JP7386449B2 - Film structure manufacturing method and manufacturing device - Google Patents

Description

The present invention relates to a method and apparatus for manufacturing a film structure.

(Background of imprint technology, application fields)
BACKGROUND ART In recent years, it has been desired to form cured films with fine shapes on the order of nanometers (nm) to microns (μm) that exhibit special optical properties in optical components used in products such as displays and lighting. By forming such a cured film, it is possible to realize a device that exhibits new functions that have never existed before, such as being able to control light reflection and diffraction.

Further, in semiconductors such as system LSIs, it is desired to form a cured film with a fine shape due to the miniaturization of interconnections accompanying higher integration.

In addition to photolithography technology and electron beam lithography technology, imprint technology has recently attracted attention as a method for forming cured films with such fine shapes.

The imprint technology is a technique in which a mold whose surface has been processed in advance with a fine shape is pressed against a resin coated on the surface of a base material, thereby forming a cured film on which the fine shape has been transferred. Examples of imprint methods include thermal imprint methods and UV imprint methods.

The thermal imprint method is a method of obtaining a cured film on which fine shapes are transferred by pressing a mold heated to a glass transition temperature or higher onto a thermoplastic resin coated on the surface of a substrate. The UV imprint method is a method of obtaining a cured film on which fine shapes have been transferred by irradiating UV light with a mold at room temperature pressed against an ultraviolet curable resin coated on the surface of a substrate.

The thermal imprint method has the advantage of wide selectivity of materials regarding resin, but has the disadvantage of low throughput because it is necessary to raise and lower the temperature of the mold when transferring the fine shape. On the other hand, UV imprinting is limited to resins that cure with ultraviolet rays, so the selectivity of materials is narrower than thermal imprinting, but it is possible to complete curing in a few seconds to tens of seconds. Very high throughput. Whether the thermal imprint method or the UV imprint method is adopted depends on the device to which it is applied, but if there is no problem with material selectivity, the UV imprint method is considered to be suitable as a mass production method.

Furthermore, when the target substrate is a film such as PET, a roll-shaped mold with fine shapes formed on the surface is used to transfer the fine shapes onto the film at the same time as the film is fed. Further improvement in throughput is expected. This method is generally called a roll-to-roll imprint method.

(UV roll-to-roll imprint method)
A general method of forming fine shapes by a roll-to-roll imprint method using a UV imprint method will be described (see Patent Document 1). FIG. 6 is a schematic diagram of a general roll-to-roll imprint method.

First, a transfer material 3 is extruded from a die unit 2 and applied onto a continuously running film (film base material) 1. Next, the film 1 is passed between a transfer roll 4 on which a transfer shape (fine shape) 8 is formed and a pressure roll 5 that is pressed against the transfer roll 4 with a predetermined pressure. The transfer material 3 is filled into the transfer shape 8 on the surface of the transfer roll 4 . Next, by irradiating the transfer roll 4 with UV light from the UV light source 6, the transfer material 3 begins to harden while being filled in the transfer shape 8. Finally, the film 1 passes between the release roll 7 and the transfer roll 4, runs along the release roll 7, is released from the transfer roll 4, and is transferred onto the film 1 with the transferred shape 8. A cured film 9 to which is transferred is formed.

In this method, the cured film 9 is formed on one side of the film 1, but recently the cured film 9 is similarly formed on the other side, and the relative positions of the cured films 9 on both sides are made to match. UV roll-to-roll imprint technology is desired.

On the other hand, after forming the cured film 9 on both sides of the film 1, an inspection camera detects the amount of relative positional deviation of the formed cured film 9, and by correcting the operation of the transfer roll 4, hardening of both sides is performed. A method of correcting the amount of relative positional deviation of the membrane 9 is utilized.

A general method of correcting the amount of relative positional deviation of the cured films 9 on both sides of the film 1 and forming a transferred shape by a roll-to-roll imprint method using a UV imprint method will be described. FIG. 7 is a schematic diagram of a construction method using a roll-to-roll imprint method when correcting the amount of relative positional deviation of the cured film 9.

First, the first transfer material 31 is applied from the first die unit 21 onto the continuously running film 1 (surface). Next, by pressing the first pressure roll 51 against the first transfer roll 41 on which the first transfer shape 81 is formed, the first transfer material 31 is filled into the first transfer shape 81, and the first curing means 61 The first transfer material 31 is cured by irradiating it with UV light. Furthermore, the film 1 is released by running along the first release roll 71 to form the first cured film 91 .

Next, the second transfer material 32 is applied from the second die unit 22 to the opposite surface (back surface) of the film 1 . The second transfer material 32 is filled by pressing the second pressure roll 52 against the second transfer roll 42 on which the second transfer shape 82 is formed. By irradiating UV light from the second curing means 62, the second transfer material 32 is cured. Furthermore, the film 1 is released from the mold by running along the second mold release roll 72, and a second cured film 92 is formed.

The amount of relative positional deviation between the formed first cured film 91 and second cured film 92 is measured by the camera 10. After measuring the amount of relative positional deviation, the amount of relative positional deviation is reduced by adjusting the position of the second transfer roll 42.

Patent No. 4976868 Patent No. 4742755

However, there is a disadvantage that the second transfer roll 42 performs the position correction operation. In other words, the surface pressure at the portion (nip portion) where the second transfer roll 42 and the second pressure roll 52 are in contact becomes non-uniform.

On the other hand, in the technical field of embossing equipment that presses a sheet-like workpiece with a pair of rolls to form unevenness on the surface, the pressure applied to both ends of the pressure rolls is adjusted independently, A method of making the surface pressure in the axial direction uniform is known (see Patent Document 2).

However, it is difficult to suppress fluctuations in the transfer width of the cured film by simply applying the method of making the surface pressure uniform, which is used in the embossing apparatus shown in the prior art document, to UV roll-to-roll imprinting.

Initially, it was assumed that uneven surface pressure at the nip was the cause of transfer width fluctuations. However, as a result of intensive verification by the present inventors, it was found that the phenomenon of temporary expansion or contraction of the transfer width could not be suppressed simply by applying a configuration that makes the surface pressure uniform.

This is thought to be due to the fact that the liquid pool of transfer material at the nip is moved by the position correction operation of the transfer roll, and the tension of the film entering the nip is changed, which causes variations in the transfer width on the back side. It's for a reason.

In view of the above-mentioned conventional problems, the present invention suppresses fluctuations in the transfer width on the back side in a roll-to-roll imprint method for manufacturing a film structure in which a cured film with a transfer shape is transferred on both sides of the film. The purpose is to provide a manufacturing method and a manufacturing device that can.

In order to achieve the above object, the method for manufacturing a film structure of the present invention is a method for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film, and the method comprises: a first curing step in which the applied transfer material containing the ultraviolet curable resin is cured by a first curing means while being pressed against the first transfer roll by a first pressure roll to form a first cured film; a second curing step in which the transfer material containing the ultraviolet curable resin applied to the back surface is cured by a second curing means while being pressed against the second transfer roll by a second pressure roll to form a second cured film; an edge detection step of detecting the position of the widthwise end of the second cured film, and from the widthwise end of the second cured film detected by the edge detection step to the widthwise end of one side of the film; a determination step of determining whether the plain width of is within a preset threshold range; and if it is determined in the determination step that the plain width exceeds the threshold range, the plain width is within the threshold range; and a pressurizing force adjustment step of adjusting the pressurizing force by the second pressurizing roll so that it falls within the range of .

The film structure manufacturing apparatus of the present invention is an apparatus for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film, and includes a first transfer roll having a transfer shape on the surface; a first pressure roll that presses the surface of the film coated with a transfer material containing an ultraviolet curing resin against the first transfer roll; and a first pressure roll that hardens the transfer material that is being pressed by the first pressure roll. a first curing means for forming a cured film; a second transfer roll disposed downstream of the first transfer roll and having a transfer shape on its surface; and a transfer material containing an ultraviolet curing resin applied to the film. a second pressure roll that presses the back surface of the second transfer roll; a second curing means that cures the transfer material being pressed by the second pressure roll to form a second cured film; an edge detection unit that detects the position of the widthwise end portion of the second cured film; a pressure variable mechanism that varies the pressure force applied by the second pressure roll; and a control unit, the control unit comprising: When the plain width from the widthwise end of the second cured film to the widthwise end of one side of the film detected by the edge detection unit exceeds a preset threshold range, the plain width exceeds the threshold. The pressurizing force variable mechanism is controlled so as to fall within the range.

According to the method and apparatus for manufacturing a film structure according to the present invention, it is possible to suppress fluctuations in the transfer width on the back surface of the film structure.

A schematic perspective view of a film structure manufacturing apparatus according to an embodiment of the present invention A schematic perspective view showing a pressurizing force variable mechanism in an embodiment of the present invention A schematic diagram showing the moving direction of the second transfer roll in an embodiment of the present invention A schematic diagram showing the moving direction of the second transfer roll in an embodiment of the present invention A plan view showing width dimensions of a film and a second cured film in an embodiment of the present invention Flowchart of control of the second pressure roll in the embodiment of the present invention Schematic diagram of a general single-sided UV roll-to-roll imprint method Schematic diagram of a general double-sided UV roll-to-roll imprint method

According to a first aspect of the present invention, there is provided a method for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film, the transfer comprising an ultraviolet curing resin applied to the surface of the film. a first curing step in which the material is cured by a first curing means while being pressed against a first transfer roll by a first pressure roll to form a first cured film; and an ultraviolet curing resin applied to the back surface of the film. a second curing step of forming a second cured film by curing the transfer material by a second curing means while applying pressure to the second transfer roll by a second pressure roll; and a widthwise end portion of the second cured film. an edge detection step of detecting the position of the film, and a plain width from the width direction end of the second cured film detected by the edge detection step to the width direction end of one side of the film is set in advance. a determination step of determining whether or not it is within a threshold range; and if it is determined in the determination step that the plain width exceeds the threshold range, applying the second pressurization so that the plain width falls within the threshold range; Provided is a method for manufacturing a film structure, including a pressure force adjustment step of adjusting pressure force by a roll.

According to the second aspect of the present invention, when it is determined in the determination step that the plain width exceeds the threshold range, the pressurizing force adjustment step is performed based on the deviation width exceeding the threshold range in the plain width. Provided is a method for manufacturing a film structure according to the first aspect, which includes a calculation step of calculating the pressing force by the second pressure roll used in the method.

According to the third aspect of the present invention, the relative position detection step of detecting the relative position of the second cured film with respect to the first cured film, and the relative position detected by the relative position detection step, Provided is a method for manufacturing a film structure according to the first aspect or the second aspect, which includes a position adjustment step of adjusting by moving a transfer roll.

According to the fourth aspect of the present invention, the threshold range includes an upper limit value and a lower limit value, and in the determination step, when it is determined that the plain width exceeds the upper limit value and exceeds the threshold range, In the pressing force adjustment step, the pressing force by the second pressure roll is increased, and in the determining step, if it is determined that the plain width is less than the lower limit value and exceeds the threshold range, the pressing force adjustment step is performed. There is provided a method for manufacturing a film structure according to any one of the first to third aspects, wherein in the step, the pressing force by the second pressure roll is reduced.

According to the fifth aspect of the present invention, in the edge detection step, the positions of one widthwise end and the other widthwise end of the second cured film are set as the positions of the widthwise ends of the second cured film. and in the determination step, a plain width from the one end in the width direction of the second cured film to one end in the width direction of the film, and a width of the film from the other end in the width direction of the second cured film. Provided is a method for manufacturing a film structure according to any one of the first to fourth aspects, in which it is determined whether the plain width from the other end in the direction is within a preset threshold range. do.

According to the sixth aspect of the present invention, in the pressurizing force adjustment step, the pressurizing force on one axial side and the other axial side of the second pressurizing roll are independently set as the pressurizing force by the second pressurizing roll. A method for producing a film structure according to the fifth aspect is provided.

According to a seventh aspect of the present invention, there is provided an apparatus for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film, the first transfer roll having a transfer shape on the surface, and the ultraviolet rays a first pressure roll that presses the surface of the film coated with a transfer material containing a cured resin against the first transfer roll; and a first curing process by curing the transfer material being pressed by the first pressure roll. a first curing means for forming a film; a second transfer roll disposed downstream of the first transfer roll and having a transfer shape on its surface; and a back surface of the film coated with a transfer material containing an ultraviolet curable resin. a second pressure roll for applying pressure to the second transfer roll; a second curing means for curing the transfer material being pressed by the second pressure roll to form a second cured film; An edge detection unit that detects the position of the widthwise end of the cured film, a pressure variable mechanism that varies the pressure applied by the second pressure roll, and a control unit, the control unit configured to detect the edge of the cured film. When the plain width from the widthwise end of the second cured film to the widthwise end of one side of the film detected by the detection unit exceeds a preset threshold range, the plain width is within the threshold range. Provided is an apparatus for manufacturing a film structure, which controls the pressure variable mechanism so that the variable pressure mechanism is within the range of the present invention.

According to the eighth aspect of the present invention, when the plain width exceeds the threshold range, the control unit applies pressure by the second pressure roll based on the deviation width in the plain width that exceeds the threshold range. There is provided an apparatus for manufacturing a film structure according to the seventh aspect, which determines the pressure.

According to a ninth aspect of the present invention, there is provided the apparatus for manufacturing a film structure according to the seventh aspect or the eighth aspect, in which the second transfer roll is provided so that its relative position with respect to the film can be adjusted.

According to the tenth aspect of the present invention, the threshold range includes an upper limit value and a lower limit value, and when the plain width exceeds the upper limit value and exceeds the threshold range, the control unit controls the pressing force to be changed. The mechanism increases the pressing force by the second pressure roll, and when the plain width falls below the lower limit and exceeds the threshold range, the variable pressure mechanism increases the pressing force by the second pressure roll. Provided is an apparatus for manufacturing a film structure according to any one of the seventh to ninth aspects, which reduces the number of particles.

According to the eleventh aspect of the present invention, the edge detection section determines the positions of one widthwise end and the other widthwise end of the second cured film as the positions of the widthwise ends of the second cured film. and the control unit detects a plain width from the one end in the width direction of the second cured film to one end in the width direction of the film, and a width of the film from the other end in the width direction of the second cured film. The film structure according to any one of the seventh to tenth aspects, wherein the variable pressure mechanism is controlled so that the plain width to the other end in the direction falls within a preset threshold range, respectively. Provides body manufacturing equipment.

According to the twelfth aspect of the present invention, the variable pressure mechanism independently adjusts the pressure on one axial side and the other axial side of the second pressure roll as the pressure applied by the second pressure roll. An apparatus for producing a film structure according to the eleventh aspect is provided.

According to the thirteenth aspect of the present invention, the pressure variable mechanism includes a shaft portion extending axially outward from the second pressure roll, a bearing portion holding the shaft portion, and a shaft portion extending from the second pressure roll. A device for producing a film structure according to any one of the seventh to twelfth aspects, comprising a drive unit that drives the bearing unit to move the bearing unit relative to the second transfer roll. provide.

According to a fourteenth aspect of the present invention, there is provided the film structure manufacturing apparatus according to the thirteenth aspect, wherein the variable pressing force mechanism includes a guide that guides movement of the bearing part.

According to a fifteenth aspect of the present invention, the drive unit includes a cylinder that moves the bearing unit along a direction in which the axis of the second transfer roll and the axis of the second pressure roll are lined up. An apparatus for manufacturing a film structure according to the thirteenth aspect or the fourteenth aspect is provided.

(Embodiment)
Embodiments according to the present invention will be described below with reference to the drawings. Note that the present invention is not limited to the following embodiments.

First, the configuration of the film structure manufacturing apparatus D1 of this embodiment will be explained using FIGS. 1 to 3B. FIG. 1 is a schematic perspective view of a film structure manufacturing apparatus D1 according to the present embodiment. FIG. 2 is a schematic perspective view showing the pressurizing force variable mechanism 50. 3A and 3B are schematic diagrams showing the moving direction of the second transfer roll 42. FIG.

The film structure manufacturing apparatus D1 according to the present embodiment is an apparatus that manufactures a film structure in which transfer materials 31 and 32 are transferred and cured onto both surfaces of a continuously running film (film base material) 1. Cured films 91 and 92 are formed on both sides of the film 1. The transfer materials 31 and 32 are materials for the cured films 91 and 92. In this embodiment, the transfer materials 31 and 32 contain ultraviolet curing resin.

As shown in FIG. 1, the manufacturing apparatus D1 includes die units 21 and 22, coating rolls 11 and 12, transfer rolls 41 and 42, pressure rolls 51 and 52, curing means 61 and 62, and a mold release unit. It includes rolls 71 and 72 and an edge detection section 100. Furthermore, as shown in FIG. 2, the manufacturing apparatus D1 includes a pressurizing force variable mechanism 50 and a control section C1.

The die units 21 and 22 are units that apply transfer materials 31 and 32 to the film 1, respectively. The first die unit 21 applies the first transfer material 31 to the front surface of the film 1, and the second die unit 22 applies the second transfer material 32 to the back surface of the film 1.

The coating rolls 11 and 12 are rollers for coating the film 1 with the transfer materials 31 and 32 while sandwiching the film 1 between them and the die units 21 and 22, respectively. The first coating roll 11 and the first die unit 21 sandwich the film 1, and the second coating roll 12 and the second die unit 22 sandwich the film 1.

The transfer rolls 41 and 42 are rollers (roll type) that transfer the transfer shapes 81 and 82 onto the transfer materials 31 and 32, respectively. Transfer shapes (fine shapes) 81 and 82 are formed on the surfaces (cylindrical outer peripheral surfaces) of the first transfer roll 41 and the second transfer roll 42 . The first transfer roll 41 transfers the transfer shape 81 to the first transfer material 31, and the second transfer roll 42 transfers the transfer shape 82 to the second transfer material 32.

The first transfer roll 41 is arranged downstream of the first die unit 21 and the first coating roll 11 , and the second transfer roll 42 is arranged downstream of the die unit 22 and coating roll 12 . The second transfer roll 42 is arranged downstream of the first transfer roll 41.

As shown in FIGS. 3A and 3B, the second transfer roll 42 is provided so that its relative position with respect to the film 1 (FIG. 1) can be adjusted. As shown in FIG. 3A, the second transfer roll 42 is provided movably in the axial direction (width direction), for example. As shown in FIG. 3B, the second transfer roll 42 is provided so as to be movable, for example, in a direction in which the axis of the second transfer roll 42 is inclined. Although not shown, the manufacturing apparatus D1 is provided with a moving section (drive section) that moves the second transfer roll 42.

As shown in FIG. 1, the pressure rolls 51 and 52 are rollers that press the film 1 coated with the transfer materials 31 and 32 against the transfer rolls 41 and 42, respectively. The first pressure roll 51 presses the surface (first main surface) of the film 1 coated with the first transfer material 31 against the first transfer roll 41 . The second pressure roll 52 presses the back surface (second main surface) of the film 1 coated with the second transfer material 32 against the second transfer roll 42 .

In order to improve the filling properties of the transfer materials 31 and 32, the first pressure roll 51 and the second pressure roll 52 may be made of an elastic body such as elastic urethane rubber, for example.

The first pressure roll 51 is provided so that its outer peripheral surface faces the first transfer roll 41 , and the second pressure roll 52 is provided so that its outer peripheral surface faces the second transfer roll 42 .

The curing means 61 and 62 are means for curing the transfer materials 31 and 32, respectively. In this embodiment, the curing means 61 and 62 are UV irradiation units (UV light sources) that irradiate the transfer materials 31 and 32 with ultraviolet light (UV light), respectively. The first curing means 61 cures the first transfer material 31 pressed by the first pressure roll 51 with ultraviolet rays to form a first cured film 91 . The second curing means 62 cures the second transfer material 32 pressed by the second pressure roll 52 with ultraviolet rays to form a second cured film 92 .

The release rolls 71 and 72 are rollers that release the cured films 91 and 92 from the transfer rolls 41 and 42, respectively. The first release roll 71 releases the first cured film 91 from the first transfer roll 41 , and the second release roll 72 releases the second cured film 92 from the second transfer roll 42 .

Note that the upstream side of the first pressure roll 51 and the downstream side of the second release roll 72 have a configuration for applying a constant tension to the film 1 (not shown). Furthermore, in this embodiment, the transport speed of the film 1 is controlled by a motor that drives the first transfer roll 41 and the second transfer roll 42, and the other rolls are driven.

The edge detection unit 100 is a member that detects the position of the widthwise end of the second cured film 92. In this embodiment, the edge detection unit 100 detects the positions of one end in the width direction and the other end in the width direction of the second cured film 92.

Furthermore, the edge detection unit 100 captures the positions of the widthwise ends of the second cured film 92 and the film 1, and determines the width between the second cured film 92 and the film 1 as the "plain width" shown in FIG. Measure W3 and W4. The edge detection unit 100 monitors the vicinity of the end of the second cured film 92 over a wide area of several tens of mm square, for example. The edge detection section 100 is provided on the back side of the film 1. The edge detection unit 100 may be, for example, a camera equipped with an image recognition function.

Here, the blank widths W3 and W4 will be explained using FIG. 4. FIG. 4 is a plan view showing the width dimensions of the film 1 and the second cured film 92 in the embodiment of the present invention.

As shown in FIG. 4, uncoated portions 93 and 94 on which the second cured film 92 is not formed are formed at one end in the width direction and the other end in the width direction (on the right side and the left side in the paper) of the film 1, as shown in FIG. The blank widths W3 and W4 are the width dimensions of one side obtained by subtracting the transfer width W2, which is the width of both ends of the second cured film 92, from the film width (original fabric width) W1, which is the width of both ends of the film 1. That is, the plain width (first plain width) W3 is the width of the plain portion (first plain portion) 93 from one end of the second cured film 92 in the width direction to one end of the film 1 in the width direction. The plain width (second plain width) W4 is the width of the plain portion (second plain portion) 94 from the other end of the second cured film 92 in the width direction to the other end of the film 1 in the width direction. In this embodiment, the blank width W3 and the blank width W4 are set to the same value.

The pressure variable mechanism 50 (FIG. 2) is a mechanism that makes the pressure applied by the second pressure roll 52 variable. In this embodiment, the pressure variable mechanism 50 independently adjusts the pressure on one axial side and the other axial side of the second pressure roll 52.

In this embodiment, the variable pressing force mechanism 50 includes a shaft portion 53, a bearing portion 54, a load cell 55, a drive portion 56, and a guide 57. In this embodiment, the variable pressure mechanism 50 is independently provided at both ends of the second pressure roll 52 in the width direction. Thereby, the pressurizing force variable mechanism 50 is controlled by the control section C1 independently on the left and right sides.

The shaft portion 53 is a member extending axially outward from the second pressure roll 52. The shaft portion 53 is, for example, a rod-shaped member connected to both ends of the second pressure roll 52 with screws. The bearing portion 54 is a member that holds the shaft portion 53. Specifically, the bearing portion 54 is a member that rotatably holds the shaft portion 53. The bearing part 54 clamps the tip of the shaft part 53 and allows it to rotate freely. The load cell 55 is a member that detects the pressing force applied to the bearing portion 54 in the pressing direction (X1). The load cell 55 detects the pressurizing force on the pressurized surface of the bearing portion 54 .

The drive section 56 is a member that drives the bearing section 54. The drive section 56 moves the bearing section 54 in the front-rear direction X1. Thereby, the drive unit 56 moves the second pressure roll 52 in the front-rear direction X2 relative to the second transfer roll 42. The drive section 56 moves the bearing section 54 along the front-rear direction. The drive unit 56 is connected to a position where the center of the load cell 55 is pushed. The drive unit 56 is, for example, a cylinder (air cylinder). Here, the front-back direction is a direction in which the axis of the second transfer roll 42 and the axis of the second pressure roll 52 are lined up.

The guide (sliding part) 57 is a member that guides the movement of the bearing part 54. The guide 57 is, for example, a plate-shaped member extending in the front-rear direction. The guide 57 slides the bearing portion 54 in a direction parallel to a plane passing through the axis of the second pressure roll 52 and the axis of the second transfer roll 42 . The guide 57 is provided below the bearing part 54.

The control unit C1 is a member that controls the operation of each component of the manufacturing apparatus D1. The control unit C1 is, for example, a microcomputer. The control unit C1 can control the pressure applied by the second pressure roll 52 by controlling the pressure variable mechanism 50. The control unit C1 can change the width of the second cured film 92, that is, the plain widths W3 and W4, by changing the pressing force by the second pressure roll 52.

Next, a method for manufacturing the film structure will be explained.

First, the film 1 is transported from the upstream side of the manufacturing apparatus D1. Film 1 is sandwiched between coating roll 11 and die unit 21. At this time, the die unit 21 applies the transfer material 31 to one surface (first main surface) of the film 1 (first application step).

Next, the film 1 is sandwiched between the first transfer roll 41 and the first pressure roll 51 such that the transfer material 31 is placed on the first transfer roll 41 side. The first pressure roll 51 presses the film 1 against the first transfer roll 41 to fill the transfer shape 81 with the transfer material 31 (first transfer step).

Next, a first curing step ST10 is performed. Specifically, the first transfer material 31 applied to the surface of the film 1 is hardened by the first curing means 61 while being pressed against the first transfer roll 41 by the first pressure roll 51 . In other words, the first curing means 61 adheres to the film 1 while curing the first transfer material 31 filled in the first transfer roll 41 . As a result, the first transfer material 31 becomes a first cured film 91 that is cured with the first transfer shape 81 transferred thereto.

Next, the first release roll 71 releases the film 1 with the cured first cured film 91 from the first transfer roll 41 (first release step).

Next, the film 1 is sandwiched between the second coating roll 12 and the second die unit 22. At this time, the second die unit 22 applies the second transfer material 32 to the other surface (second main surface) of the film 1, that is, the surface not having the first cured film 91 (second coating step).

Next, the film 1 is sandwiched between the second transfer roll 42 and the second pressure roll 52 such that the second transfer material 32 is placed on the second transfer roll 42 side. The second pressure roll 52 presses the film 1 against the second transfer roll 42 to fill the second transfer shape 82 with the second transfer material 32 (second transfer step).

Next, a second curing step ST20 is performed. Specifically, the second transfer material 32 applied to the back surface of the film 1 is hardened by the second curing means 62 while being pressed against the second transfer roll 42 by the second pressure roll 52 . In other words, the second curing means 62 adheres to the film 1 while curing the second transfer material 32 filled in the second transfer roll 42 . As a result, the second transfer material 32 becomes a second cured film 92 that is cured with the second transfer shape 82 transferred thereto.

Next, the second release roll 72 releases the film 1 on which the second cured film 92 has been cured from the second transfer roll 42 (second release step).

Next, a relative position detection step ST30 is performed. In the relative position detection step ST30, the relative position of the second cured film 92 with respect to the first cured film 91 is detected. Specifically, in the relative position detection step ST30, the amount of relative positional deviation between the first cured film 91 and the second cured film 92 in the width direction of the film 1 is detected.

Next, a position adjustment step ST40 is performed. In the position adjustment step ST40, the second transfer roll 42 is moved to adjust the relative position detected in the relative position detection step ST30 so as to reduce the amount of relative positional deviation.

Next, an edge detection step ST50 is performed. In the edge detection step ST50, the position of the widthwise end portion of the second cured film 92 is detected. In the present embodiment, in the edge detection step ST50, the positions of one widthwise end and the other widthwise end of the second cured film 92 are detected as the positions of the widthwise ends of the second cured film 92. At the same time, the positions of one end in the width direction and the other end in the width direction of the film 1 are detected. Thereby, the difference between the widthwise end of the film 1 and the widthwise end of the second cured film 92 is calculated, and the plain widths W3 and W4 are detected.

Next, a determination step ST60 is performed. In the determination step ST60, it is determined whether the plain widths W3, W4 detected in the edge detection step ST50 are within the threshold ranges A1, A2. In the present embodiment, in the determination step ST60, it is determined whether the blank width W3 and the blank width W4 are within preset threshold ranges A1 and A2, respectively. That is, it is determined whether the plain width W3 is greater than or equal to W5 and less than or equal to W6, and whether the plain width W4 is greater than or equal to W7 and less than or equal to W8, respectively.

Here, the threshold ranges A1 and A2 are preset ranges of allowable blank widths W3 and W4. The threshold ranges A1 and A2 include upper limit values (upper limit plain width) W6 and W8 and lower limit values (lower limit plain width) W5 and W7. As shown by the broken line in FIG. 4, the maximum values of the threshold ranges A1 and A2 are the upper limit values W6 and W8, and the minimum values of the threshold ranges A1 and A2 are the lower limit values W5 and W7. In this embodiment, the upper limit value (first upper limit value) W6 and the upper limit value (second upper limit value) W8 are set to the same value, and the lower limit value (first lower limit value) W5 and the lower limit value (second lower limit value) W7 is set to the same value.

Next, a calculation step ST70 is performed. Specifically, when it is determined in the determination step ST60 that the plain widths W3 and W4 exceed the threshold ranges A1 and A2, the pressing force is determined based on the deviation width that exceeds the threshold ranges A1 and A2 in the plain widths W3 and W4. The pressing force by the second pressure roll 52 used in the adjustment step ST80 is calculated.

Specifically, the pressure applied by the second pressure roll 52 is determined by using the correlation between the increase/decrease in the widthwise end portion of the second cured film 92 and the increase/decrease in the pressure applied by the second pressure roll 52. Calculated from the width. Here, the correlation means that, for example, as the pressing force by the second pressure roll 52 increases, the plain widths W3, W4 become smaller, and as the pressing force by the second pressure roll 52 decreases, the plain widths W3, W4 become smaller. The relationship is such that .

The control unit C1 controls the pressurizing force variable mechanism 50 so that the plain width W3 and the plain width W4 fall within preset threshold ranges A1 and A2, respectively. That is, the control unit C1 controls the pressurizing force variable mechanism 50 so that the plain width W3 is greater than or equal to W5 and less than or equal to W6, and the plain width W4 is greater than or equal to W7 and less than or equal to W8.

Next, a pressing force adjustment step ST80 is performed. In the pressurizing force adjustment step ST80, if it is determined that the plain widths W3, W4 exceed the threshold ranges A1, A2 in the determination step ST60, a second pressurization is applied so that the plain widths W3, W4 fall within the threshold ranges A1, A2. The pressure applied by the roll 52 is adjusted. Adjustment of the pressing force by the second pressure roll 52 is performed by the control unit C1 controlling the pressing force variable mechanism 50.

In the determination step ST60, if it is determined that the plain widths W3, W4 exceed the upper limit values W6, W8 and exceed the threshold ranges A1, A2, the pressing force by the second pressure roll 52 is increased in the pressing force adjustment step ST80. let In the determination step ST60, if it is determined that the plain widths W3, W4 are below the lower limits W5, W7 and exceed the threshold ranges A1, A2, the pressing force by the second pressure roll 52 is reduced in the pressing force adjustment step ST80. let The pressure applied by the second pressure roll 52 is increased or decreased by the control unit C1 controlling the variable pressure force mechanism 50.

In the present embodiment, in the pressurizing force adjustment step ST80, as the pressurizing force by the second pressurizing roll 52, the pressurizing force on one axial side and the other axial side of the second pressurizing roll 52 is adjusted independently. . Specifically, the control unit C1 independently adjusts the respective pressing forces using the pressing force variable mechanisms 50 that are independently provided on one axial side and the other axial side of the second pressure roll 52. .

A film structure is manufactured by performing the steps described above.

Next, the basic operation of transferring the first cured film 91 and the second cured film 92 onto both sides of the film 1 will be explained in detail.

After the first transfer material 31 is applied by the first die unit 21 to one side (front surface) of the film 1 unwound from the direction of arrow A shown in FIG. It passes under pressure between the first transfer roller 41 and the first transfer roller 41 which is rotating. At that time, the first transfer material 31 filled on the surface of the first transfer roll 41 is cured by the ultraviolet rays irradiated from the first curing means 61, and is applied to the surface of the first transfer roll 41 on one side of the film 1. The first transfer shape 81 is transferred and a first cured film 91 is formed.

Thereafter, the film 1 passes through the first release roll 71 which is disposed close to a predetermined position on the downstream side of the first transfer roll 41 while bringing the other surface into contact with the first release roll 71 . At that time, the first cured film 91 is separated from the first transfer roll 41.

The second transfer material 32 is applied to the other surface of the film 1 directly under the second pressure roll 52 by the second die unit 22 while the film 1 remains wound around the second pressure roll 52 . Thereafter, the film 1 passes under pressure between the second pressure roll 52 and the second transfer roll 42 rotating at a predetermined speed. At this time, the second transfer material 32 filled on the surface of the second transfer roll 42 is cured by the ultraviolet rays irradiated from the second curing means 62, and is applied to the second transfer material 32 on the other surface of the film 1. The transferred shape 82 is transferred and a second cured film 92 is formed.

At the same time, in a position adjustment step ST40, a second cured film 91, on which the first transfer shape 81 is formed on one side, is adjusted so that the relative positions of the second cured film 92 and the first cured film 91 coincide with each other. The transfer roll 42 also performs alignment operations in, for example, the width direction and the vertical direction (FIGS. 3A and 3B). The amount of movement is calculated from the amount of relative positional deviation detected by a camera (not shown) installed on the downstream side of the manufacturing apparatus D1 in the relative position detection step ST30.

Thereafter, the film 1 passes through the second release roll 72, which is disposed close to a predetermined position on the downstream side of the second transfer roll 42, with one side (surface) in contact with the second release roll 72. At that time, due to the tension acting between the second transfer roll 42 and a tension roll (not shown) provided on the downstream side, and the force of the second release roll 72 pushing the film 1 from one side, The second cured film 92 is released from the second transfer roll 42 and transported in the direction of arrow B.

Next, the basic operation of the second pressure roll 52 will be explained in detail using FIG. 2.

When increasing the pressure applied by the second pressure roll 52, first a predetermined air pressure is applied to the drive unit (air cylinder) 56. As a result, the bearing portion 54 is pressed in the direction shown by the arrow in FIG. 2, and the bearing portion 54 moves forward using the guide 57 as a guide. Then, the second pressure roll 52, the shaft portion 53, and the bearing portion 54 come into contact with the second transfer roll 42 together, and the second transfer roll 42 is pressed.

When reducing the pressure applied by the second pressure roll 52, the air pressure of the drive unit (air cylinder) 56 may be reduced, contrary to the above. As a result, the bearing portion 54 retreats using the guide 57 as a guide, and the pressure on the second transfer roll 42 becomes smaller.

The above-mentioned variation in the pressure force can be performed independently on each side of the second pressure roll 52. Therefore, although the axis of the second pressure roll 52 and the axis of the second transfer roll 42 are on the same plane in the vertical direction, they are not parallel when viewed from above.

Next, the basic operation of pressure adjustment using the edge detection section 100 and the second pressure roll 52 will be explained using FIG. 5. FIG. 5 is a flowchart of the control of the second pressure roll 52.

First, after starting double-sided imprinting, in an edge detection step ST50, plain widths W3 and W4 are measured using the edge detection section 100.

Next, it is determined whether the measured values W3 and W4 of the plain width fall within preset threshold ranges (tolerable ranges) A1 and A2. Specifically, it is determined whether the measured value W3 of the plain width is greater than or equal to W5 and less than or equal to W6, and whether the measured value W4 of the plain width is greater than or equal to W7 and less than or equal to W8.

When the measured values W3 and W4 of the plain width fall within the threshold ranges A1 and A2, the pressure force of the second pressure roll 52 is maintained without adjusting the pressure force. If the measured values W3, W4 of the plain width are out of the threshold ranges A1, A2, the pressure force is adjusted. For example, if the measured value W3, W4 of the plain width is smaller than the lower limit value W5, W7, the pressure force is decreased, and if the measured value W3, W4 of the plain color width is larger than the upper limit value W6, W8, the pressure force is increased. The second pressure roll 52 is controlled in the direction of increasing the pressure.

When adjusting the pressing force, first, the difference between the measured values W3, W4 of the plain width and the threshold ranges A1, A2 is calculated. Specifically, when the plain widths W3, W4 are smaller than the lower limits W5, W7 of the threshold ranges A1, A2, the difference between the plain widths W3, W4 and the lower limits W5, W7 (W5-W3, W7-W4). Calculate. When the plain widths W3, W4 are larger than the upper limits W6, W8 of the threshold ranges A1, A2, the differences (W3-W6, W4-W8) between the plain widths W3, W4 and the upper limits W6, W8 are calculated.

Next, a pressing force (pressure adjustment force) F0 corresponding to the difference between the measured values W3, W4 of the plain width and the threshold ranges A1, A2 is calculated. In this embodiment, the results of the blank widths W3 and W4 for each pressing force are measured in advance. Using the result, for example, the pressing force F1 for increasing or decreasing the plain widths W3 and W4 by 1 mm is calculated in advance. The pressing force F0 is calculated by multiplying the pressing force F1 by the difference between the measured values W3, W4 of the plain width and the threshold ranges A1, A2.

Next, by replacing the calculated pressing force F0 with the set value of the load cell 55, the air pressure that controls the pressing force is changed. As a result, the pressing force of the nip portion of the second pressure roll 52 is changed, and the widthwise end (edge) of the second cured film 92 is moved.

Next, it is determined again whether the measured values W3 and W4 of the plain width fall within the preset threshold ranges A1 and A2. When the measured values W3 and W4 of the plain width fall within the threshold ranges A1 and A2, the pressure force is not readjusted, and the corrected pressure force of the second pressure roll 52 is maintained. If the measured value W3, W4 of the plain width is outside the threshold range A1, A2, the above operation is repeated until it is determined that the measured value W3, W4 of the plain width falls within the threshold range A1, A2. This allows the plain widths W3 and W4 to maintain the range between the upper limits W6 and W8 and the lower limits W5 and W7.

Next, the first feature of this embodiment will be explained. The first feature of this embodiment is that the variation in one plain width W3, W4 of the second cured film 92 is controlled by the pressing force of one of the second pressure rolls 52.

In the general UV roll-to-roll imprinting method, the plain width of the cured film is mainly determined by the applied amount and viscosity of the transfer material supplied and the pressing force of the entire pressure roll, and is evenly distributed at both ends. It is normal for it to change.

When controlling by coating amount, a method of partially deforming the opening at the tip of the nozzle of the die unit can be considered. However, in this case, not only does the structure of the die unit become complicated and the equipment cost increases, but also it takes time for the flow inside the die unit to stabilize, so there is a drawback that the responsiveness during adjustment is low. Further, when adjusting the viscosity of the transfer material, a method such as spraying an additive that partially adjusts the viscosity may be considered. However, selection of additives is not easy because it is directly linked to the quality of the cured film.

On the other hand, by using the method of applying pressure to the second pressure roll 52 one side at a time in this embodiment, introduction becomes easier and responsiveness becomes faster. In other words, by adopting the configuration shown in FIG. 2, it is not only possible to reduce the cost of the mechanism that separates both ends of the second pressure roll 52 and moves them back and forth, but also allows the instantaneous air pressure to move the second pressure roll 52 forward and backward. 2. Since only the flow of the transfer material 32 is changed, the response becomes faster.

According to such a configuration, fluctuations in one of the plain widths W3 and W4 of the second cured film 92 can be easily and quickly controlled, making it possible to reduce equipment costs and reduce quality loss.

Next, the second feature of this embodiment will be explained. A second feature of this embodiment is that it includes an edge detection section 100 that monitors variations in the plain widths W3 and W4 of the second cured film 92.

As mentioned above, in the general UV roll-to-roll imprint method, the plain width of the cured film usually changes uniformly at both ends. However, in the embodiment of the present invention, as shown in FIGS. 3A and 3B, a position correction operation is performed in which the second transfer roll 42 is tilted or moved parallel to the axial direction of the second pressure roll 52. ing. Therefore, when rotational vibration of the second pressure roll 52 is applied, the liquid pool in the nip portion tends to move to one side. Furthermore, as the distance between the second transfer roll 42 and the immediately preceding second coating roll 12 changes, the tension applied to both ends of the film 1 tends to become unstable. As a result, variations in the plain widths W3 and W4 may be difficult to predict.

However, by providing the edge detection unit 100 of this embodiment, it is possible to constantly monitor variations in the plain widths W3 and W4. Therefore, by combining this with the above-described divided control of the second pressure roll 52, the quality of the second cured film 92 can be significantly improved.

According to this configuration, fluctuations in the second cured film 92 can be instantaneously captured and fed back to the control system of the apparatus, making it possible to significantly reduce quality loss.

According to the film structure manufacturing method and manufacturing apparatus D1 according to the present embodiment, the following effects can be achieved.

The method for manufacturing a film structure according to this embodiment is a method for manufacturing a film structure in which transfer materials 31 and 32 are transferred and cured onto both surfaces of a continuously running film 1. The method for manufacturing a film structure includes a first curing step ST10, a second curing step ST20, an edge detection step ST50, a determination step ST60, and a pressing force adjustment step ST80. In the first curing step ST10, the transfer material 31 containing an ultraviolet curable resin applied to the surface of the film 1 is cured by the first curing means 61 while being pressed against the first transfer roll 41 by the first pressure roll 51. This is a step of forming a first cured film 91. In the second curing step ST20, the transfer material 32 containing the ultraviolet curable resin applied to the back surface of the film 1 is cured by the second curing means 62 while being pressed against the second transfer roll 42 by the second pressure roll 52. This is a step of forming a second cured film 92. The edge detection step ST50 is a step of detecting the position of the widthwise end portion of the second cured film 92. In the determination step ST60, the plain widths W3 and W4 from the widthwise end of the second cured film 92 to the widthwise end on one side of the film 1 detected in the edge detection step ST50 fall within a preset threshold range A1. , A2. In the pressurizing force adjustment step ST80, when it is determined in the determination step ST60 that the plain widths W3, W4 exceed the threshold ranges A1, A2, a second pressurizing force is applied so that the plain widths W3, W4 fall within the threshold ranges A1, A2. This is a step of adjusting the pressure applied by the roll 52.

Further, the film structure manufacturing apparatus D1 according to the present embodiment is an apparatus that manufactures a film structure in which transfer materials 31 and 32 are transferred and cured onto both surfaces of the continuously running film 1. The manufacturing apparatus D1 includes a first transfer roll 41, a first pressure roll 51, a first curing means 61, a second transfer roll 42, a second pressure roll 52, a second curing means 62, and an edge. It includes a detection section 100, a pressure variable mechanism 50, and a control section C1. The first transfer roll 41 has a transfer shape 81 on its surface. The first pressure roll 51 presses the surface of the film 1 coated with the transfer material 31 containing an ultraviolet curable resin against the first transfer roll 41 . The first hardening means 61 hardens the transfer material 31 pressed by the first pressure roll 51 to form a first cured film 91 . The second transfer roll 42 is arranged downstream of the first transfer roll 41 and has a transfer shape 82 on its surface. The second pressure roll 52 presses the back surface of the film 1 coated with the transfer material 32 containing an ultraviolet curable resin against the second transfer roll 42 . The second hardening means 62 hardens the transfer material 32 pressed by the second pressure roll 52 to form a second cured film 92 . The edge detection unit 100 detects the position of the widthwise end of the second cured film 92. The pressure variable mechanism 50 is a mechanism that makes the pressure applied by the second pressure roll 52 variable. The control unit C1 controls whether the plain color width W3, W4 from the detected widthwise end of the second cured film 92 to the one widthwise end of the film 1 exceeds a preset threshold range A1, A2. The variable pressure mechanism 50 is controlled so that the widths W3 and W4 fall within the threshold ranges A1 and A2.

According to this manufacturing method and manufacturing apparatus D1, in the pressurizing force adjustment step ST80, the pressurizing force by the second pressurizing roll 52 is adjusted by the pressurizing force variable mechanism 50, so that the plain widths W3, W4 are adjusted to the threshold ranges A1, A2. It can be contained within. Therefore, fluctuations in the transfer width on the back surface can be suppressed.

The method for manufacturing a film structure according to the present embodiment also includes a calculation step ST70. In the calculation step ST70, when it is determined in the determination step ST60 that the plain widths W3 and W4 exceed the threshold ranges A1 and A2, a second This is a step of calculating the pressing force by the pressure roll 52.

Furthermore, in the film structure manufacturing apparatus D1 according to the present embodiment, when the plain widths W3 and W4 exceed the threshold ranges A1 and A2, the control unit C1 controls the threshold ranges A1 and A2 for the plain widths W3 and W4. The pressing force by the second pressure roll 52 is determined based on the exceeded deviation width.

According to this manufacturing method and manufacturing apparatus D1, it is possible to calculate the pressing force that allows the plain widths W3, W4 to fall within the threshold ranges A1, A2 from the deviation width, so that the plain widths W3, W4 can be determined more easily. can be kept within the threshold ranges A1 and A2.

Furthermore, the method for manufacturing a film structure according to the present embodiment includes a relative position detection step ST30 and a position adjustment step ST40. The relative position detection step ST30 is a step of detecting the relative position of the second cured film 92 with respect to the first cured film 91. The position adjustment step ST40 is a step of adjusting the relative position detected by the relative position detection step ST30 by moving the second transfer roll 42.

Further, in the film structure manufacturing apparatus D1 according to the present embodiment, the second transfer roll 42 is provided so that its relative position with respect to the film 1 can be adjusted.

According to this manufacturing method and manufacturing apparatus D1, since the relative position of the second cured film 92 with respect to the first cured film 91 can be adjusted, the amount of relative positional deviation between the first cured film 91 and the second cured film 92 can be eliminated. As a result, fluctuations in the transfer width on the back side of the film 1 can be suppressed while ensuring the transfer quality on both sides of the film 1 and the relative positional accuracy of the cured films 91 and 92.

Further, in the method for manufacturing a film structure according to the present embodiment, the threshold ranges A1 and A2 include upper limit values W6 and W8 and lower limit values W5 and W7. In the determination step ST60, if it is determined that the plain widths W3, W4 exceed the upper limit values W6, W8 and exceed the threshold ranges A1, A2, the pressing force by the second pressure roll 52 is increased in the pressing force adjustment step ST80. let In the determination step ST60, if it is determined that the plain widths W3, W4 are below the lower limits W5, W7 and exceed the threshold ranges A1, A2, the pressing force by the second pressure roll 52 is reduced in the pressing force adjustment step ST80. let

Furthermore, in the film structure manufacturing apparatus D1 according to the present embodiment, the threshold ranges A1 and A2 include upper limit values W6 and W8 and lower limit values W5 and W7. When the plain widths W3, W4 exceed the upper limit values W6, W8 and exceed the threshold ranges A1, A2, the control unit C1 causes the pressure variable mechanism 50 to increase the pressure applied by the second pressure roll 52. When the plain widths W3, W4 fall below the lower limits W6, W8 and exceed the threshold ranges A1, A2, the control unit C1 causes the pressure variable mechanism 50 to reduce the pressure applied by the second pressure roll 52.

According to this manufacturing method and manufacturing apparatus D1, the plain widths W3, W4 can be more easily kept within the threshold ranges A1, A2 by the upper limits W6, W8 and the lower limits W5, W7 of the threshold ranges A1, A2. .

In the method for manufacturing a film structure according to the present embodiment, in the edge detection step ST50, the position of the widthwise end of the second cured film 92 is determined as one widthwise end of the second cured film 92 and the other widthwise end of the second cured film 92. Detect the position of the edge. In the determination step ST50, the plain width W3 from one end in the width direction of the second cured film 92 to one end in the width direction of the film 1, and the other end in the width direction of the film 1 from the other end in the width direction of the second cured film 92. It is determined whether the plain width W4 up to and including the blank width W4 is within preset threshold ranges A1 and A2.

In the film structure manufacturing apparatus D1 according to the present embodiment, the edge detection unit 100 determines the position of the widthwise end of the second cured film 92 at one widthwise end of the second cured film 92 and the widthwise end of the second cured film 92. Detect the position of the other end. The control unit C1 controls the pressurizing force variable mechanism 50. The control section C1 has a plain width W3 from one end of the second cured film 92 in the width direction to one end of the film 1 in the width direction, and a width W3 from the other end of the second cured film 92 in the width direction to the other end of the film 1 in the width direction. The blank width W4 is controlled to fall within preset threshold ranges A1 and A2, respectively.

According to this manufacturing method and manufacturing apparatus D1, the blank widths W3 and W4 at both ends in the width direction of the second cured film 92 can be kept within the threshold ranges A1 and A2.

In addition, in the method for manufacturing a film structure according to the present embodiment, in the pressing force adjustment step ST80, the pressing force by the second pressure roll 52 is set to one side in the axial direction and the other side in the axial direction of the second pressure roll 52. Adjust the pressing force of each independently.

Further, in the film structure manufacturing apparatus D1 according to the present embodiment, the variable pressure mechanism 50 adjusts the pressure applied by the second pressure roll 52 to one side of the second pressure roll 52 in the axial direction and the other side of the second pressure roll 52 in the axial direction. Adjust the pressing force on each side independently.

According to this manufacturing method, by independently adjusting the pressing force on one side in the axial direction and the other side in the axial direction of the second pressure roll 52, the plain width W3 at both ends in the width direction of the second cured film 92 is adjusted. , W4 can be more easily kept within the threshold ranges A1 and A2.

Further, in the film structure manufacturing apparatus D1 according to the present embodiment, the variable pressure mechanism 50 includes a shaft portion 53, a bearing portion 54, and a drive portion 56. The shaft portion 53 extends axially outward from the second pressure roll 52 . The bearing portion 54 holds the shaft portion 53. The drive unit 56 drives the bearing unit 54 to move the second pressure roll 52 relative to the second transfer roll 42 .

According to this configuration, the variable pressurizing force mechanism 50 can more easily keep the blank widths W3 and W4 within the threshold ranges A1 and A2.

Further, in the film structure manufacturing apparatus D1 according to the present embodiment, the variable pressure mechanism 50 includes a guide 57 that guides the movement of the bearing portion 54.

According to this configuration, the guide 57 can drive the bearing portion 54 more accurately.

Further, in the film structure manufacturing apparatus D1 according to the present embodiment, the drive section 56 drives the bearing section 54 along the direction in which the axis of the second transfer roll 42 and the axis of the second pressure roll 52 are lined up. It has a cylinder 56 for moving.

According to this configuration, the cylinder 56 allows the blank widths W3 and W4 to be more easily kept within the threshold ranges A1 and A2.

Note that the present invention is not limited to the embodiments described above, and can be implemented in various other forms. In the embodiment described above, the edge detection section 100 is a camera equipped with an image recognition function, but the present invention is not limited to this. The edge detection unit 100 may have another configuration as long as the position of the widthwise end portion of the second cured film 92 can be detected. The edge detection unit 100 may detect only the end position of the second cured film 92 by, for example, laser sensing or the like. The edge detection unit 100 may roughly estimate the distance using the edge position of the film 1 as a reference position, assuming that the edge position of the film 1 is not shifted. In this case, the transport system may be configured to be able to control the end position of the film 1 within ±0.1 mm.

In addition, it was assumed that the plain width W3 and the plain width W4 are set to the same value, the upper limit value W6 and the upper limit value W8 are set to the same value, and the lower limit value W5 and the lower limit value W7 are set to the same value. but not limited to. That is, the plain width W3 and the plain width W4 may be different, and the threshold ranges A1 and A2 of the plain widths W3 and W4 may be different on one side in the width direction and on the other side in the width direction.

Furthermore, although the threshold ranges A1 and A2 include the upper limit values W6 and W8 and the lower limit values W5 and W7, the threshold ranges A1 and A2 may be one numerical value (threshold value). That is, the upper limit values W6, W8 and the lower limit values W5, W7 may be set to the same value.

Further, although the variable pressure mechanism 50 includes the drive unit 56 (air cylinder), the present invention is not limited to this as long as the variable pressure mechanism 50 can make the pressure applied by the second pressure roll 52 variable.

In addition, although the amount of relative positional deviation between the first cured film 91 and the second cured film 92 is detected by the camera, other configurations may be used if the amount of relative positional deviation between the first cured film 91 and the second cured film 92 can be detected. There may be.

Furthermore, the edge detection unit 100 captures the positions of the width direction ends of the second cured film 92 and the film 1 and measures the plain widths W3 and W4 as the width between the second cured film 92 and the film 1. However, it is not limited to this. The edge detection unit 100 may detect the position of either one end of the second cured film 92 in the width direction or the other end of the second cured film 92 in the width direction. That is, the edge detection unit 100 may detect either the plain width W3 at one end in the width direction or the plain width W4 at the other end in the width direction.

Although the invention has been fully described with reference to preferred embodiments and with reference to the accompanying drawings, various variations and modifications will become apparent to those skilled in the art. It is to be understood that such variations and modifications are included insofar as they do not depart from the scope of the invention as defined by the appended claims. Further, combinations and changes in the order of elements in the embodiments can be realized without departing from the scope and spirit of the present invention.

The method and apparatus for manufacturing a film structure according to the present invention can also be applied, for example, to forming fine wiring in flexible displays and the like.

D1 Manufacturing device C1 Control part 1 Film 2 Die unit 3 Transfer material 4 Transfer roll 5 Pressure roll 6 UV light source 7 Release roll 8 Transfer shape 9 Cured film 10 Camera 11 First coating roll 12 Second coating roll 21 First die Unit 22 Second die unit 31 First transfer material 32 Second transfer material 41 First transfer roll 42 Second transfer roll 50 Pressure force variable mechanism 51 First pressure roll 52 Second pressure roll 53 Shaft portion 54 Bearing portion 55 Load cell 56 Drive section 57 Guide 61 First curing means 62 Second curing means 71 First release roll 72 Second release roll 81 First transfer shape 82 Second transfer shape 91 First cured film 92 Second cured film 93, 94 Plain area 100 Edge detection area A1, A2 Threshold range W1 Film width W2 Transfer width W3, W4 Plain width W5, W7 Lower limit W6, W8 Upper limit ST10 First curing process ST20 Second curing process ST30 Relative position detection process ST40 Position Adjustment process ST50 Edge detection process ST60 Judgment process ST70 Calculation process ST80 Pressure force adjustment process

Claims (11)

A method for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film, the method comprising:
a first curing step in which a transfer material containing an ultraviolet curable resin applied to the surface of the film is cured by a first curing means while being pressed against a first transfer roll by a first pressure roll to form a first cured film; ,
A second curing step in which the transfer material containing the ultraviolet curable resin applied to the back surface of the film is cured by a second curing means while being pressed against a second transfer roll by a second pressure roll to form a second cured film. and,
The position of the widthwise end of the second cured film and the widthwise end of the film is detected, and the plain width from the widthwise end of the second cured film to the widthwise end of one side of the film is determined. an edge detection step to detect the
a determination step of determining whether the plain width is within a preset threshold range;
If it is determined in the determination step that the plain width exceeds the threshold range, a pressing force adjustment step of adjusting the pressing force by the second pressure roll so that the plain width falls within the threshold range;
including;
In the edge detection step,
Detecting the positions of one widthwise end and the other widthwise end of the second cured film as the positions of the widthwise ends of the second cured film,
Detecting the positions of one widthwise end and the other widthwise end of the film as the positions of the widthwise ends of the film,
A difference between one end in the width direction of the second cured film and one end in the width direction of the film is calculated to detect a plain width from one end in the width direction of the second cured film to one end in the width direction of the film. ,
A difference between the other end in the width direction of the second cured film and the other end in the width direction of the film is calculated to determine the plain color from the other end in the width direction of the second cured film to the other end in the width direction of the film. detect the width,
In the determination step, the plain width from one end in the width direction of the second cured film to one end in the width direction of the film, and from the other end in the width direction of the second cured film to the other end in the width direction of the film. determine whether the plain width of and are within a preset threshold range, respectively,
In the pressurizing force adjustment step, as the pressurizing force by the second pressurizing roll, the pressurizing force on one side in the axial direction and the other side in the axial direction of the second pressurizing roll are each independently adjusted. Method. If it is determined in the determination step that the plain width exceeds the threshold range, apply pressure by the second pressure roll used in the pressure force adjustment step based on the deviation width exceeding the threshold range in the plain width. The method for manufacturing a film structure according to claim 1, comprising a calculation step of calculating the pressure. a relative position detection step of detecting a relative position of the second cured film with respect to the first cured film;
3. The method for manufacturing a film structure according to claim 1, comprising a position adjustment step of adjusting the relative position detected by the relative position detection step by moving the second transfer roll. The threshold range includes an upper limit value and a lower limit value,
In the determination step, if it is determined that the plain width exceeds the upper limit value and exceeds the threshold range, in the pressing force adjustment step, increasing the pressing force by the second pressure roll,
If it is determined in the determination step that the plain width is less than the lower limit value and exceeds the threshold range, in the pressing force adjustment step, the pressing force by the second pressure roll is reduced. 3. The method for producing a film structure according to any one of 3. An apparatus for manufacturing a film structure in which a transfer material is transferred and cured on both sides of a continuously running film,
a first transfer roll having a transfer shape on its surface;
a first pressure roll that presses the surface of the film coated with a transfer material containing an ultraviolet curable resin against the first transfer roll;
a first curing means for curing the transfer material being pressed by the first pressure roll to form a first cured film;
a second transfer roll that is disposed downstream of the first transfer roll and has a transfer shape on its surface;
a second pressure roll that presses the back surface of the film coated with a transfer material containing an ultraviolet curable resin against the second transfer roll;
a second curing means for curing the transfer material being pressed by the second pressure roll to form a second cured film;
an edge detection unit that detects the position of the widthwise end of the second cured film and the widthwise end of the film ;
a variable pressure mechanism that varies the pressure applied by the second pressure roll;
a control unit;
Equipped with
The control unit is configured to control the control unit, when the plain width from the widthwise end of the second cured film to the widthwise end of one side of the film, detected by the edge detection unit, exceeds a preset threshold range. controlling the variable pressure force mechanism so that the plain width falls within the threshold range;
The edge detection unit detects the positions of one end in the width direction and the other end in the width direction of the second cured film as the positions of the ends in the width direction of the second cured film, and detects the positions of the ends in the width direction of the second cured film. Detecting the positions of one end in the width direction and the other end in the width direction of the film as the positions,
The control unit is configured to control a plain width from one end in the width direction of the second cured film to one end in the width direction of the film based on a difference between one end in the width direction of the second cured film and one end in the width direction of the film. , a plain width from the other end in the width direction of the second cured film to the other end in the width direction of the film due to the difference between the other end in the width direction of the second cured film and the other end in the width direction of the film; , each of which controls the variable pressure force mechanism so as to fall within a preset threshold range;
The variable pressure mechanism independently adjusts the pressure on one axial side and the other axial side of the second pressure roll as the pressure applied by the second pressure roll, and manufactures a film structure. Device. The control unit determines the pressing force by the second pressure roll based on the deviation width exceeding the threshold range in the plain width when the plain width exceeds the threshold range. production equipment for film structures. The film structure manufacturing apparatus according to claim 5 or 6, wherein the second transfer roll is provided so that its relative position with respect to the film can be adjusted. The threshold range includes an upper limit value and a lower limit value,
The control unit includes:
When the plain width exceeds the upper limit and exceeds the threshold range, the variable pressure mechanism increases the pressure applied by the second pressure roll;
8. When the plain width is below the lower limit and exceeds the threshold range, the variable pressure mechanism reduces the pressure applied by the second pressure roll. Film structure manufacturing equipment. The variable pressure mechanism includes a shaft portion extending axially outward from the second pressure roll, a bearing portion that holds the shaft portion, and a shaft portion that adjusts the second pressure roll relative to the second transfer roll. 9. The film structure manufacturing apparatus according to claim 5, further comprising a drive section that drives the bearing section so as to move the bearing section. 10. The film structure manufacturing apparatus according to claim 9, wherein the variable pressing force mechanism includes a guide that guides movement of the bearing part. The film structure according to claim 9 or 10, wherein the drive section has a cylinder that moves the bearing section along a direction in which the axis of the second transfer roll and the axis of the second pressure roll are lined up. manufacturing equipment.

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