JP6535535B2 - Film pattern transfer apparatus and film pattern transfer method - Google Patents

Description

  An embodiment of the present invention is an apparatus for simultaneously transferring a film-like mold (imparting surface of a shaped film) on both sides of a film (base film) as a base of pattern transfer, a so-called roll-to-roll type simultaneous transfer apparatus and It relates to the transfer method.

  For example, in Patent Document 1, a photoreactive composition is applied on both sides of a base film to form a photoreactive composition layer, and a light transmitting film is attached on the formed photoreactive composition layer. There is disclosed an apparatus which peels a laminated light transmitting film after irradiating the light to cure the composition layer. Such an apparatus is provided with a light transmissive film feeder and a winder respectively on one side and the other side of the base film. Therefore, if a resin film is formed on the film surface with a transparent resin or the like having ultraviolet curability and the surface of the resin layer is processed as a molding surface (concave / convex portion), the photoreaction of the base film is used. It is possible to transfer the shaping surface to the base composition layer and simultaneously form on the base film a predetermined pattern (concave / convex portions obtained by reversing the irregularities of the shaping surface) on both sides simultaneously.

  As described above, the device described in Patent Document 1 can be used as a device (a double-sided simultaneous transfer type device) that simultaneously forms a pattern on which a shaping surface is transferred on both sides of a base film, and the operation in this case will be described. . In such an apparatus, the base film is fed out from the delivery roll in a horizontal direction (a predetermined direction on a plane orthogonal to the gravity direction). In this case, for example, an ultraviolet curable resin is applied to the upper and lower film surfaces of the drawn base film from the upper side and the lower side to form a layer of the ultraviolet curable resin (hereinafter simply referred to as a resin layer). The upper and lower sides are defined based on the direction of gravity, and in the following description, the upper film surface of the base film is referred to as the front surface, and the lower film surface is referred to as the back surface for the sake of convenience.

  Next, a shaped film for the surface is attached to the resin layer on the surface of the base film. At that time, the shaping film for the surface directs the shaping surface to the surface of the base film. At the same time, a shaping film for the back surface is bonded to the resin layer on the back surface of the base film. At that time, the shaping film for the back surface directs the shaping surface to the back surface of the base film. A pressing roll is disposed at the bonding site, and by pressing the shaping film against the base film from above and below, the shaping surface of the shaping film is transferred to the resin layers on the front and back surfaces of the base film, respectively. It has become. Thereby, a pattern is formed on the surface of the resin layer of the base film.

  Then, the resin layer on the front and back of the base film is irradiated with ultraviolet light from the light source of the cured resin layer in a state of being sandwiched between the upper and lower forming films, and the resin layer on which the pattern is formed is cured and fixed to the base film Let Thereby, a transfer film is produced | generated as a base film which has a pattern on the surface of a resin layer. Thereafter, the shaping film is peeled off from the transfer film by a peeling roll. Thus, according to the apparatus described in Patent Document 1, it is possible to simultaneously form a pattern transferred from the forming film on both sides of the base film.

Unexamined-Japanese-Patent No. 2004-322408

  However, when the same pattern is formed on both sides of the base film, the following problems occur in the apparatus described in Patent Document 1.

  In the apparatus described in Patent Document 1, the base film is conveyed horizontally, and the application of the ultraviolet curable resin to the base film is performed from above and below. The coating liquid of the ultraviolet-curable resin spreads in a plane (leveling) because it has fluidity until it is cured after being applied. Leveling improves the uniformity of the resin layer formed on the base film. Since the base film is continuously transported, the applied ultraviolet curable resin tends to spread in the transport direction. On the other hand, it is difficult for the applied ultraviolet curable resin to spread in the direction (hereinafter referred to as the width direction) orthogonal to the transport direction on the film surface of the base film. That is, on the upper side (surface side) of the base film, the coating liquid is discharged in the direction of gravity (downward) at the time of formation of the resin layer, so it is relatively easy to spread in the width direction. On the other hand, on the lower side (back side) of the base film, the coating liquid is discharged in the opposite direction (upward) to the gravity direction, so it is difficult to spread in the width direction. Therefore, a difference occurs in the degree of leveling between the front surface and the back surface of the base film, which may cause a difference in the thickness of the resin layer on the front surface and the back surface.

  In a pattern transfer portion (arrangement portion of pressing roll) in which the shaping film is pressed against the base film to transfer the shaping surface to the resin layer, the shaping film is supplied from above on the surface of the base film and from below on the back surface. Ru. At the portion where the shaping surface of the shaping film and the resin layer of the base film merge, the shaping surface of the shaping film is in contact with the ultraviolet curable resin forming the resin layer of the base film. The air between the resin layer and the resin layer is pushed out by the ultraviolet curable resin and escapes from the shaping surface. Therefore, if the resin layer is cured by the irradiation of ultraviolet rays before the air is completely released between the shaping surface and the resin layer, the accuracy of the pattern formed on the resin layer may be deteriorated by the remaining air. In particular, when the transport speed of the base film is high, the resin layer is cured before the air between the shaping surface and the resin layer is completely exhausted, and the pattern accuracy of the resin layer is further likely to be reduced. The air between the shaping surface and the resin layer rises due to buoyancy, but the back surface side of the base film is less likely to be released of air than the front surface side because the upper portion is blocked by the base film. For this reason, in order to pull out the air between the shaping surface and the resin layer on the back surface side of the base film, it may be necessary to suppress the transport speed of the base film.

  Further, in the pattern transfer portion, the pressing rolls are vertically arranged so as to sandwich the upper and lower shaped films bonded to the resin layer of the base film. The pressing roll is deformed to bend downward by its own weight. Therefore, the base film and the resin layer are deformed so that the central portion in the width direction on the front surface side bends downward and the rear surface side protrudes downward by that amount. When the resin layer is cured in this state, the base film may be curved downward, and as a result, the patterns of the front and back surfaces are likely to be different.

  In the resin layer cured portion in which the resin layer on which the pattern is formed is cured and fixed to the base film, ultraviolet irradiation lamps for irradiating the resin layer with ultraviolet rays are vertically disposed. The ultraviolet irradiation lamp also generates light of a wavelength other than ultraviolet light, and the heat of polymerization is generated when the resin layer is cured, so the ambient temperature of the cured portion of the resin layer rises. The warmed air goes up. Therefore, on the surface side of the base film, an ascending air flow is generated toward the ultraviolet irradiation lamp, but on the back surface side, the ascending air flow is blocked by the base film and heat is easily accumulated. For this reason, a difference arises in atmospheric temperature by the surface side and the back side of a base film, and a difference may arise in curability by the resin layer by the side of a surface, and the resin layer by the side of a back. In this case, a difference may occur in the form of the front and back patterns.

  In the resin layer cured portion, when the tension of the base film and the forming film is small, these films deform so as to sag downward by their own weight. Such deformation due to its own weight occurs in both the transport direction and the width direction, but since the width direction is supported by the pressure roller, the slack in the transport direction becomes a problem. In particular, when it is necessary to transport the base film and the shaping film with low tension, there is a possibility that these films will be greatly slackened in the transport direction. In such a state, a compressive force acts on the front side of the base film, and a pulling force acts on the back side. Therefore, when the resin layer is cured in this state, the force acting on the front surface side and the back surface side of the base film is different, so that there is a possibility that the form of the pattern of the front surface and the back surface may be different.

  Thus, in the apparatus described in Patent Document 1, when forming a pattern in which the shaping surface of the shaping film is transferred on both sides of the base film, the conditions of the formation environment are the front side (upper side) and the back side (bottom side). Often do not match.

  In this case, from the resin layer forming portion forming the resin layer on the base film to the pattern transfer portion and the resin layer curing portion, the transfer film provided with the base film and the resin layer having the pattern formed on the base film It is conceivable to solve the above-mentioned problems by conveying from the top to the bottom.

  With such an apparatus configuration, it is possible to make the influence of gravity on one surface side and the other surface side of the base film coincide with each other. On the other hand, it is necessary to arrange the resin layer forming portion, the pattern transfer portion, and the resin layer curing portion along the direction of gravity, and the height (dimension along the direction of gravity) of the device increases accordingly. Therefore, even when the height of the apparatus is increased, it is required to ensure that the transport path (pass line) of the base film and the transfer film is along the direction of gravity.

  Therefore, the film is stably transported from the top to the bottom along the direction of gravity, and the film pattern can be formed simultaneously on both sides with the film surely along the direction of gravity. Provided are a transfer device and a method for transferring a pattern of a film.

  The pattern transfer apparatus of a film of the embodiment applies a liquid resin on both sides of a base film to form a resin layer, and a forming film is pressed against the resin layer of the base film to form a forming film. The pattern transfer portion which forms a pattern on the surface of the resin layer by transferring the form surface to the resin layer, and the resin layer on which the pattern is formed are cured and fixed to the base film to form a transfer film. A cured portion, a shaping film peeling portion for peeling the shaping film from the transfer film, a base film is fed out, and a resin layer forming portion, a pattern transfer portion, a resin layer curing portion and the shaping film peeling portion are allowed to pass. And a film transport unit for winding up the transferred film. The film transport unit has a guide roll that directs the transport direction of the base film from the top to the bottom along the gravity direction before the resin layer forming unit. The resin layer forming portion has a pair of dies disposed one on each side of the base film with the positions of the resin discharge ports shifted vertically. Of the pair of dies, the dies disposed on the upper side are disposed on the side of the base film not in contact with the guide rolls.

  According to the film pattern transfer device of the embodiment and the film pattern transfer method of the embodiment, the film can be stably transported from the top to the bottom along the gravity direction. Also, in a state where the film is surely aligned with the direction of gravity, it is possible to simultaneously form a pattern on both sides thereof.

BRIEF DESCRIPTION OF THE DRAWINGS The schematic block diagram which shows the pattern transfer apparatus of the film for enforcing the pattern transfer method of the film of embodiment. In the pattern transfer apparatus of the film of the embodiment, a transfer film having a pattern in which the shaping surface of the shaping film is transferred to the resin layer of the base film is generated, and an aspect is shown until the shaping film is peeled from the transfer film. Schematic configuration diagram. BRIEF DESCRIPTION OF THE DRAWINGS The schematic block diagram which shows the apparatus (general roll-to-roll-type single-sided UV transfer apparatus) which forms a shaping surface to a shaping film. It is a figure which shows the embodiment of a shaping surface and a pattern, Comprising: (a) is a top view of the shaping surface made into the line and space (a vertical groove or a horizontal groove), (b) is the application in the arrow A41 part of (a). (C) shows the pattern corresponding to the line and space of (a) in the same cross section as (b), (d) shows the cross-groove shaped surface A top view, (e) shows the cross section of the shaping surface in the arrow A 42 part of (d) from the arrow direction, (f) shows the pattern corresponding to the cross groove of (d) in the same cross section as (e) Figure showing (g) is a plan view of the shaping surface with dots, (h) shows the cross section of the shaping surface in the arrow A43 part of (g) from the arrow direction, (i) is the dot with (h) The figure which shows the pattern corresponding to (e) by the same cross section. It is a figure which shows the example of the alignment mark formed in a base film, Comprising: (a) is a figure which shows the form of the alignment mark of the surface of a base film, and a back surface from the back side, (b) is a base film FIG. 8 is a view showing an aspect of misalignment in the transport direction and width direction of the alignment mark that occurs on the front and back surfaces. It is a figure which shows the relationship between the holding angle (lap angle) of the base film with respect to a guide roll, and the position of the die in the both sides of a base film, Comprising: (a) is a die of the front side of a base film The figure which shows the aspect example arrange | positioned on upper side and enlarging a holding angle, (b) arrange | positions the die | dye of the back surface side of a base film above the die | dye of surface side, and reduces the holding angle. Figure showing. It is a figure which shows the movement aspect of the die | dye and guide roll by a movement mechanism, Comprising: (a) is a state in which the base film and the shaping film are displaced to the back surface side of the base film with respect to the gravity direction (pass line). (B) shows a state in which the die film and the guide roll are moved in the direction indicated by the arrow A7 in (a) and the base film and the shaping film are placed along the pass line. It is a figure which shows the movement aspect of the die | dye and guide roll by a movement mechanism, Comprising: (a) is a state in which the base film and the shaping film are displaced to the surface side of the base film with respect to the gravity direction (pass line). (B) shows a state in which the base film and the shaping film are made to pass along the pass line by moving the die and the guide roll in the direction indicated by the arrow A8 in (a). The figure which shows the cross section in the arrow A11 part of FIG. 1 from an arrow direction. The figure which shows the example of a press roll of a resin layer hardening part. The figure which shows the modification of the aspect of the press roll of a resin layer hardening part. The figure which shows the cross section in the arrow A 12 part of FIG. 1 from an arrow direction. The schematic block diagram which shows the moving mechanism of the shaping film delivery axis | shaft for surfaces (roll of the shaping film for surfaces).

  Hereinafter, a film pattern transfer apparatus and a film pattern transfer method according to an embodiment of the present invention will be described with reference to FIGS. 1 to 13.

  FIG. 1 is a schematic configuration view showing a film pattern transfer apparatus 1 for carrying out the film pattern transfer method of the present embodiment. The pattern transfer apparatus 1 is an apparatus that simultaneously transfers a film-like mold (imformed film) 3 on both sides of a film (base film) 2 serving as a base of pattern transfer to form a pattern to generate a transfer film 20 ( Roll-to-roll type double-sided simultaneous transfer device).

  As shown in FIG. 1, the pattern transfer device 1 includes a resin layer forming unit 4, a pattern transfer unit 5, a resin layer curing unit 6, a shaping film peeling unit 7, and a film transport unit 8. The resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, and the shaping film peeling unit 7 are disposed in this order along the gravity direction from the top to the bottom. The film conveyance unit 8 sequentially conveys the base film 2 to the resin layer forming unit 4, the pattern transfer unit 5, and the resin layer curing unit 6, and sequentially transfers the transfer film 20 to the resin layer curing unit 6 and the shaping film peeling unit 7. Are being transported.

  In FIG. 2, the shaping surface (concave portion) 31 of the shaping film 3 is transferred to the resin layer 22 of the base film 2, and the pattern 21 (concave portion in which the concavo-convex portion of the shaping surface 31 is reversed) is formed. It is the schematic which shows the aspect until the shaping | molding film 3 peels from the base film 2 which hardened | cured the resin layer 22 after that, and was made to adhere. In the following description, the base film 2 on which the resin layer 22 in which the pattern 21 is formed is cured and fixed is referred to as a transfer film 20 and is appropriately distinguished from the base film 2.

  As shown in FIG. 2, the base film 2 is a resin film in which a flat film surface is continuous over a predetermined length. In the present embodiment, the base film 2 having light transmission (light transmission), specifically, ultraviolet transmission, is applied as an example, but a light shielding film (for example, an opaque film such as a metal foil) is used as a base It is also possible to apply as a film 2. In the following description, for convenience, of the film surfaces of the base film 2, the film surface (surface on the outer peripheral side of the curve) of one side of the base film 2 not in contact with the guide roll 83 described later The film surface (surface on the inner peripheral side of the curve in contact with the guide roll 83) is referred to as the back surface 2b. Also about the transfer film 20 mentioned later, the film surface corresponded to the surface side and back surface side of the base film 2 is called front surface and back surface, respectively.

  The shaping film 3 is a transparent resin film having an ultraviolet ray transmittance in which the film surface is continuous over a predetermined length. The shaping film 3 is configured as a resin mold, and a predetermined shaping surface 31 is formed on one side. Before forming the pattern 21 on the base film 2, the shaping surface 31 corresponding to the pattern 21 is formed on the film surface on one side of the shaping film 3 in advance. That is, the pattern 21 and the shaping surface 31 are concavo-convex portions obtained by inverting the concavo-convex portions with each other, and the shaping surface 31 corresponds to a forming die of the pattern 21. The formation of the shaping surface 31 on the shaping film 3 will be described later.

  The resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, the shaping film peeling unit 7, and the film transport unit 8 are divided by a floor material and divided into a plurality of spaces arranged vertically along the gravity direction. Are arranged. Each of these spaces may be, for example, each floor of a two- or more-story building, or an arrangement area in which one floor of a building or a single-story building is divided into a plurality of levels having different heights from the floor surface. Or the like. Specifically, the arrangement area can be formed by applying a frame structure in which square tubes are combined, a structure in which plate members are connected by stays, or the like.

  As described above, by arranging the resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, the shaping film peeling unit 7, and the film transport unit 8 in layers, individual work with a certain length is possible. Even when the process distance is required, the resin layer forming portion 4, the pattern transfer portion 5, the resin layer curing portion 6, and the shaping film peeling portion 7 along the gravity direction (finally in the height direction) The base film 2 or the transfer film 20 can be transported by the film transport unit 8 to the respective portions 4 to 7. For example, when curing the ultraviolet curable resin layer of the base film 2 in the resin layer curing unit 6 as described later, even if it is necessary to irradiate ultraviolet rays over a certain transport distance (time), etc. The pattern transfer device 1 can be configured vertically.

  In the present embodiment, as shown in FIG. 1, four arrangement areas F1 to F4 are formed by dividing the inside of the building with floor materials 11 to 13. The floor materials 11 to 13 are supported by columns 14 provided on the floor 10 of the building. In this case, the third floor material 13 raises the floor surface 10, the first floor material 11 further raises the third floor material 13, and the second floor material 12 raises the first floor material 11. ing. The pattern transfer portion 5 and the resin layer curing portion 6 are separated by a first floor material 11, and the resin layer forming portion 4 and the pattern transfer portion 5 are separated by a second floor material 12. Further, in the arrangement area F2, the resin layer curing unit 6 and the shaping film peeling unit 7, the arrangement area F3, the pattern transfer unit 5, and the arrangement area F4, the resin layer formation unit 4 are respectively arranged. The film transport unit 8 is disposed across all of the placement areas F1 to F4.

  Through holes 11 a to 13 a are formed in the floorings 11 to 13 respectively in a straight line along the gravity direction. The base film 2 (transfer film 20) and the shaping film 3 are passed through the through holes 11a to 13a. In this case, both the base film 2 and the shaping film 3 are passed through the first through hole 11a, the base film 2 is passed through the second through hole 12a, and the transfer film 20 is passed through the third through hole 13a. There is. The virtual straight line in the direction of gravity passing through the through holes 11a to 13a corresponds to the normal transport path of the base film 2 (transfer film 20) and the shaping film 3, and the virtual straight line (transport path) is hereinafter referred to It is called line PL.

  The pattern transfer apparatus 1 according to the present embodiment is an apparatus for simultaneously transferring the shaping surface 31 of the shaping film 3 on both sides of the base film 2 to form the pattern 21. The formation of the forming surface 31 will be described.

  FIG. 3 shows a schematic configuration of a device (general roll-to-roll type single-sided UV transfer device) 30 for forming the shaping surface 31 on the film surface on one side of the shaping film 3. As shown in FIG. 3, in the shaping film 3, the resin layer 30 b is formed on one surface of the base film 30 a for shaping film, and the molding roll 305 is pressed against the resin layer 30 b. It forms by transferring the uneven | corrugated | grooved part which becomes a type | mold of 31) to the resin layer 30b. In the following description, for convenience, the film side of the resin film 30b of the base film 30a for forming film, that is, the film side of the forming surface 31 of the forming film 3 is the surface, and the film side of the back side. Is called the back side.

  The base film 30 a for shaping film is a transparent resin film having an ultraviolet ray permeability in which a flat film surface is continuous over a predetermined length, and is fed out from the feeding shaft 301. A resin is discharged from the die 303 onto the surface of the base film 30a for a forming film that has been drawn out, and the resin layer 30b is formed of the discharged resin. As the resin, a transparent resin which is ultraviolet curable and which is liquid at normal temperature is used.

  The forming film base film 30a having the resin layer 30b formed on its surface is pressed against the forming roll 305 by the pressing roll 304, and the forming die 306 of the forming roll 305 is transferred to the resin layer 30b. As a result, the shaping surface 31 is formed on the resin layer 30 b as an uneven portion in which the unevenness of the molding die 306 is reversed. The resin layer 30 b on which the shaping surface 31 is formed is irradiated with ultraviolet light from the ultraviolet irradiation lamp 307 to be cured.

  The resin film 30b on which the shaping surface 31 is formed is cured, and the shaping film base film 30a fixed to the surface, that is, the shaping film 3 is peeled off from the molding roll 305 by the peeling roll 308 and It is taken up. The forming film base film 30a and the forming film 3 are appropriately relayed and conveyed by the plurality of relay rolls 310.

  The shaping surface 31 has an uneven shape in which the unevenness of the molding die 306 is reversed. FIG. 4 shows an embodiment of the shaping surface 31. 4 (a) and 4 (b) are vertical grooves (horizontal grooves) called line and space, FIGS. 4 (d) and 4 (e) are cross grooves, and FIGS. 4 (g) and 4 (h) are examples of dots. However, the shaping surface 31 may be in any form. In the present embodiment, a shaping film 3a for the front surface 2a of the base film 2 (hereinafter suitably referred to as a shaping film for surface) 3a and a shaping film 3b for the back surface 2b (hereinafter suitably referred to as a shaping film for back surface) Form each. The shaping surface 31a of the shaping film 3a for surface and the shaping surface 31b of the shaping film 3b for back may be the same or different.

  For example, when the shaping surface 31a of the shaping film 3a for the front surface and the shaping surface 31b of the shaping film 3b for the back surface are the same, the shaping surface 31a of the surface 2a and the back surface 2b of the base film 2 The same pattern 21 is formed, which is composed of concavo-convex portions obtained by inverting the concavo-convex portions 31b. FIG. 4C shows an aspect of the pattern 21 formed when the shaping surfaces 31a and 31b are both line and space shown in FIGS. Similarly, FIG. 4 (f) shows the cross grooves shown in FIGS. 4 (d) and 4 (e), and FIG. 4 (i) shows the dots formed in FIG. 4 (d) and 4 (e). The aspect of the pattern 21 shown in FIG.

  Here, since it is necessary to transmit ultraviolet light to the resin layer 22 of the base film 2 as described later, the base film 30a for forming film and the resin layer 30b are both formed of a transparent resin having ultraviolet light permeability. In addition, as the transparent resin for forming the resin layer 30b, a resin that can be easily peeled off from the resin layer 22 is applied.

  In the apparatus 30 shown in FIG. 3, the molding die 306 is transferred onto the resin layer 30b using the molding roll 305 in which the molding die (concave and convex part) 306 is directly cut on the roll surface. The stamper manufactured in the above (plate-like base material having a concavo-convex portion formed on the surface) may be wound around a plain roll for transfer.

  Further, in the present embodiment, an alignment mark shaping portion for the front surface and a shaping surface 31b for the back surface shaping film 3b on the shaping surface 31a of the shaping film 3a for the front surface are provided with alignment marks for the back surface. Form the shape respectively. By monitoring the position of the alignment mark of the base film 2 formed by transferring these alignment mark shaping parts, the accuracy of pattern transfer to the base film 2 (for example, transfer of pattern 21, deviation of formation position, etc.) is adjusted. It is possible to A forming die (concave part or convex part) for the alignment mark shaping part is formed at one or a plurality of places on the roll surface of the forming roll 305. As a result, the alignment mark shaping portion (the uneven portion of the mold for the alignment mark shaping portion of the forming roll 305) is commonly provided at one or a plurality of positions common to the shaping films 3a and 3b for the front and back surfaces. The concave and convex portion is formed by inverting the

  In FIG. 5, an embodiment of an alignment mark (concave / convex portion obtained by inverting the uneven portion of the alignment mark shaped portion of the shaped film 3) formed on the base film 2 by the shaped film 3 for the front surface and the back surface. An example is shown. FIG. 5A is a view showing an aspect of the alignment mark 23a on the front surface 2a of the base film 2 and the alignment mark 23b on the back surface 2b from the back surface 2b side. In this case, the alignment marks 23a and 23b are circular, but the shape may be any figure, and may be characters, symbols, or the like. The accuracy adjustment of pattern transfer using these alignment marks 23a and 23b will be described later.

  Next, the pattern transfer device 1 of the present embodiment will be described along the flow of the base film 2 and the transfer film 20. As shown in FIG. 1, the base film 2 is transported by the film transport unit 8 from the resin layer forming unit 4 to the pattern transfer unit 5 and the resin layer curing unit 6 from the top to the bottom along the gravity direction. The transfer film 20 is conveyed by the film conveyance unit 8 from the resin layer curing unit 6 to the shaping film peeling unit 7 along the gravity direction from the top to the bottom.

  The film transport unit 8 includes a film feeding shaft 81 for feeding the base film 2 and a film winding shaft 82 for winding the transfer film 20 generated from the fed base film 2. The film delivery shaft 81 and the film take-up shaft 82 are both rotating shafts that rotate in a predetermined direction (clockwise in FIG. 1) by a motor (not shown), and the film delivery shaft 81 corresponds to the resin layer forming portion 4. A film winding shaft 82 is disposed on the front side (upstream side in the transport direction of the base film 2) on the tip side (downstream side of the shaping film peeling portion 7). Thus, the base film 2 maintains a predetermined tension from the resin layer forming unit 4 to the pattern transfer unit 5, the resin layer curing unit 6, and the shaping film peeling unit 7, including the modes before and after generation of the transfer film 20. It is transported. At that time, the film feeding shaft 81 and the film winding shaft 82 are rotationally controlled by a control unit (not shown) or the like so that the base film 2 and the transfer film 20 are always conveyed at a constant speed (line speed). There is.

  When arranged on the same side in the horizontal direction with the base film 2 (transfer film 20) as a boundary, the film feeding shaft 81 and the film winding shaft 82 rotate in the same direction, and are arranged on the opposite side in the horizontal direction The film feeding shaft 81 and the film winding shaft 82 rotate in opposite directions to each other. In FIG. 1, the film feeding shaft 81 is disposed in the placement area F3 and the film winding shaft 82 is disposed in the placement area F2, respectively, but the hierarchy in which these are disposed is not particularly limited.

  Further, the film transport unit 8 includes a guide roll 83 and a plurality of relay rolls 84 disposed on a transport path between the film feeding shaft 81 and the film winding shaft 82. Both the guide roll 83 and the relay roll 84 are idle rolls that rotate together with the base film 2 or the transfer film 20 conveyed by the film feeding shaft 81 and the film winding shaft 82, which are rotation shafts.

  The guide roll 83 curves the base film 2 in front of (on the upstream side of) the resin layer forming portion 4 and is disposed in the arrangement area F4 so as to direct the transport direction thereof from the top to the bottom along the gravity direction. The relay roll 84 changes the transport direction of the base film 2 or the transfer roll 20 together with the guide roll 83 between the film feeding shaft 81 and the film winding shaft 82. One of the relay rolls 84 (the relay roll 84b shown in FIG. 1) is disposed below the guide roll 83 along the gravity direction. The relay roll 84b is disposed in the placement area F1 such that the transport direction of the transfer film 20 is directed from the direction of gravity to another direction (horizontal direction in this embodiment) from the direction of gravity at the tip (downstream side) of the shaping film peeling section 7. It is done. In FIG. 1, the guide roll 83 and the relay roll 84a are arranged in the arrangement area F4, and the relay roll 84b and the relay roll 84c are arranged in the arrangement area F1, respectively, but the hierarchy in which these are arranged is not limited thereto.

  The resin layer forming unit 4 applies a liquid resin on both sides of the base film 2 to form a resin layer 22. As shown in FIG. 1, the resin layer forming unit 4 includes a tank 41 for storing resin, a pump 42 for delivering resin from the tank 41, and a die for discharging the resin delivered from the pump 42 on both sides of the base film 2. And 43. As a resin for forming the resin layer 22, a transparent resin which is ultraviolet curable and which is liquid at normal temperature is used. The tank 41, the pump 42, and the die 43 are connected by piping, and are disposed in the arrangement area F4 for the front surface 2a and the rear surface 2b of the base film 2, respectively. However, the tank 41 and the pump 42 may be combined into one unit for the front surface 2a and the rear surface 2b, and the pipes may be branched to supply resin to the pair of dies 43, respectively. .

  As shown in FIG. 1 and FIG. 2, the die 43 is disposed with the position of the resin discharge port 431 shifted vertically one by one on each side (surface 2a side and back surface 2b side) across the base film 2 ing. Specifically, of the pair of dies 43, the die 43a disposed on the upper side forms the resin layer 22a on one surface of the base film 2 not in contact with the guide roll 83, that is, the surface 2a of the base film 2. The resin discharge port 431 is disposed toward the surface 2a. On the other hand, the die 43b disposed on the lower side is disposed with the resin discharge port 431 directed to the back surface 2b so that the resin layer 22b is formed on the back surface 2b of the base film 2.

  When the resin is discharged from the resin discharge port 431 of the die 43, the base film 2 is slightly pushed (about several millimeters) by the resin discharge port 431. Therefore, as shown in FIG. 6, the die 43b can be a die by disposing the die 43a on the front surface 2a side of the base film 2 above the die 43b on the back surface 2b side (aspect shown in FIG. 6A). The holding angle (lap angle) of the base film 2 with respect to the guide roll 83 can be made larger (α1> α2) as compared to the case where it is arranged above the 43a (the embodiment shown in FIG. As a result, the guide roll 83 can be brought into contact with the base film 2 and smoothly rotated, and the base film 2 can be stably transported from the top to the bottom along the gravity direction. As a result, for example, it is possible to prevent the base film 2 from sliding on the roll surface of the guide roll 83 and to suppress a defect or the like occurring in the base film 2.

  The reason why the base film 2 is pressed by the die 43 when discharging the resin is to adjust the surface state of the resin layer 22 to be formed to be good. As a result, it is possible to form a smooth resin layer 22 on the surface without streaks and the like.

  The resin layer 22 of the base film 2 has different thicknesses on the front surface 2 a side and the rear surface 2 b side. In the present embodiment, as shown in FIG. 2, the resin layer 22 is thicker on the back surface 2 b side than on the front surface 2 a side (Da <Db). Therefore, the die 43 b forming the resin layer 22 b on the back surface 2 b side has a larger discharge amount per unit time from the resin discharge port 43 1 than the die 43 a forming the resin layer 22 a on the front surface 2 a side. The supply of resin from the tank 41 and the pump 42 to the dies 43a and 43b is adjusted.

  As shown in FIG. 1, the pattern transfer device 1 combines the one and the other of the pair of dies 43 (the die 43 a and the die 43 b) and the guide roll 83 together to form the pattern transfer portion 5, the resin layer curing portion 6 and the shaping. A moving mechanism 9 for moving the film peeling section 7 in the horizontal direction is provided.

  FIGS. 7 and 8 are diagrams showing movement of the dies 43a and 43b and the guide roll 83 by the movement mechanism 9. FIG. As shown in FIGS. 7 and 8, in the moving mechanism 9, the base film 2 or the base film 2 and the shaping film 3 are along the pass line PL in the gravity direction in the through holes 11 a to 13 a of the floorings 11 to 13. Thus, the dies 43a and 43b and the guide roll 83 are moved.

  As shown in FIG. 1, the moving mechanism 9 unitizes the die 43a, the die 43b, and the guide roll 83 into one unit, and moves these together with the unit. Therefore, the die 43a, the die 43b, and the guide roll 83 are moved by the moving mechanism 9 while maintaining the mutual positional relationship.

  When discharging the resin from the resin discharge port 431 of the dies 43a and 43b, the base film 2 is pushed slightly (approximately several millimeters) by the resin discharge port 431. At this time, the base film 2 is positioned from the pass line PL. There is a possibility of shifting. 7A, the base film 2 and the shaping film 3 are misaligned with respect to the pass line PL on the back surface 2b side (left side in FIG. 7A), and FIG. An example of the state which the base film 2 and the shaping film 3 shifted position with respect to the pass line PL to the surface 2a side (the right side in the figure (a)) is shown, respectively.

  When it is in the state shown in FIG. 7A, the die 43a is in the direction from the back surface 2b side to the front surface 2a side of the base film 2 along the horizontal direction (direction of arrow A7 shown in FIG. 7A). , 43b and the guide roll 83 are moved by the moving mechanism 9 by the distance L7. As a result, as shown in FIG. 7B, the base film 2 and the shaping film 3 can be made to pass along the pass line PL in the pattern transfer portion 5, the resin layer curing portion 6, and the shaping film peeling portion 7. .

  Further, in the state shown in FIG. 8A, in the direction from the front surface 2a side to the back surface 2b side of the base film 2 along the horizontal direction (direction of arrow A8 shown in FIG. 8A), The dies 43a and 43b and the guide roll 83 are moved by the moving mechanism 9 by the distance L8. As a result, as shown in FIG. 8B, the base film 2 and the shaping film 3 can be made to pass along the pass line PL in the pattern transfer portion 5, the resin layer curing portion 6, and the shaping film peeling portion 7. .

  The moving mechanism 9 can be linearly moved in a predetermined direction and can be positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanisms can be applied.

  As described above, according to the present embodiment, the dies 43a and 43b and the guide roll 83 can be moved in the horizontal direction by the moving mechanism 9. That is, the deviation from the pass line PL of the base film 2 and the shaping film 3 at the time of initial installation of the pattern transfer device 1 can be easily adjusted. In addition, even if a deviation from the pass line PL occurs after the operation of the pattern transfer apparatus 1, such deviation can be easily readjusted. Therefore, transfer of the shaping surface 31 to the resin layer 22 in the pattern transfer portion 5 and formation of the pattern 21, curing and adhesion of the resin layer 22 in the resin layer curing portion 6 (formation of transfer film 20), peeling of the shaping film Peeling of the shaping film 3 from the transfer film 20 in the part 7 can always be performed along the pass line PL.

  Therefore, the state of the transfer of the shaping surface 31 to the resin layer 22 and the state of formation of the pattern 21, the state of curing and fixation of the resin layer 22 on which the pattern 21 is formed, the peeling state of the shaping film 3 from the transfer film 20 , The front surface 2a and the back surface 2b can be matched. Thereby, the pattern 21 can be simultaneously and precisely formed on the front surface 2 a and the back surface 2 b of the base film 2.

  In the moving mechanism 9 of this embodiment, the die 43a, the die 43b, and the guide roll 83 are moved together as a unit, but the die 43a, the die 43b, and the guide roll 83 are individually or collectively and individually It is good also as a moving mechanism which can be moved. For example, as shown in FIG. 2, the die 43 a and the die 43 b are arranged with the positions of the resin discharge ports 431 shifted up and down, so even when these are moved individually, It is possible to avoid the situation of hitting each other and damaging.

  Further, in the present embodiment, as described later, the pattern transfer unit 5, the resin layer curing unit 6, and the shaping film peeling unit 7 are also movable in the horizontal direction by a predetermined moving mechanism.

  As shown in FIG. 1, the pattern transfer unit 5 is configured to draw the flow of the shaping film feeding shaft 51 for feeding the shaping film 3 and the shaping film 3 fed from the shaping film feeding shaft 51 along the gravity direction. And a roll 52 which is directed downward (simply along the pass line PL). The shaping film delivery shaft 51 and the roll 52 are in contact with the back surface of the shaping film 3 (the film surface on the back side of the shaping surface 31).

  In addition, the shaping film feeding shaft 51 and the roll 52 are respectively disposed in sets for the front surface 2 a and the back surface 2 b of the base film 2. On the surface 2a side of the base film 2, a surface-forming film delivery shaft 51a for delivering the surface-forming film 3a and a backup roll 52a for changing the flow of the surface-forming film 3a delivered are disposed downward There is. On the other hand, on the back surface 2b side of the base film 2, a back surface forming film delivery shaft 51b for delivering the back surface forming film 3b and an infeed roll 52b for changing the flow of the delivered back surface forming film 3b downward It is arranged.

  The front surface forming film delivery shaft 51a and the rear surface forming film delivery shaft 51b are rotation shafts that rotate in opposite directions to each other by a motor (not shown). In FIG. 1, the shaping film delivery shaft 51a for the front surface rotates counterclockwise, and the shaping film delivery shaft 51b for the back surface rotates clockwise. At that time, the shaping film delivery shaft 51a for the front surface and the shaping film delivery shaft 51b for the back surface are designed to deliver the shaping film 3a for the front surface and the shaping film 3b for the back surface at the same speed as the line speed of the base film 2 at all times. The rotation is controlled by a controller (not shown) or the like.

  As shown in FIG. 1 and FIG. 9, the backup roll 52a is a rubber idle roll that rotates along with the surface forming film 3a drawn by the surface forming film feeding shaft 51a. The in-feed roll 52b is a metal rotary roll rotated by a motor 53, and the roll surface is plated with, for example, hard chrome. The backup roll 52a and the infeed roll 52b flow the top forming film 3a and the bottom forming film 3b from top to bottom, and press the forming films 3a and 3b while pressing the base film 2 from top to bottom. It is opposed to send it out.

  As the base film 2 is fed by the backup roll 52a and the infeed roll 52b, the shaping surface 31a of the shaping film 3a for surface is brought into contact with the resin layer 22a of the base film 2 and transferred, and is transferred onto the surface of the resin layer 22a. A pattern 21a is formed. In addition, the shaping surface 31b of the shaping film 3b for back surface is brought into contact with the resin layer 22b of the base film 2 and transferred, and the pattern 21b is formed on the surface of the resin layer 22b. Since the shaping films 3a and 3b are brought into contact with the resin layers 22a and 22b of the base film 2, the resin layers 22a and 22b are inhibited from being uncured due to oxygen inhibition in the subsequent resin layer curing portion 6.

  The infeed roll 52 b is fixed to the first floor material 11, whereas the backup roll 52 a is movable relative to the first floor material 11. As shown in FIG. 1, the pattern transfer apparatus 1 includes a moving mechanism 54 for moving the backup roll 52a. The moving mechanism 54 moves the backup roll 52a in the horizontal direction so that the resin layer 22a of the base film 2 can be advanced and retracted relative to the infeed roll 52b in another way.

  Thereby, the pushing amount of the backup roll 52a with respect to the in-feed roll 52b can be appropriately adjusted. That is, since the contact pressure of the shaping surfaces 31a and 31b to the resin layers 22a and 22b can be adjusted, the transfer state of the shaping surfaces 31a and 31b to the resin layers 22a and 22b can be adjusted.

  The moving mechanism 54 can be linearly moved in a predetermined direction and can be positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanisms can be applied.

  As shown in FIGS. 1 and 2, the resin layer curing portion 6 has an action portion 61 for curing the resin layer 22 of the base film 2 on which the shaping surface 31 of the shaping film 3 has been transferred and the pattern 21 is formed. And a pressing roll 62 for pressing the resin layer 22 cured by the action portion 61 toward the base film 2. Since the resin layer 22 is formed of a transparent resin having an ultraviolet curing property, in the present embodiment, the light source 61a for irradiating the resin layer 22 with ultraviolet light and the light shielding plate 61b for shielding the ultraviolet light emitted from the light source 61a The action part 61 is configured. Further, since all of the resin layer 22, the base film 2 and the shaping film 3 are resins having ultraviolet permeability, the light source 61a is disposed on one side bordering the base film 2, and the light shielding plate 61b is disposed on the other side. ing. Thus, even if the arrangement of the light source 61a is only one side, the resin layer 22a on the surface 2a side of the base film 2 and the resin layer 22b on the back surface 2b side are both cured by the light source 61a. It can be fixed to the base film 2. In the present embodiment, the light source 61a is disposed on the front surface 2a side of the base film 2, and the light shielding plate 61b is disposed on the back surface 2b side.

  For example, a high pressure mercury lamp or an LED lamp can be applied as the light source 61a. When the light source 61a is an LED lamp, the amount of heat generation is extremely small, the heat damage to the base film 2 is small, and the base film 2 does not need to be cooled. In addition, the lamp itself is small, and power saving can be achieved. In addition, the light source 61 a is one or so that the resin layer 22 can be cured and fixed to the base film 2 until the base film 2 is transported to the shaping film peeling section 7. A plurality of pieces may be arranged side by side along the gravity direction (pass line PL). When the base film 2 is a light-shielding film (for example, an opaque film such as a metal foil), the light source 61a is disposed on both the front surface 2a side and the back surface 2b side of the base film 2.

  The pressing roll 62 is disposed between the light source 61 a of the action part 61 and the thin resin layer 22 cured by the action part 61, and presses the thin resin layer 22 toward the base film 2. In the present embodiment, the pressing roll 62 is disposed on the surface 2 a side of the base film 2 and configured to press the resin layer 22 a. In this case, the pressure roll 62 is made of an ultraviolet light transmissive material (for example, transparent resin having ultraviolet light permeability), and is disposed in front of the irradiation direction of the light source 61a. Thereby, the ultraviolet rays can be irradiated to the resin layer 22 b through the resin layer 22 a and the base film 2 without being blocked by the pressing roll 62.

  In the present embodiment, the resin layer 22b on the back surface 2b side of the base film 2 is thicker than the resin layer 22a on the surface 2a side. Since the thicker resin layer 22b has a larger shrinkage upon curing than the thinner resin layer 22a, as shown in FIG. 10, when the resin layers 22a and 22b are cured by irradiating ultraviolet light from the light source 61a. There is a possibility that the base film 2 may be warped so that the back surface 2b side (left side in the same figure) has a concave shape (state of broken line shown in the figure).

  Therefore, the pressing roll 62 is disposed on the front surface 2 a side of the base film 2 and presses the front surface 2 a side so as to resist the warpage to the back surface 2 b side. Thereby, the base film 2 is prevented from being warped to any side of the front surface 2 b and the back surface 2 b. That is, by pressing the surface 2a side of the base film 2 with the pressing roll 62, the resin layers 22a and 22b can be irradiated with ultraviolet light in a state in which the base film 2 is warped so that the surface 2a side becomes concave. it can.

  Thereby, it is possible to reduce the warping of the base film 2 toward the back surface 2b at the time of curing and fixing of the resin layers 22a and 22b, and the state of the base film 2 along the gravity direction (pass line PL) (solid line shown in FIG. 10) Can be Therefore, even if the resin layer 22b on the back surface 2b side of the base film 2 is thicker than the resin layer 22a on the surface 2a side, simultaneously forming the patterns 21 accurately on the surface 2a and the back surface 2b of the base film 2 it can. That is, the generation accuracy of the transfer form 20 can be enhanced.

  The resin layer curing unit 6 includes a moving mechanism (not shown) for moving the pressing roller 62 alone or together with the light source 61a. The moving mechanism moves the pressing roll 62 in the horizontal direction so as to be able to advance and retreat toward the resin layer 22 a of the base film 2. Thereby, the amount of pressure of the pressure roll 62 against the resin layer 22a can be appropriately adjusted. As the moving mechanism, a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, a mechanism using a rail and a slider, etc., can be linearly moved in a predetermined direction and can be positioned at a predetermined position. The mechanism can be applied.

  In the case where the two pressing rolls 62 are disposed away from the irradiation direction of the light source 61a (the direction from the right to the left in FIG. 11) as in the modified example shown in FIG. It does not have to be made of a transparent material (for example, a transparent resin having ultraviolet light permeability), and may be made of an ultraviolet light shielding material (for example, an opaque resin having an ultraviolet light shielding property). As shown in FIG. 11, if two pressing rolls 62 are disposed above and below the light source 61a in front of the irradiation direction of the light source 61a, even if the pressing roll 62 is made of an ultraviolet light blocking material, pressing is performed. The resin layer 22 b can be irradiated with ultraviolet light through the resin layer 22 a and further through the base film 2 without being blocked by the roll 62.

  As shown in FIG. 1 and FIG. 2, the shaping film peeling section 7 forms the shaping film 3 from the transfer film 20 (the base film 2 on which the resin layer 22 is cured and fixed) generated by the resin layer curing section 6. A roll 71 for peeling and a shaping film winding shaft 72 for winding the shaping film 3 peeled off from the base film 2 are provided. The roll 71 and the shaping film winding shaft 72 are in contact with the back surface of the shaping film 3 (the film surface on the back side of the shaping surface 31).

  Further, the roll 71 and the shaping film winding shaft 72 are respectively disposed in a set for the shaping film 3a for the front surface and the shaping film 3b for the back surface. On the surface 2a side of the base film 2, there are a peeling roll 71a for peeling the surface shaping film 3a from the resin layer 22a and a surface shaping film winding shaft 72a for winding the peeled surface shaping film 3a. It is arranged. On the other hand, on the back surface 2b side of the base film 2, an outfeed roll 71b which peels the back surface forming film 3b from the resin layer 22b, and a back surface forming film winding winding the peeled back surface forming film 3b. An axis 72b is disposed.

  The front surface forming film winding shaft 72a and the rear surface forming film winding shaft 72b are rotation shafts that rotate in opposite directions to each other by a motor (not shown). In FIG. 1, the front forming film winding shaft 72 a rotates counterclockwise, and the rear forming film winding shaft 72 b rotates clockwise. At that time, the shaping film winding shaft 72a for the front surface and the shaping film winding shaft 72b for the back surface wind the shaping film 3a for the front surface and the shaping film 3b for the back surface at the same speed as the line speed of the transfer film 20. As it takes, rotation control is performed by a control unit (not shown) or the like. The forming films 3a and 3b taken up by the forming film winding shafts 72a and 72b should be set on the forming film feeding shaft 51 and reused, in the case where there is no damage such as adhesion of scratches or dust. Is possible.

  As shown in FIG. 1 and FIG. 12, the peeling roll 71a is a rubber idle roll that rotates along with the surface forming film 3a to be peeled from the resin layer 22a. The outfeed roll 71 b is a metal rotary roll rotated by a motor 73, and the roll surface is plated with, for example, hard chrome. The peeling roll 71a and the outfeed roll 71b are formed from the transfer film 20 (the resin layer 22a and the resin layer 22b of the base film 2) while peeling the front forming film 3a and the rear forming film 3b from them. It faces so that the flow of 3a and 3b may be sent out from the direction of gravity toward the horizontal direction. As a result, the surface shaping film 3a is peeled off from the resin layer 22a, and the back surface shaping film 3b is peeled off from the resin layer 22b.

  The outfeed roll 71 b is fixed to the third floor material 13, whereas the peeling roll 71 a is movable relative to the third floor material 13. As shown in FIG. 1, the pattern transfer apparatus 1 is provided with a moving mechanism 74 for moving the peeling roll 71a. The moving mechanism 74 moves the peeling roll 71a in the horizontal direction so as to be able to advance and retract relative to the surface shaping film 3a and the outfeed roll 71b in another way.

  Thereby, the pushing amount of the peeling roll 71a with respect to the out feed roll 71b can be adjusted suitably. That is, since the contact pressure of the shaping films 3a and 3b to the resin layers 22a and 22b can be adjusted, the peeling state of the shaping films 3a and 3b from the resin layers 22a and 22b can be adjusted.

  The moving mechanism 74 can be linearly moved in a predetermined direction and can be positioned at a predetermined position, such as a mechanism using a motor and a ball screw, a mechanism using an air cylinder and a stopper, and a mechanism using a rail and a slider. Mechanisms can be applied.

  The transfer film 20 from which the shaping film 3 has been peeled off at the shaping film peeling section 7 is taken up by the film winding shaft 82 of the film conveyance section 8. Although not shown in the figure, at this time, for example, in a state in which the front surface 2 a and the back surface 2 b are laminated, or in a state of being sandwiched by a spacer, the transfer film 20 is wound with a film winding shaft You may wind at 82. In addition, the shaping film peeling portion 7 is omitted, and the shaping film 3 is not peeled from the transfer film 20, and is wound by the film winding shaft 82 of the film conveyance portion 8 as it is. The shaped film 3 may be peeled off.

  As shown in FIG. 1, the film transfer device 1 captures an image of the alignment mark 23 of the transfer film 20 (the base film 2 to which the resin layer 22 on which the pattern 21 is fixed is fixed) before winding by the film winding shaft 82. The alignment camera 80 is provided. FIG. 1 shows, as an example, a configuration of an alignment camera 80 which is disposed in the disposition area F1 and which picks up the base film 2 on which the pattern 21 is formed from the back surface 2b side.

  In the present embodiment, as shown in FIG. 5, the alignment mark 23 is formed on the base film 2 together with the pattern 21 by the pattern transfer portion 5. In this case, an alignment mark 23a is formed on the resin layer 22a on the front surface 2a side of the base film 2, and an alignment mark 23b is formed on the resin layer 22b on the back surface 2b side. Since both the base film 2 and the resin layer 22 are transparent resin, even when the image is taken by the alignment camera 80 from the back surface 2 b side of the base film 2, the alignment mark 23 b of the back surface 2 b and the alignment mark 23 a of the front surface 2 a Both can be imaged together. Therefore, the alignment camera 80 may pick up an image from the surface 2 a side of the base film 2.

  In addition, when the base film 2 and the resin layer 22 are comprised by opaque resin, it is necessary to arrange the alignment camera 80 in both the surface 2a side of the base film 2, and the back surface 2b side. When the alignment camera 80 is disposed on both the front surface 2a side and the back surface 2b side of the base film 2, the base film 2 and the resin layer 22 may be made of either transparent resin or opaque resin.

  By monitoring the positions of the alignment marks 23a and 23b captured by the alignment camera 80, it is possible to adjust the accuracy of pattern transfer (for example, transfer of the pattern 21, deviation of formation position, etc.) on the base film 2.

  The adjustment of the accuracy of pattern transfer to the base film 2 using such an alignment mark 23 will be described. In the accuracy adjustment, first, the amount of displacement between the alignment mark 23a on the surface 2a of the base film 2 and the alignment mark 23b on the back surface 2b captured by the alignment camera 80, specifically, the amount of displacement of the center of gravity is measured. In the present embodiment, the pattern position of the front surface 2a is adjusted based on the deviation amount of the center of gravity position of the alignment marks 23a and 23b with the pattern position of the back surface 2b of the base film 2 as a reference.

  For example, as shown in FIG. 5B, with reference to the alignment mark 23b on the back surface 2b, the base film 2 is displaced by the reference distance L50 in the transport direction of the base film 2 (direction of arrow A51 shown in FIG. 5A). The same position is taken as the normal position of the alignment mark 23a on the surface 2a (in the direction of the arrow A52 shown in FIG. 6A). In the state shown in FIG. 5B, the alignment mark 23a is delayed from the normal position by the distance L51 with respect to the transport direction of the base film 2, and is shifted left by the distance L52 with respect to the width direction. There is.

  When the alignment mark 23a on the front surface 2a is behind the alignment mark 23b on the back surface 2b (the state shown in FIG. 5 (b)), the positional deviation in the transport direction is the feeding distance of the front side shaping film 3a (film path To shorten the formation timing of the alignment mark 23a. Conversely, when the alignment mark 23a precedes the alignment mark 23b, the film path of the shaping film 3a for surface is lengthened to delay the formation timing of the alignment mark 23a.

  As shown in FIG. 1, the pattern transfer unit 5 is disposed on the compensator roll 55 and the upstream and downstream sides of the compensator roll 55 for film path adjustment of the shaping film 3 a for surface as described above. And a shaping film relay roll 56. The compensator roll 55 is disposed on the downstream side of the surface forming film feeding shaft 51a and on the upstream side of the backup roll 52a, and can be moved up and down along the gravity direction by the moving mechanism 57. By moving the compensator roll 55 up and down, the length of the film path of the front forming film 3a can be adjusted according to the movement distance. As the moving mechanism 57, a mechanism using a motor and a ball screw is applied as an example, but linear movement in a predetermined direction is possible, such as a mechanism using an air cylinder and a stopper, a mechanism using a rail and a slider, And the mechanism which can be positioned in a predetermined position is applicable.

  When the alignment mark 23a on the front surface 2a is shifted leftward in the transport direction with respect to the alignment mark 23b on the back surface 2b (the state shown in FIG. 5B), the positional deviation in the width direction is the surface side shaping The delivery position of the film 3a is moved to the right in the transport direction. Conversely, when the alignment mark 23a is shifted to the right with respect to the alignment mark 23b in the transport direction, the delivery position of the front side shaped film 3a is moved to the left in the transport direction.

  In order to adjust the delivery position of the shaping film 3a for surface as described above, as shown in FIG. 13, the surface shaping film winding shaft 51a, in other words, the surface application film wound around the shaping film delivery shaft 51a for surface The roll of the form film 3a is movable by the moving mechanism 58 right and left in the delivery direction of the front forming film 3a. FIG. 13 is a side view showing the vicinity of the shaping film delivery shaft 51a for the surface as viewed from the right of FIG.

  Thus, by moving the shaping film delivery shaft 51a for surface (roll of the shaping film 3a for surface) to the left and right, the delivery of the shaping film 3a for surface in the horizontal direction (direction of arrow A13 shown in FIG. 13). The position can be adjusted. As the moving mechanism 58, a mechanism using a motor and a ball screw is applied as an example, but linear movement in a predetermined direction is possible, such as a mechanism using an air cylinder and a stopper, a mechanism using a rail and a slider, And the mechanism which can be positioned in a predetermined position is applicable.

  The movement of the compensator roll 55 by the movement mechanism 57 and the movement of the surface for forming film feeding shaft 51a (the roll for the surface forming film 3a) by the movement mechanism 58 are the alignment marks 23a and 23b captured by the alignment camera 80. This is automatically performed by a control unit (not shown) or the like based on the position information of.

  Although it is possible to adjust the delivery position of the shaping film 3a for surface by attaching a steering roll, in this case, a space for attaching a steering roll unit and a guide roll is additionally required. Therefore, it is more desirable to adjust the delivery position of the shaping film 3a for surface by a moving mechanism 58 such as a motor and a ball screw.

  Further, in the pattern transfer portion 5, since the resin layer 22 of the base film 2 is not yet cured, the backup roll 52a is moved by the moving mechanism (for example, the motor and ball screw similar to the moving mechanism 57). The delivery position of the base film 2 by the surface shaping film 3a may be adjusted by moving it in the flow direction of the formed film 3a to the left and right.

  As described above, according to the film pattern transfer device 1 of the present embodiment and the film pattern transfer method implemented by the pattern transfer device 1, the base film 2 and the shaping film 3 in the direction of gravity (pass line PL) It can be stably transported along the top to bottom. Moreover, the pattern 21 can be simultaneously formed with respect to both surfaces of the base film 2 in a state in which the base film 2 and the shaping film 3 are surely aligned with the direction of gravity.

  In addition to the effects described above, the pattern transfer device 1 of the present embodiment conveys the base film 2 and the shaping film 3 from the top to the bottom along the direction of gravity (pass line PL). It also has the following effect of making the environmental conditions on the front surface 2a side and the back surface 2b side equal.

  In the resin layer forming unit 4, the resin film 22 is formed on the front surface 2a and the back surface 2b while conveying the base film 2 and the shaping film 3 along the direction of gravity (pass line PL). Can be matched on both sides. Therefore, when forming the resin layer 22 on both the front surface 2a and the back surface 2b, it is not necessary to make a difference in the leveling of the resin. For this reason, it is possible to prevent an unintended difference in thickness between the resin layer 22 formed on the front surface 2 a and the back surface 2 b of the base film 2.

  In the pattern transfer unit 5, the shaping film 3 is caused to flow along the gravity direction (pass line PL), and the base film 2 is fed downward from above while pressing the shaping film 3. For this reason, since the air between the resin layer 22 and the shaping surface 31 can be pushed out by the resin forming the resin layer 22, the air can be easily extracted out of the shaping surface 31. Accordingly, since it is not necessary to suppress the transport speed (line speed) of the base film 2 in order to extract air from between the resin layer 22 and the shaping surface 31, it is possible to improve the processing efficiency by increasing the line speed. It becomes.

  Further, in the pattern transfer portion 5, the backup roll 52a and the in-feed roll 52b may be deformed so as to be bent downward by their own weight. However, since the rolls 52a and 52b are arranged side by side in the horizontal direction to feed the base film 2 from the top to the bottom, the base film 2 is not deformed by the deformation of the rolls 52a and 52b. Accordingly, it is possible to prevent an unintended difference between the form of the patterns 21a and 21b formed on the front surface 2a and the back surface 2b of the base film 2.

  In the resin layer curing unit 6, the resin film 22 on the front surface 2a and the back surface 2b is cured while the base film 2 and the shaping film 3 are transported along the direction of gravity (pass line PL). The difference in ambient temperature can be almost eliminated. Further, in the resin layer curing portion 6, when curing the resin layer 22 of the front surface 2a and the back surface 2b of the base film 2, the base film 2 is deformed so as to sag downward by its own weight even if the tension of the base film 2 is small. There is no Therefore, since the curability of the resin layer 22 can be made to substantially coincide with the front surface 2a and the back surface 2b of the base film 2, it is possible to prevent an unintended difference in the form of the pattern 21 to be formed.

  As mentioned above, although embodiment of this invention was described, embodiment mentioned above is shown as an example, and limiting the scope of invention is not intended. In addition, the novel embodiments described above can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and the gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  For example, although the pattern transfer apparatus 1 of the present embodiment forms the patterns 21 on both sides (front surface 2 a and back surface 2 b) of the base film 2, it is also possible to form the patterns 21 on only one side.

  Further, the pattern transfer device 1 of the present embodiment includes the base including before and after the generation of the transfer film 20 in the resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, and the shaping film peeling unit 7. Although the film 2 is transported from the top to the bottom along the gravity direction (pass line PL), it is also possible to transport the film 2 from the bottom to the top. In this case, the resin layer forming unit 4, the pattern transfer unit 5, the resin layer curing unit 6, and the shaping film peeling unit 7 are disposed in this order from the bottom to the top along the gravity direction. However, when the base film 2 is transported from the top to the bottom as in the present embodiment, there are the following advantages as compared to the case where the base film 2 is transported from the bottom to the top.

  As shown in FIG. 1, in the present embodiment, the resin layer curing portion 6 is disposed below the pattern transfer portion 5. For this reason, heat (for example, heat generation by the light source 61 a) generated in the resin layer curing portion 6 is easily transmitted to the pattern transfer portion 5 by the rising air flow. When the ambient temperature of the pattern transfer portion 5 rises, the fluidity of the resin forming the resin layer 22 of the base film 2 is increased, and as a result, it can be expected that the transfer accuracy of the shaping surface 31 is improved. When the base film 2 is transported from the bottom to the top, since the resin layer curing portion 6 is disposed above the pattern transfer portion 5, such improvement in transfer accuracy of the shaping surface 31 can not be expected.

  Further, in the present embodiment, since the resin layer curing portion 6 is disposed below the pattern transfer portion 5, the heat generated in the resin layer curing portion 6 escapes upward, so the heat treatment is disposed below the resin layer curing portion 6. The formed film peeling portion 7 is less susceptible to such heat. The lower the ambient temperature, the better the releasability of the shaping film 3 at the shaping film peeling section 7. When the base film 2 is transported from the bottom to the top, since the shaping film peeling portion 7 is disposed above the resin layer curing portion 6, such improvement in the peeling property of the shaping film 3 can not be expected.

  Taking these into consideration, it is preferable to transport the base film 2 from the top to the bottom along the direction of gravity (pass line PL) as in the present embodiment.

  DESCRIPTION OF SYMBOLS 1 ... Pattern transfer apparatus, 2 ... Base film, 2a ... Surface, 2b ... Back surface, 3 ... Shaped film, 4 ... Resin layer formation part, 5 ... Pattern transfer part, 6 ... Resin layer hardened part, 7 ... Shaped film Peeling part, 8: film transport part, 9: moving mechanism, 10: floor surface, 11: first floor material, 11a: first through hole, 12: second floor material, 12a: second through hole 13, 13: third floor material, 13 a: third through hole, 20: transfer film, 21: pattern, 22: resin layer, 31: shaping surface, 41: tank, 42: pump, 43: die, 51 ... forming film feeding shaft, 52a ... backup roll, 52b ... infeed roll, 61 ... action part, 61a ... light source, 61b ... light shielding plate, 62 ... pressing roll, 71a ... peeling roll, 71b ... outfeed roll, 72 ... Shaped film winding shaft, 81 ... Fill Feeding shaft, 82 ... film winding shaft, 83 ... guide roll, 431 ... resin discharge port, F1, F2, F3, F4 ... arrangement area, PL ... pass line.

Claims (7)

A resin layer forming portion for applying a liquid resin on both sides of the base film to form a resin layer;
A pattern transfer portion for forming a pattern on the surface of the resin layer by pressing the shape forming film against the resin layer of the base film and transferring the shape forming surface of the shape forming film to the resin layer;
A resin layer cured portion that produces a transfer film by curing the resin layer on which the pattern is formed and fixing the resin layer to the base film;
A shaping film peeling portion for peeling the shaping film from the transfer film;
A film transport unit for unwinding the base film, passing the resin layer forming unit, the pattern transfer unit, the resin layer curing unit, and the shaping film peeling unit, and winding the generated transfer film; ,
The film transport unit has a guide roll that directs the transport direction of the base film from the top to the bottom along the gravity direction before the resin layer forming unit,
The resin layer forming portion has a pair of dies disposed one on each side of the base film with the positions of the resin discharge ports shifted vertically.
Among the pair of dies, a die disposed on the upper side is disposed on the side of the base film not in contact with the guide roll. A moving mechanism is provided to move one or the other of the pair of dies and the guide roll individually or collectively, in the horizontal direction with respect to the pattern transfer portion, the resin layer curing portion, and the shaping film peeling portion. The film pattern transfer apparatus according to Item 1. The pattern transfer portion and the resin layer cured portion are separated by a first floor material having a first through hole formed through the base film and the shaping film.
The movement mechanism moves one and the other of the pair of dies and the guide roll such that the base film and the shaping film are in the first through holes along the direction of gravity. Film pattern transfer device. The resin layer forming portion and the pattern transfer portion are separated by a second floor material in which a second through hole passing through the base film is formed,
The film transfer according to claim 3, wherein the moving mechanism moves one and the other of the pair of dies and the guide roll such that the base film follows the direction of gravity in the second through hole. apparatus. The film transport unit
A feeding shaft for feeding the base film before the resin layer is formed;
A winding shaft for winding the transfer film;
And a plurality of relay rolls for changing the transport direction of the base film or the transfer film together with the guide roll between the feeding shaft and the winding shaft;
The film pattern transfer apparatus according to any one of claims 1 to 4, wherein one of the plurality of relay rolls is disposed below the guide roll along a gravity direction. The film pattern transfer apparatus of a film according to claim 5, wherein the relay roll disposed below the guide roll directs the transfer direction of the transfer film from the gravity direction to another direction at the tip of the shaping film peeling portion. Applying a liquid resin on both sides of the base film to form a resin layer;
Forming a pattern on the surface of the resin layer by pressing the shaping film against the resin layer of the base film and transferring the shaping surface of the shaping film to the resin layer;
Curing the resin layer on which the pattern is formed and fixing it to the base film to form a transfer film;
Peeling off the shaping film from the transfer film;
The base film is fed out, the formation of the resin layer on the base film which has been fed out, the transfer of the shaping surface to the resin layer, the formation of the pattern, the curing of the resin layer and the adhesion to the base film Winding the formed transfer film through the peeling of the shaped film from the transfer film,
Before the formation of the resin layer on the base film, the base film is curved to convey the base film so that the conveyance direction of the base film is directed downward from above along the gravity direction.
When forming the resin layer on the base film, the resin layer is formed on the outer peripheral surface of the curve which is the surface of the base film on the upper side in the transport direction, and the base film on the lower side in the transport direction. A method of transferring a pattern to a film, wherein the resin layer is formed on the surface on the inner peripheral side of a curve to be the back surface .

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