JPH07234307A - Production of reflection mirror - Google Patents

Abstract

PURPOSE:To reduce the cost of a reflection mirror by using a plastic film in place of a mold plate made of glass, etc. CONSTITUTION:A film laminate 10 of the reflection films is produced by forming a metallic film 2 on the surface 1a of the plastic film 1 having high surface accuracy. This laminate 10 of the reflection films is pressed to a base plate 4 dropped thereon with an adhesive 3 and to transfer the metallic film 2 onto the base plate 4, by which the reflection mirror 20 is obtd. Since the plastic film 1 is soft, easy to handle and inexpensive, the production cost of the reflection mirror 20 is drastically reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a reflecting mirror used in optical devices such as cameras, copying machines and laser printers.

[0002]

2. Description of the Related Art Reflecting mirrors used in optical devices such as cameras, copying machines and laser printers require extremely high surface accuracy (surface roughness accuracy).
It was generally manufactured by the method shown in.

First, as shown in FIG. 7A, a metal film 102 of aluminum, copper or the like is vapor-deposited on the surface of a template 101 such as a glass plate having a high surface precision, and as shown in FIG. The template 1 is placed on the surface of the substrate 104 on which the adhesive 103 is dropped.
01 is pressed to bond the metal film 102 to the surface of the substrate 104 as shown in (c), and after the adhesive 103 is cured, the template 101 is peeled off as shown in (d) and as shown in (e). A reflecting mirror 100 including a substrate 104 and a metal film 102 transferred to the surface thereof is obtained (Japanese Patent Laid-Open No. 50-155243).
Japanese Patent Laid-Open No. 61-102601).

That is, first, a reflecting mirror is manufactured by carrying a template into a vapor deposition chamber to form a metal film, taking out the template having the metal film deposited thereon, and transferring it to a predetermined substrate. It was common to do.

[0005]

However, according to the above-mentioned prior art, first, a template such as a glass plate is complicated in the process of finishing its surface with high surface precision, which results in high manufacturing cost and high weight. Moreover, since it is fragile, it must be handled with care when carrying it in and out of the vapor deposition chamber, which makes the work complicated and time consuming, and also when peeling the template after adhering the metal film to the substrate. Also has a tendency to deform and crack.

That is, since the template itself is expensive and difficult to handle, it becomes a major obstacle in automating the manufacturing process of the reflecting mirror and shortening the manufacturing time, which hinders the cost reduction of the reflecting mirror.

The present invention has been made in view of the problems of the above-mentioned prior art, and significantly reduces the manufacturing cost of the reflecting mirror by reducing the material cost, shortening the manufacturing time, and promoting the automation of the manufacturing process. It is an object of the present invention to provide a method for manufacturing a reflecting mirror that can be reduced to a minimum.

[0008]

In order to achieve the above object, a method of manufacturing a reflecting mirror according to the present invention comprises a step of forming a reflecting film on a surface of a plastic film to manufacture a reflecting film laminate, and The method further comprises the step of transferring the reflective film of the laminated reflective film film laminate to a substrate.

Further, a step of forming a reflection film on the surface of the plastic film to produce a reflection film film laminate, winding the reflection film film laminate, and a step of rewinding the wound reflection film film laminate. And a step of transferring the unwound reflective film of the reflective film laminate to the substrate.

Surface roughness Rmax of plastic film
Is preferably 0.05 μm or less.

The reflective film of the reflective film laminate may be transferred to the substrate via an adhesive.

Further, when the reflection film of the reflection film laminate is transferred to the substrate, it is preferable to apply a pressing member having high surface accuracy to the reflection film laminate.

Further, when the reflection film of the reflection film laminate is transferred to the substrate, it is preferable to apply tension to the reflection film laminate.

Further, the reflection film of the reflection film laminate may be transferred onto a plurality of substrates successively or simultaneously.

[0015]

Since the plastic film is lightweight and flexible, it is easy to handle without fear of cracking, and in addition, it is easy to obtain high surface accuracy (surface roughness accuracy) and the material cost is low. As a result, the material cost can be reduced, the manufacturing time can be shortened, the manufacturing process can be automated, and the manufacturing cost of the reflecting mirror can be significantly reduced.

A step of forming a reflective film on the surface of a plastic film to produce a reflective film film laminate and winding the reflective film laminate, and a step of rewinding the wound reflective film laminate. If there is a step of transferring the reflection film of the rewound reflection film film laminate to the substrate, a large-area reflection film can be formed by continuously forming the reflection film while winding the reflection film film laminate. Can be a membrane. Further, by mass-reflecting a large-area reflecting film onto a plurality of substrates simultaneously or successively, it is easy to mass-produce the reflecting mirror. As a result, the manufacturing cost of the reflecting mirror can be further reduced.

[0017]

Embodiments of the present invention will be described with reference to the drawings.

FIGS. 1A to 1F illustrate a process of manufacturing a reflecting mirror according to the first embodiment. First, FIG.
As shown in (a) of FIG.
A plastic film 1 having a surface roughness a of Rmax of 0.05 μm or less is prepared. The material of the plastic film 1 may be any plastic material such as polyester, polypropylene, polyamide, polyethylene, polycarbonate, polyimide, polyvinyl chloride, etc. However, in order to increase the reflectance of the reflecting mirror to be manufactured, an inorganic filler such as an inorganic filler contained in the plastic material may be used. The lower the content, the better.
In particular, when the content of the inorganic filler or the like is zero, the plastic film 1 has sufficient gloss and it is easy to set the surface roughness to 0.05 μm or less as described above.

Since the plastic film 1 needs to have a certain degree of tensile strength as described later, it is desirable that the plastic film 1 has an improved tensile strength by a biaxial stretching method or the like. Further, it is desirable to apply a known release agent of fluorine type or silicone type to the surface 1a of the plastic film 1 as described later. The thickness of the release agent is preferably 1 μm or less, preferably 0.1 μm or less so as not to impair the surface accuracy (surface roughness accuracy) of the surface 1a of the plastic film 1. The method for applying this is roll Any method such as a coating method, a spray coating method and a printing method may be used.

Next, as shown in FIG. 1 (b), a metal film 2 which is a reflection film is formed on the surface 1a of the plastic film 1 by a known method to manufacture a reflection film laminate 10. The material of the metal film 2 is aluminum, copper, silver, gold,
The film forming method is nickel, chromium, or the like, and any method such as a vacuum deposition method such as vapor deposition or sputtering or a plating method may be used. The film thickness of the metal film 2 may be such that a desired reflectance can be obtained without defects such as pinholes, for example, about 20 to 200 nm.

Next, as shown in FIG. 1C, the reflective film laminated body 10 is pressed against the substrate 4 on which the adhesive 3 is dropped, and the reflective film laminated as shown in FIG. 1D. The metal film 2 of the body 10 is adhered to the substrate 4. The adhesive 3 is a reflection mirror made of an epoxy adhesive, a silicone adhesive, a urethane adhesive, a phenol adhesive, an acrylic adhesive, a hot melt adhesive, a chloroprene adhesive, a nitrile rubber adhesive, or the like. Select according to the environment in which it is used and the required strength. In addition, the amount of the adhesive 3 is the same as that of the metal film 2 on the substrate 4
The thickness when adhered to is 10 to 500 μm, preferably 2
When the thickness is controlled so as to be about 0 to 100 μm, there is no risk of transfer failure of surface accuracy due to curing shrinkage of the adhesive.

Further, the material of the substrate 4 is selected according to the use of metal, plastic, glass or other reflecting mirror, and the shape thereof is not limited to a flat plate, and the curved surface 1 as shown in FIG.
4a, or as shown in FIG.
It may have a surface 24a forming a groove such as a letter shape. As a method of curing the adhesive 3, a known method such as heating, leaving at room temperature, or irradiating with ultraviolet rays if the substrate is transparent is adopted.

Finally, as shown in FIG. 1 (e), the plastic film 1 is peeled off using a known release tool, and the substrate 4 is removed.
Then, the reflecting mirror 20 composed of the metal film 2 transferred to the above is obtained. Subsequently, if necessary, the surface 2a of the metal film 2 is provided with a reflection enhancing film and a transparent hard coat for preventing scratches.

According to this embodiment, the plastic film 1 is extremely light and does not have a risk of cracking as compared with the case where a template such as a glass plate is used. Therefore, the metal film 2 can be easily handled. Therefore, the time spent for the work is small. Moreover, since the plastic film 1 has excellent flexibility, it is easy to peel off the plastic film 1 after transferring the metal film 2 to the substrate 4, and the plastic film 1 is permanently deformed or cracked like a glass template. There is no fear of it. In addition, large-sized plastic film 1
It is also easy to form the metal film 2 on the substrate and transfer it to a plurality of substrates sequentially or simultaneously. Furthermore, since the plastic film 1 is much cheaper than the glass template in terms of material cost, the manufacturing cost of the reflecting mirror can be greatly reduced in terms of both material cost and manufacturing process.

As shown in FIG. 4A, the adhesive 3
When the metal film 2 of the reflective film laminate 10 is adhered to the surface of the substrate 4 onto which the liquid crystal has been dropped, a block plate 5 which is a highly rigid pressing member having high surface accuracy is applied to the reflective film laminate 10, and 4 is pressed against the substrate 4 together with the reflective film laminate 10 as shown in FIG. 4B, it is easy to significantly improve the surface accuracy of the metal film 2 transferred to the substrate 4. In particular, in the case of the curved substrate 14 and the grooved substrate 24 as shown in FIGS. 2 and 3, it is essential to apply a block plate having an inverted shape of the surfaces 14a and 24a.

In addition to the block plate 5 or instead of using the block plate 5, as shown in FIG. 5 (a), a pair of clamps 6a, 6 are provided at both ends of the reflection film laminate 10.
Alternatively, a predetermined axial tension may be applied to the reflective film laminated body 10 by holding the clamp 6b and moving the clamps 6a and 6b in opposite directions. In addition, the clamp 6a,
Instead of 6b, as shown in FIG. 5 (b), a plurality of pressure rolls 7a and 7b are used to form the reflection film laminate 10
You may apply tension to. The clamps 6a, 6
Needless to say, it is even more effective to apply tension in the axial direction orthogonal to the axial direction using a clamp similar to b.

Further, as shown in FIG. 6, a metal film 42, which is a reflection film, is formed on the entire surface of a long plastic film 41 to produce a long reflection film laminate 40, which is manufactured. After being wound on the supply roll 48a, it is conveyed to a continuous transfer device having a winding roll 48b, a plurality of pressing rolls 48c and a conveyor 49, and the reflection film laminate 40 is continuously fed from the supply roll 48a by the winding roll 48b. While unwinding, the adhesive 4 is applied to each surface of the plurality of substrates 44 continuously supplied by the conveyor 49.
3 was dropped, and the reflection film laminate 40 was pressed by the pressing rolls 48c to the reflection film laminate 4
If the 0 metal film 42 is transferred to the surface of each substrate 44, the manufacturing time of each reflecting mirror 50 can be further shortened, and the automation and speedup of the apparatus can be promoted.

Next, a specific example of this embodiment will be described.

First Example A metal film of aluminum having a thickness of about 150 nm was vacuum-deposited on the surface of a polyester film (commercially available) having a thickness of 25 μm. Next, about 300 mg of an epoxy adhesive (1565 made by Cemedine) was dropped on an L-shaped press-bending steel plate having a flat portion of 25 × 90 mm, and then the polyester film deposited with the metal film was pressed to transfer the metal film, After heating the adhesive at 60 ° C. for 3 hours to cure the adhesive, only the polyester film was peeled off to produce a flat reflecting mirror. When the reflectance of the plane reflecting mirror was examined, the reflectance at wavelengths of 450 nm and 700 nm was 6 respectively.
It is 8% and 72%, and even after the environment resistance test of leaving it in a high temperature and high humidity chamber of 45 ° C-90% for 500 hours, the reflectance does not decrease, and it has high performance and excellent reliability. It turned out to be a reflector.

Second Specific Example When a similar metal film was formed on the same polyester film as the first specific example and transferred to a similar steel plate, the surface was optically polished to 25 × 90 × 30 (height). ) Mm blue glazing block was applied to the back of the polyester film. When the reflectance of the obtained flat reflecting mirror was examined,
The reflectance at wavelengths of 450 nm and 70 nm is 7 each
It was 2% and 76%, respectively, and it was proved that the reflectance was significantly improved by using the block plate. No decrease in reflectance was observed even after the same environment resistance test as described above.

Third Embodiment Polypropylene film having a thickness of 15 μm (commercially available)
A copper metal film having a thickness of about 100 nm was vacuum-deposited on the surface of the. Next, a thickness of 3 m with a flat portion of 50 × 50 mm
m acrylic board with epoxy adhesive (Sumitomo 3M DP1
00) After dropping about 180 mg, press the polypropylene film on which the metal film is deposited to transfer the metal film, leave it at room temperature for 30 minutes to cure the adhesive, and then peel off only the polypropylene film to perform plane reflection I made a mirror. When the reflectivity was examined by irradiating the plane reflecting mirror with a semiconductor laser beam having a wavelength of 780 nm, the reflectivity was 70%, and the reflectivity did not decrease even after the environment resistance test similar to that described above. It turned out to be a reflector with excellent performance and reliability.

[0032]

Since the present invention is constructed as described above, it has the following effects.

By reducing the material cost, shortening the manufacturing time, and promoting automation of the manufacturing process, the manufacturing cost of the reflecting mirror can be significantly reduced.

[Brief description of drawings]

1A and 1B show a manufacturing process of a reflecting mirror according to an embodiment, in which FIG. 1A is a plastic film before a metal film is formed, and FIG. 1B is a reflective film in which a metal film is formed on a plastic film. A state in which a laminated body is obtained, (c) a substrate on which an adhesive is dropped and a reflective film laminated body before being pressed against the substrate, (d) a state in which the reflective film laminated body is pressed against the substrate, and (e) is plastic When peeling the film,
(F) is a schematic cross-sectional view showing each of the obtained reflecting mirrors.

FIG. 2 is a perspective view showing a case where a substrate of a reflecting mirror has a curved surface.

FIG. 3 is a perspective view showing a case where the substrate of the reflecting mirror has a groove-shaped surface.

FIG. 4 shows a case where a block plate is used to press the reflection film laminate to the substrate, (a) before pressing the reflection film laminate to the substrate, and (b) showing the reflection film laminate. It is a schematic cross section which respectively shows the state pressed on the board | substrate.

FIG. 5 shows a case where a tension is applied to a reflective film laminate by a clamp or a pressing roll when the reflective film laminate is pressed against a substrate, where (a) is a clamp and (b) is a press roll. 3A and 3B are schematic cross-sectional views each showing a case of using.

FIG. 6 is an explanatory diagram illustrating a continuous transfer device that continuously transfers a metal film to a plurality of substrates.

FIG. 7 shows a manufacturing process of a conventional reflecting mirror,
(A) is a state in which a metal film is formed on the template, (b) is a substrate on which an adhesive is dropped and the template before pressing it, (c) is a state in which the template is pressed against the substrate, (d) FIG. 3E is a schematic cross-sectional view showing the reflecting mirror obtained when the template is peeled off.

[Explanation of symbols]

 1,41 Plastic film 2,42 Metal film 3,43 Adhesive 4,14,24,44 Substrate 5 Block plate 6a, 6b Clamp 7a, 7b, 48c Pressure roll 10,40 Reflective film laminated body 20,50 Reflector 48a Supply roll 48b Winding roll 49 Conveyor

Claims (7)

[Claims] 1. A method comprising the steps of forming a reflective film on the surface of a plastic film to produce a reflective film laminate, and transferring the produced reflective film of the reflective film laminate to a substrate. And a method for manufacturing a reflecting mirror. 2. A step of forming a reflective film on the surface of a plastic film to produce a reflective film film laminate, winding the reflective film laminate, and a step of rewinding the wound reflective film laminate. And a step of transferring the rewound film of the unwound rewound film laminate to a substrate. 3. Surface roughness Rma of plastic film
2. x is 0.05 μm or less.
Alternatively, the method of manufacturing the reflecting mirror according to the item 2. 4. The method of manufacturing a reflecting mirror according to claim 1, wherein the reflecting film of the reflecting film film laminate is transferred onto a substrate via an adhesive. 5. The pressing member having high surface accuracy is applied to the reflective film laminated body when transferring the reflective film of the reflective film laminated body to the substrate. A method for manufacturing a reflecting mirror according to item 1. 6. The reflecting mirror according to claim 1, wherein tension is applied to the reflection film laminate when the reflection film of the reflection film laminate is transferred to a substrate. Production method. 7. The method for producing a reflecting mirror according to claim 1, wherein the reflecting film of the reflecting film film laminate is transferred onto a plurality of substrates successively or simultaneously.