated | required from Ohm's law shown to following formula (3), and the resistance value formula shown to following formula (4).
Voltage E [V] = current I × resistance R (3)
Resistance R [Ω] = resistivity ρ × length (thickness) L / cross-sectional area A (4)
Here, the resistivity ρ is a value determined by the concentration of the electrolytic solution, and the length L is a distance between the anode and the cathode, and is a value determined by the shape of the anodizing tank. The voltage E is a value determined by anodization conditions, that is, the voltage E is a value of a chemical conversion voltage at the time of anodization, and a cross-sectional area A is a contact area of the body portion 10 with respect to the electrolytic solution. The resistivity ρ, the length L, and the voltage E are fixed values. That is, the resistivity ρ, the length L, and the voltage E can be easily set by those skilled in the art within the range having the effects of the present invention.
From the above formulas (1) to (4), when the value of the cross-sectional area A is decreased, the value of the resistance R is increased. As a result, since the value of the current I becomes small, the value of the heat flow rate Q also becomes small.
Therefore, if the contact area of the body part 10 with respect to the electrolyte is reduced, the amount of heat generated by the body part 10 can be reduced. As a result, the temperature rise of the electrolytic solution is suppressed and the temperature of the electrolytic solution during anodic oxidation is stabilized, so that it is possible to manufacture a transfer roll in which variation in the depth of the pores is suppressed. Further, when it is necessary to gradually heat the body 10 when the body 10 is anodized, the temperature of the body 10 and the electrolytic solution can be increased by performing anodization while supplying the temperature control medium to the temperature control medium flow path 20. Can be controlled to a higher degree.

  In the anodizing step, the body 10 is sandwiched in the axial direction from both ends in the axial direction, the electrolyte can be prevented from entering the temperature control medium flow path 20, and the body 10 can be energized. It is preferable to use a jig. In addition, a jig that can prevent the electrolyte from entering the temperature control medium flow path 20 of the body 10 and can supply current to the body 10 while supplying the temperature control medium to the temperature control medium flow path 20 is used. Is more preferable. As an example of such a jig, an electrode member (not shown) that has the same structure as the shaft portion illustrated in FIGS. 1 and 3 and supplies current to the body portion 10 from a portion in contact with the body portion 10. )).

  And after forming the oxide film 54 which has the pore 52 as shown in FIG.4 (b), the process (anodization process) which forms the anodized alumina which has a several pore by anodizing, The transfer roll is manufactured by repeating the step of expanding the pore diameter (pore diameter expansion treatment).

  On the other hand, when forming more regular pores, first, before repeating the anodizing process and the pore diameter expanding process, an oxide film is formed by anodizing as shown in FIG. After that, it is preferable to remove at least a part of the oxide film 54 once as shown in FIG. The regularity of the pores formed in the transfer roll can be improved by making the recesses formed in this way into the pore generation points 56 of the anodic oxidation performed in the next step.

  Examples of the method for removing the oxide film 54 include a method of removing the oxide film by immersing it in a solution that selectively dissolves the oxide film without dissolving the base aluminum. Examples of such a solution include a chromic acid / phosphoric acid mixed solution.

  Then, when the body 10 from which the oxide film has been removed is anodized again, an oxide film 54 having cylindrical pores 52 is formed as shown in FIG.

  The conditions for anodizing, that is, the conditions for performing the anodizing process again on the body 10 from which the oxide film has been removed may be the same as those for forming the oxide film 54 shown in FIG. Various changes may be made. In general, the deeper the pores, the longer the anodic oxidation time.

  And after forming the oxide film 54 which has the cylindrical pore 52, as shown in FIG.4 (e), the process which expands the diameter of the pore 52 is performed. The pore diameter expansion treatment is a treatment for expanding the diameter of the pores obtained by anodic oxidation by immersing in a solution dissolving the oxide film. Examples of such a solution include a phosphoric acid aqueous solution of about 5% by mass. The longer the pore diameter expansion processing time, the larger the pore diameter.

  Then, when the body 10 is anodized again, as shown in FIG. 4F, cylindrical pores 52 having a small diameter that extend downward from the bottom of the cylindrical pores 52 are further formed. That is, after performing the pore diameter enlargement process of the pores 52, the body 10 is again anodized, so that the cylindrical pores 52 are deeper into the oxide film 54 as shown in FIG. Can be formed.

  Anodizing conditions, that is, conditions for performing anodizing treatment on the body 10 again after performing the pore diameter enlargement processing of the pores 52 may be the same conditions as described above, and are variously changed. It doesn't matter. Deeper pores can be obtained as the anodic oxidation time is lengthened.

  Then, by repeating the pore diameter expansion process and the anodizing process as described above, the pores 52 having a shape in which the diameter continuously decreases in the depth direction from the opening as shown in FIG. Thus, a roll-shaped mold 60 (transfer roll) in which an anodized alumina (a porous oxide film of aluminum (alumite)) having selenium is formed is obtained.

  The total number of repetitions of the pore enlargement treatment and the anodizing treatment is preferably 3 times or more, and more preferably 5 times or more. The upper limit of the number of repetitions of the anodizing treatment is preferably 10 times or less. When the total number of repetitions is 2 or less, the diameter of the pores decreases discontinuously. Therefore, the optical film produced by transferring such pores is insufficient in the reflectance reduction effect. It is preferable that the repetition of the pore diameter expansion process and the anodizing process is terminated by the pore diameter expansion process from the viewpoint of forming a shape in which the diameter of the formed pores continuously changes. By forming a shape in which the diameter of the pores to be continuously changed, the refractive index can be continuously increased, the fluctuation of the reflectance due to wavelength (wavelength dependence) is suppressed, and the visible light This is preferable because the effect of suppressing the scattering and reducing the reflectance can be obtained.

  Examples of the shape of the pore 52 shown in FIG. 4G include a substantially conical shape and a pyramid shape. The average period between the pores 52 is preferably not more than the wavelength of visible light, that is, not more than 400 nm. By setting the average period to 400 nm or less, scattering of visible light can be suppressed, and it can be suitably used as an antireflection film for optical applications. The average period between the pores 52 is preferably 25 nm or less. By setting the average period to 25 nm or less, release of the transferred material from the transfer roll can be facilitated.

  The aspect ratio (depth of the pore / width of the opening of the pore) of the pore 52 shown in FIG. 4G is preferably 1.5 or more, and more preferably 2.0 or more. If the aspect ratio of the pore 52 shown in FIG. 4 (g) is 1.5 to 2.0, the wavelength dependency of reflected light is reduced while exhibiting excellent antireflection performance, and the color by visual observation is reduced. The difference in taste is preferable because it is difficult to recognize.

(Connection process)
The manufacturing method of the transfer roll of the present invention includes a connecting step of connecting the shaft portion 40 to both end portions of the cylindrical axial direction of the body portion 10 obtained through the above-described anodizing step.
The connecting step includes a step of connecting the barrel portion 10 and the shaft portion 40 with the flange portion 11 provided on the barrel portion 10 and a flange portion 41 provided on one end surface of the shaft portion 40, or It is preferable to be a step of connecting the shaft portion 42 with the formed concave portion (or convex portion). Moreover, when connecting the trunk | drum 10 and the axial part 40, it is preferable that it connects so that removal is possible.

<Production method>
Next, on at least a part of the outer peripheral surface, the fine uneven shape formed on the cylindrical body portion of the transfer roll based on the present invention composed of the cylindrical body portion and the shaft portion having the fine uneven shape, A method for obtaining an article having a plurality of convex portions whose surfaces are inverted by the imprint method and transferred to the transfer medium will be described.

  Examples of the imprint method include an optical imprint method, which will be described later, or heat that transfers a plurality of pores of anodized alumina to a transfer target by pressing a heated transfer roll against the transfer target made of a thermoplastic resin. An imprint method may be mentioned. Among these, the optical imprint method is preferable from the viewpoint of equipment and productivity.

  Hereinafter, the method for producing the article of the present invention by the optical imprint method will be described in detail.

  Examples of the method for producing the article of the present invention by the photoimprint method include a method having the following steps (I) to (III).

  Step (I): A step of sandwiching the active energy ray-curable resin composition between the surface of the base film and the surface of the transfer roll while moving the base film along the surface of the rotating transfer roll. .

  Step (II): The active energy ray-curable resin composition sandwiched between the surface of the base film and the surface of the transfer roll is irradiated with active energy rays to cure the active energy ray-curable resin composition. And a step of forming a cured resin layer having a plurality of convex portions having inverted pores of anodized alumina on the surface.

  Process (III): The process of peeling a base film from a transfer roll with a cured resin layer.

  Examples of the base film include a polyethylene terephthalate film, a polycarbonate film, an acrylic film, and a triacetyl cellulose film.

  Examples of the active energy ray-curable resin composition include active energy ray-curable compositions described in paragraphs [0046] to [0055] of JP2009-174007A (Patent Document 1), and JP2009-241351A. Examples include active energy ray-curable resin compositions described in paragraphs [0052] to [0094] of the publication.

  The manufacturing method of the article of the present invention by the optical imprinting method is manufactured as follows using, for example, a manufacturing apparatus shown in FIG.

  Active energy ray curable from a tank 74 between a transfer roll 70 in which anodized alumina having a plurality of pores is formed on the outer peripheral surface and a belt-like substrate film 72 that moves along the surface of the transfer roll 70. The resin composition 76 is supplied.

  The base film 72 and the active energy ray curable resin composition 76 are nipped between the transfer roll 70 and the nip roll 80 whose nip pressure is adjusted by the pneumatic cylinder 78, and the active energy ray curable resin composition 76 is The base film 72 and the transfer roll 70 are uniformly distributed, and at the same time, the pores on the outer peripheral surface of the transfer roll 70 are filled.

  Using the active energy ray irradiating device 82 installed below the transfer roll 70 in a state where the active energy ray curable resin composition 76 is sandwiched between the transfer roll 70 and the base film 72, the base film The active energy ray-curable resin composition 76 is irradiated with active energy rays from the side 72 and the active energy ray-curable resin composition 76 is cured, whereby a plurality of pores on the outer peripheral surface of the transfer roll 70 are transferred. A cured resin layer 84 is formed.

  The article 88 is obtained by peeling the base film 72 having the cured resin layer 84 formed on the surface from the transfer roll 70 by the peeling roll 86.

When the active energy ray-curable resin composition 76 is cured by irradiating ultraviolet rays, the resin composition generates heat, or the transfer roll 70 and the active energy ray resin composition 76 are heated by the irradiated ultraviolet rays. There is a case. If the temperature of the transfer roll or the active energy ray-curable resin composition 76 varies greatly during the manufacture of the article 88, the shape transferred to the article 88 may vary, which is not preferable.
Since the temperature control medium flow path is formed in the body portion of the transfer roll according to the present invention, the temperature control medium is supplied to the temperature control medium flow path during the manufacture of the article 88, so that the article 88 is being manufactured. In addition, the temperature of the transfer roll and the active energy ray-curable resin composition 76 can be adjusted.
As the temperature control medium supplied to the temperature control medium flow path, water, oil, or a fluorine-based heat medium can be used. In the method for producing an article of the present invention, when the article is produced while supplying the temperature control medium to the temperature control medium flow path, the temperature control medium is supplied to the temperature control medium flow path using a conventionally known method such as a pump. It is preferable to supply.
30-80 degreeC is preferable and, as for the temperature of the temperature control medium supplied to a temperature control medium flow path, 40-70 degreeC is more preferable.

As the active energy ray irradiation device 82, a high-pressure mercury lamp, a metal halide lamp or the like is preferable. In this case, the amount of light irradiation energy is preferably 100 to 10,000 mJ / cm ² .

Examples of the article 88 include an optical film (such as an antireflection film).
That is, the article 88 obtained by the method for producing an article of the present invention can be used for applications such as an optical film (antireflection film or the like).

  In the transfer roll according to the present invention, even if the nip roll 80 is pressed against the transfer roll using the pneumatic cylinder 78, the shaft portion is made of a material having high rigidity. Displacement / deformation can be prevented.

  In the transfer roll according to the present embodiment described above, at least a part of the outer peripheral surface includes a body portion having a fine uneven shape, and shaft portions made of a material different from the body portion on both end surfaces of the body portion from both sides. By fastening, even when the body part is widened, it is not necessary to perform an intermediate machining of the inner diameter part of the body part. Further, since there is no sleeve and mandrel, the space for mounting the transfer roll can be greatly reduced. Further, the shaft portion made of a material different from that of the body portion improves the strength of the bearing portion in the shape of the transfer roll, and the rotary joint can be attached. Furthermore, it is not necessary to perform complicated processing on the body portion made of high-purity aluminum, and a transfer roll can be manufactured even when the body portion is widened.

  Even when the transfer roll is widened, a transfer roll that does not require intermediate machining of the inner diameter portion of the body portion, can maintain the strength of the bearing portion, and can easily form a temperature control medium flow path inside the transfer roll. Can be provided.

10 trunk 11 flange (body)
12 Mounting gap 20 Temperature control medium flow path (trunk)
30 Temperature control medium flow path (shaft)
32 Groove-shaped channel 40, 42 Shaft part 41 Flange part (shaft part)
50 connecting hole 51 fitting part 52 pore 54 oxide film 56 pore generation point 60 roll-shaped mold 70 transfer roll 72 base film 74 tank 76 active energy ray curable resin composition 78 pneumatic cylinder 80 nip roll 82 active energy ray irradiation Device 84 Cured resin layer 86 Peeling roll 88 Article

Claims (9)

At least a part of the outer peripheral surface, a cylindrical roll having a fine uneven shape, and a transfer roll composed of a shaft part,
The body is made of high purity aluminum;
The shaft portion is made of a material having higher rigidity than the material forming the body portion, and is disposed on both sides of the body portion in the columnar axial direction so as to sandwich the body portion in the axial direction. and,
A transfer roll characterized in that a temperature control medium flow path is formed in the body portion .   The both end surfaces of the body portion and one end surface of the shaft portion each have a flange portion, and the body portion and the shaft portion are fastened by fastening means at the flange portion. Item 2. The transfer roll according to Item 1.   The both end surfaces of the body portion and one end surface of the shaft portion each have a fitting portion, and the body portion and the shaft portion are fitted in the fitting portion. Item 2. The transfer roll according to Item 1. The transfer roll according to any one of claims 1 to 3 , wherein the temperature control medium flow path is a through hole penetrating the body portion along a cylindrical axial direction. A transfer roll manufacturing method comprising:
Forming a high-purity aluminum into a cylindrical shape, and forming a temperature control medium flow path in the high-purity aluminum formed into the cylindrical shape ; and
Anodizing the high-purity aluminum molded into the columnar shape to obtain a body having a fine irregular shape on at least a part of the outer peripheral surface;
The manufacturing method of the transfer roll characterized by including the connection process which connects a axial part to the both ends of the cylindrical axial direction of the said trunk | drum. The method for producing a transfer roll according to claim 5 , wherein the anodizing step includes anodizing the high-purity aluminum while supplying a temperature control medium to the temperature control medium flow path. The transfer roll according to claim 5 or 6 , wherein the temperature control medium flow path is a through hole formed in the high-purity aluminum along a cylindrical axial direction of the high-purity aluminum. Manufacturing method. An article having fine irregularities transferred to the surface using the transfer roll according to any one of claims 1 to 4 or the transfer roll produced by the method according to any one of claims 5 to 7. A method for producing an article, characterized in that The fine concavo-convex structure was transferred to the surface using the transfer roll according to any one of claims 1 to 4 or the transfer roll produced by the method according to any one of claims 5 to 7 . An article manufacturing method for obtaining an article, comprising: producing the article while supplying the temperature adjustment medium to the temperature adjustment medium flow path when obtaining the article.

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