JPWO2016208353A1 - Method and apparatus for producing surface structure film - Google Patents

Abstract

An apparatus and method is provided for continuously transferring a structure to a film surface with high accuracy and at a low mold cost. It is a manufacturing apparatus which manufactures the surface structure film which has the surface structure containing a thermosetting material on the surface of a film, Comprising: It is a manufacturing apparatus of the surface structure film provided with following (1)-(6) at least. (1) An endless belt-shaped mold having a structure formed on the surface, and (2) a mold conveying means for rotating and conveying the mold held in two or more heating rolls by rotating the heating roll. And (3) a nip roll disposed in parallel with one heating roll in the mold conveying means and having a surface covered with an elastic body, and a pressing means using the heating roll and the nip roll roll. A pressurizing mechanism, (4) a coating unit installed upstream of the pressurizing mechanism in the mold conveyance direction, (5) a film supply means for supplying a film to the surface of the mold, and (6) the above Film peeling means for peeling the film on the surface of the mold.

Description

  The present invention relates to a method for manufacturing a surface structure film by transferring the surface structure to a film and an apparatus for manufacturing the same. The surface structure film obtained by the method of the present invention is of micron size, such as an optical film having optical functions such as diffusion, condensing, reflection, and transmission, and a concavo-convex structure film having super-liquid-repellent function and cell culture suitability. It is used as a member that requires a nano-sized microstructure on its surface.

  As a method for producing a surface structure film having a fine structure on the surface, a mold having a fine structure formed on the surface is used to apply a thermosetting or radiation curable material to the mold or the film before being supplied to the mold. After coating, the film is held in a heated mold to form a fine structure in the coating film and cured, and further, the film is peeled from the mold to form a fine structure on the surface of the film. There is a method of obtaining a surface structure film by transferring.

  In Patent Document 1, after applying a sol-gel, which is a thermosetting material, to a film mold drawn out by roll-to-roll, heat treatment is performed while pressing the mold against the substrate, thereby forming a fine structure made of the sol-gel material on the substrate surface. A method for transferring to a substrate is described. A fine structure is formed in advance on the surface of the film mold, and a structure having substantially the same shape as this fine structure is also formed on the substrate surface. Since the sol-gel material is used, a concavo-convex structure with relatively high heat resistance can be formed.

  Further, in Patent Document 2, a film having a surface coated with a radiation curable resin is irradiated with radiation while pressing the film against an endless belt having a microstructure formed on the surface, thereby forming a microstructure on the film surface, and then molding. And a method for producing a film having a fine structure formed on the surface thereof by peeling the film. The endless belt is described as using a replica made of a resin, which makes it possible to reduce the molding cost.

Japanese Patent No. 5695804 JP 2008-137282 A

  However, in the manufacturing method of the fine structure transfer film described in Patent Document 1, there is a problem that a mold cost is increased because a long film roll is used as a mold. Moreover, although it can be applied to a sheet-like substrate, when applied to a roll-to-roll film, the mold and the substrate are peeled off while the thermosetting material is uncured due to shrinkage during heating, and a predetermined surface structure cannot be formed. There was a problem.

  Moreover, in the manufacturing method of the microstructure transfer film described in Patent Document 2, when applied to a material made of a thermosetting material, the mold and the substrate are peeled off while the thermosetting material is uncured due to shrinkage during curing, and a predetermined transfer There was a problem that the surface structure could not be formed.

  An object of the present invention is to solve the above-mentioned problems, and to provide an apparatus and a method for continuously transferring a fine surface structure made of a thermosetting material onto a film surface with high accuracy and low cost of molding. There is.

  The present invention is the following manufacturing method and manufacturing apparatus.

A manufacturing apparatus for manufacturing a surface structure film having a surface structure including a thermosetting material on the surface of the film,
(1) an endless belt-shaped mold having a surface structure formed thereon;
(2) Mold conveying means for rotating and conveying the mold held by two or more heating rolls by rotating the heating roll;
(3) Pressurization including at least a nip roll disposed in parallel with the first heating roll in the mold conveying means and having a surface covered with an elastic body, and a pressing means using the heating roll and the nip roll roll Mechanism,
(4) a coating unit installed on the upstream side in the conveyance direction of the mold from the pressure mechanism;
(5) film supply means for supplying a film to the surface of the mold;
(6) film peeling means for peeling the film on the surface of the mold;
An apparatus for producing a surface structure film comprising at least

A method for producing a surface structure film, comprising:
(1) In a mold conveyance section that circulates the mold while heating it by holding the endless belt-shaped mold on which the surface structure is formed on at least two heated rolls, on the surface of the mold Applying a thermosetting material;
(2) A step of bonding a film from the thermosetting material side with a thermosetting material applied to the mold surface (3) A nip roll in a state where the film, the thermosetting material, and the mold are laminated. (4) The step of transporting the film, the thermosetting material, and the mold after pressing while heating in a laminated state,
(5) The process of peeling the surface structure film which is the state which the said film and the said thermosetting material contact | adhered from the said mold,
A method for producing a surface structure film, comprising at least

  According to the present invention, the surface structure film can be manufactured by applying an endless belt-shaped mold. Since the process of manufacturing a roll film-like long mold for each product as in the conventional technique can be omitted, the cost of the mold can be reduced. Moreover, since a laminated state can be maintained without peeling between the film and the mold even during the curing process, a highly accurate surface structure can be formed.

It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the manufacturing apparatus of the surface structure film of this invention from the cross section. It is the schematic which looked at an example of the apparatus which manufactures the mold applied to the surface structure film concerning this invention from the cross section. It is the perspective view which showed an example of the surface structure film manufactured by the manufacturing method of the surface structure film of this invention. 2 is a photograph of the surface of a surface structure film produced according to Example 1 observed with an electron microscope.

  The apparatus for producing a surface structure film of the present invention is for circulating the endless belt-shaped mold having a surface structure and the mold held by two or more heating rolls by rotating the heating roll. A mold conveying means, a nip roll disposed in parallel with one heating roll in the mold conveying means and having a surface covered with an elastic body, and a pressing means using the heating roll and the nip roll. A mechanism, a coating unit installed on the upstream side of the pressing direction of the mold with respect to the pressurizing mechanism, a film supply means for supplying a film to the surface of the mold, and a film peeling for peeling the film on the surface of the mold A device comprising at least means.

  FIG. 1 is a schematic view of an example of a production apparatus for a surface structure film of the present invention as seen from a cross section. The surface structure film manufacturing apparatus 10 is an example of an apparatus that forms a surface structure film 15 in which a structure made of a thermosetting material 13 is formed on the surface of a film 11.

  As shown in FIG. 1, the surface structure film manufacturing apparatus 10 of the present invention circulates the endless belt-shaped mold 12 and the mold 12 suspended around a first heating roll 21 and a second heating roll 22. The mold conveying means 20, the pressurizing mechanism 27 that presses the nip roll 28 disposed in parallel with the first heating roll 21 against the first heating roll 21, and the thermosetting material is applied to the surface of the mold 12. A coating unit 30, a film supply means 23 for supplying the film 11 to the surface of the mold 12, and a film peeling means 24 for peeling the surface structure film 15 from the mold 12 are provided. The outline of each component is as follows.

  The mold conveying means 20 includes a first heating roll 21, a second heating roll 22, and a drive unit that rotates both rolls or the first heating roll 21. When only the first heating roll 21 is rotationally driven, the second heating roll 22 is held so that it can freely rotate and rotates by friction with the mold 20. Moreover, the 1st heating roll 21 and the 2nd heating roll 22 contain a heating means. As the heating means, a structure of heating from the inside of the roll is preferable, but an infrared heater or an induction heating device may be installed near the outer surface of the roll to promote heating from the outer surface of the roll.

  The pressure mechanism 27 is a mechanism that can press the nip roll 28 against the first heating roll 21 with uniform pressure in the width direction. The nip roll 28 has a structure in which an outer surface of the core layer is covered with an elastic body. The core layer is rotatably supported at both ends by bearings. The nip roll 28 is opened and closed by the stroke of the pressurizing mechanism 27, and is clamped or released in a state where the mold 12, the thermosetting material 13 and the film 11 are laminated. Further, the nip roll 28 may have a temperature adjusting mechanism in accordance with a desired process and film material.

  As the film supply means 23, an unwinding roll 23 a that unwinds the film from a roll-shaped film, and one or more guide rolls 23 b so as to match the transport path of the film 11 are provided. Is held in the nip roll and then carried into the pressurizing unit 27a.

  As the film peeling means 24, a peeling roll 24a for peeling off the surface structure film 15 which is a laminate composed of the film 11 and a thermosetting material from the mold 12, and a winding for winding the peeled surface structure film 15 into a roll shape. One or more guide rolls 25b are provided so as to match the take-up roll 25a and the transport path of the surface structure film 15.

  The coating unit 30 only needs to be capable of continuously and uniformly ejecting the thermosetting material 13 that is a coating material in the width direction. For example, the coating unit 30 may be continuous with a dispenser including a slit die 31 as illustrated. In addition, a structure in which a liquid feeding mechanism capable of supplying a constant amount of coating liquid is combined may be used. Moreover, in order to maintain the space | interval of the discharge tip surface of a slit die, and a mold with high precision, you may arrange | position the support roll 32 on the opposite side to application | coating of a mold. It is preferable to provide a position adjustment mechanism that can adjust the position of the applicator on the left and right with high resolution.

  The endless belt-shaped mold 12 is an endless belt on which a surface structure is formed. A flexible one is preferable because it can be held on the roll during the conveyance process. Moreover, in order to uniformly pressurize and heat, a thin and uniform material is preferable. The shape is preferably a surface structure having a height difference of 1 mm or less in consideration of the deformation time and the curing time of the thermosetting material. Moreover, since it heats during conveyance, the material which can endure heating temperature is preferable.

  A series of molding operations by the surface structure film manufacturing apparatus 10 is as follows. The mold 12 is conveyed around by the first heating roll 21 and the second heating roll 22 and is heated to a predetermined temperature. Then, the thermosetting material 13 is applied to the surface of the mold 12 by the application unit 30. Further, the forming film 11 unwound from the unwinding roll 23 a serving as the film supply means 23 is supplied to the surface of the mold 12 in the pressurizing unit 27 a. The pressurizing mechanism 27 sandwiches the mold 12, the thermosetting material 13, and the film 11 with the pressurizing unit 27a. Although the thermosetting material is heated and gradually cured immediately after being applied, it is formed on the surface of the mold 12 by being pressurized by the pressure mechanism 27 in a state where the curing is not completely completed. Since the thermosetting material enters the surface structure thus formed, the surface of the heating roll 21 continues to receive further thermal energy, so that curing is accelerated. By promoting the curing, adhesion between the thermosetting material and the film starts to occur and does not easily peel off. In this state, the laminate 14 of the mold, the thermosetting material, and the film is conveyed to the second heating roll 22, and the thermosetting material further receives thermal energy from the heated roll surface, and the curing reaction of the thermosetting material. To complete. When the curing of the thermosetting material is completed, the adhesion of the thermosetting material to the mold 12 and the film 11 is in a strong state. Next, it is divided into the mold 12 side and the surface structure film 15 side where the film 11 and the thermosetting material are laminated by the peeling roll 24a which is the film peeling means 24. The surface structure of the surface structure film is an inverted shape of the mold surface structure. After peeling, a thermosetting material is applied again to the surface of the mold 12. On the other hand, the surface structure film 15 is wound up by a winding roll 25a. The above operation is continuously performed.

  With the above apparatus configuration and operation, a surface structure made of a thermosetting material can be formed on the surface of the film 11. The thermosetting material is not applied to the film 11 as a base material, but is applied to a preheated mold so that it is slightly cured to the extent that fluidity remains before pressurization to obtain an appropriate elastic modulus. A fine surface structure can be obtained with high accuracy by satisfying both the penetration of the resin into the shape during pressing (high filling property) and the shape (high flatness) as a film on the mold surface. Here, the high filling property of the resin means that the resin flows to the gap of the structure formed on the mold surface by nipping at a sufficiently high pressure with respect to the elastic modulus of the thermosetting material. In addition, high flatness means that the end portion in the nip width direction and the flow into the resin in the transport direction are suppressed during pressurization, and a uniform thickness is obtained in both the width direction and the transport direction.

  Furthermore, by applying an endless belt-shaped mold, a sufficiently long distance between the heating rolls can be taken, and in some cases, a sufficient heating time can be ensured by adding a heating device between the rolls. Thereby, it becomes possible to increase the application range of speed-up and a thermosetting material. The endless belt-shaped mold may be managed so that the mold is replaced when it deteriorates or when a defect occurs, and it is not disposable like a roll film mold, so the cost of the mold can be kept low. .

  Next, the configuration of each part will be described in detail with reference to FIG.

  Since the first heating roll 21 constituting the mold conveying means 20 receives a load at the time of nip, strength and processing accuracy are required, and further includes a heating means. Examples of the material include steel, fiber reinforced resin, ceramics, and aluminum alloy. Also, as a heating means, a structure that heats from the inside of the roll by hollowing the inside and installing a cartridge heater or an induction heating device, or processing a flow path inside and flowing a heat medium such as oil, water, or steam But you can. Further, an infrared heater or induction heating device may be installed near the outer surface of the roll and heated from the outer surface of the roll.

  The processing accuracy of the first heating roll 21 is preferably 0.03 mm or less in cylindricity tolerance defined in JIS B 0621 (revised year 1984) and 0.03 mm or less in circumferential runout tolerance. If these values become too large, there will be a partial gap between the first heating roll 21 and the nip roll 28 at the time of clamping, so that the laminate 14 cannot be pressed uniformly, and the shape of the surface structure to be transferred will be May cause variation. The surface roughness of the roll is preferably 0.2 μm or less in terms of arithmetic average roughness Ra defined by JIS B 0601 (revised year 2001). This is because when Ra exceeds 0.2 μm, the shape of the first heating roll 21 is transferred to the back surface of the mold 12, which may be transferred to the surface structure of the film 11.

  The surface of the first heating roll 21 is preferably subjected to a treatment for forming a hard film such as hard chrome plating, ceramic spraying, diamond-like carbon coating, or the like. Since the first heating roll 21 is always in contact with the mold 12 and receives a pressing force from the nip roll 28 through the laminate 14, the surface thereof is very easily worn, and the surface of the first heating roll 21 This is because, when the surface is worn or scratched, problems such as variations in the shape of the surface structure as described above and transfer of the shape of the roll surface may occur.

  On the other hand, the second heating roll 22 also includes heating means. The material and heating means are the same as those of the first heating roll. The processing accuracy of the second heating roll 22 is preferably 0.05 mm or less in cylindricity tolerance defined in JIS B 0621 (revised year 1984) and 0.05 mm or less in circumferential runout tolerance. If these values are too large, the conveyance accuracy may be lowered, and there is a possibility that uneven tension in the width direction or excessive meandering may occur in the laminate 14 or the mold 12. The surface roughness of the second heating roll 22 is preferably 0.2 μm or less in terms of arithmetic average roughness Ra as defined in JIS B 0601 (revised year 2001), like the first heating roll. If Ra exceeds 0.2 μm, heat conduction to the mold may be insufficient. In addition, as with the first heating roll 21, the material is preferably subjected to a treatment for forming a high hardness film such as hard chrome plating, ceramic spraying, diamond-like carbon coating, or the like. This is to prevent scratches and wear due to contact with the mold.

  And the edge part of each roll is rotatably supported by the rolling bearing etc. The first heating roll 21 is connected to driving means such as a motor (not shown) and can rotate while controlling the speed. The second heating roll 22 is preferably rotated by the driving force of the first heating roll 21 through the mold 12. It is also possible to increase the productivity while conveying the surface structure with high accuracy, preferably by conveying in the range of 1 to 30 m / min as the speed.

  In addition, it is preferable to provide a mold meandering correction mechanism in order to stably transport the mold 12. As shown in FIG. 1, the preferred embodiment of the mold meandering suppression mechanism includes a second end detection sensor 35 that detects the position of the end of the mold 12 in the conveyance path of the mold 12 and a second value based on the detected value. A controller 36 for adjusting the conveyance position of the mold 12 is provided by controlling the movement of the heating roll 22.

  As the moving means of the second heating roll 22, one that can adjust the angle of the second heating roll 22 with respect to the conveying direction of the mold 12 is preferable. A structure in which the angle of the second heating roll with respect to the mold conveyance direction is adjusted based on the value from the end detection sensor so that the tension decreases in the direction in which the movement is desired. By providing the above-described meandering suppression mechanism of the mold 12, it is possible to suppress the meandering of the mold due to thermal deformation and to realize stable conveyance and molding operation of the mold 12. Moreover, it is preferable that the 2nd heating roll 22 presses the non-surface structure surface of the mold 12 with a fixed load by pressing means, such as an air cylinder. Since the mold undergoes dimensional changes due to temperature changes, the above structure is effective for maintaining a constant tension.

  Moreover, after applying a thermosetting material in a mold conveyance process, it may heat by another heating unit until it pressurizes, and hardening of a thermosetting material may be accelerated | stimulated. FIG. 2 shows an example of an apparatus to which a heating unit is added, and is a schematic view of the surface structure film manufacturing apparatus 40 as seen from a cross section. By setting the heating unit 41 at a position immediately after application, the thermosetting material immediately after application is started to be cured, and in a state where it is cured to some extent, the pressure is applied in a state where the film 11 is laminated. . The spread of the end portion in the width direction of the material at the time of pressing can be suppressed, and the thickness of the thermosetting material film after pressing can be made uniform in the width direction. The heating unit 41 may be any unit that can heat the thermosetting material, such as a configuration in which the heating unit 41 such as an infrared heater is set apart, or a heating roll brought into contact with the non-application side of the mold 12 to conduct heat. The structure which heats by may be sufficient.

  Moreover, you may provide the planarization means which planarizes the application surface of a thermosetting material after apply | coating the thermosetting material 13 in a mold conveyance process until it pressurizes. FIG. 3 shows an example of an apparatus to which the flattening means 46 is added, and is a schematic view of the surface structure film manufacturing apparatus 45 as seen from a cross section. The flattening means 46 is a structure for flattening the coating surface having irregularities, and preferably has a structure having an edge that contacts the coating surface. Furthermore, it is preferable that the edge portion has a mechanism or a structure that can contact the application surface in a state in which a uniform pressure in the width direction of the mold 12 or a uniform distance from the mold 12 surface is maintained.

  In addition, the flattening means 46 may be provided with a means for removing or recovering excess thermosetting material 13 generated by the flattening of the application surface. By removing or collecting the surplus thermosetting material 13, continuous and stable flattening can be achieved, or the thermosetting material 13 can be prevented from wrapping around the non-application side of the mold 12. . The removal or recovery means is preferably a suction nozzle system connected to a vacuum pump or the like, but may be a system that mechanically scrapes off excess liquid with a blade, and is not particularly limited.

  Moreover, you may provide the press mechanism in which the film 11 is closely_contact | adhered to a thermosetting material, while heating after pressing a thermosetting material in a mold conveyance process. FIG. 4 shows an example of an apparatus to which a pressing mechanism is added, and is a schematic view of the surface structure film manufacturing apparatus 50 as seen from a cross section. The pressing mechanism 51 is an example of a mechanism that presses the laminated body 14 pressed by the pressing mechanism 27 by the endless belt 54 on the surface of the first heating roll 21. The endless belt 54 is suspended from the rolls 52 and 53, and the endless belt 54 circulates by friction with the film 11 following the conveyance of the laminated body 14. Rolls 52 and 53 are rotatably held. The endless belt 54 is preferably heated, and the rolls 52 and 53 are preferably provided with a temperature control mechanism. The material of the endless belt 54 is preferably resin so as not to damage the film 11, but may be a metal belt such as stainless steel. With the above configuration, the surface structure of the mold 12 is promoted by promoting the curing of the thermosetting material 13 by pressing the film 11 against the thermosetting material 13 while the laminate 14 after being pressed is heated. It is possible to promote filling of the thermosetting material 13 into the film and adhesion between the film 11, the thermosetting material 13 and the film 11.

  Further, a heating roll may be added to the mold conveying means in order to promote the curing after pressurization of the thermosetting material 13 in the mold conveying process. FIG. 5 shows an example of an apparatus in which three or more heating rolls are added to the mold conveying means, and is a schematic view of the surface structure film manufacturing apparatus 60 as seen from a cross section. Heating rolls 66a, 66b, 66c, and 66d are provided as conveying means, and a pressing mechanism 51 for pressing the first heating roll 21 and the laminate 14 is provided as in FIG. With the configuration in which the heating rolls 66a to 66d and the pressing mechanism 51 are added, it is possible to promote the curing while maintaining the adhesion between the film 11 and the thermosetting material 13, and therefore, FIG. 1 and FIG. The illustrated mold conveying means is effective for materials that are insufficiently cured.

  Here, the pressurizing mechanism 27 will be described with reference to FIG. The pressurizing mechanism 27 includes a nip roll 28 and a mechanism that presses against the first heating roll 21 that is disposed to face the nip roll 28 in parallel. The nip roll 28 has a structure in which the outer surface of the core layer is covered with an elastic body. The core layer is required to have strength and processing accuracy. For example, steel, fiber reinforced resin, ceramics, aluminum alloy or the like is applied. The elastic body is a layer that is deformed by a pressing force, and a resin layer represented by rubber or an elastomer material is preferably applied. The core layer is rotatably supported by bearings at both ends thereof, and the bearing is connected to pressing means 29 such as a cylinder. The nip roll 28 is opened and closed by the stroke of the pressing means 29 to clamp or release the laminate 14.

  Further, the nip roll 28 may have a temperature adjusting mechanism in accordance with a desired process and film material. The temperature control mechanism is a structure that heats from the inside of the roll by hollowing the inside of the roll and embedding a cartridge heater or induction heating device, or by processing a flow path in the inside and flowing a heat medium such as oil, water, or steam But you can. Further, an infrared heater may be installed near the outer surface of the roll and heated from the outer surface of the roll.

  The processing accuracy of the nip roll 28 is preferably 0.03 mm or less in the cylindricity tolerance defined in JIS B 0621 (revised year 1984) and 0.03 mm or less in the circumferential runout tolerance. If these values become too large, a partial gap is formed between the first heating roll 21 and the nip roll 28 during clamping, and the laminate 14 cannot be pressed with a uniform force in the width direction. 14 cannot be pressed uniformly, and the shape of the surface structure to be transferred may vary. The surface roughness of the elastic body is preferably one having an arithmetic average roughness Ra of 1.6 μm or less as defined in JIS B 0601 (revised year 2001). This is because when Ra exceeds 1.6 μm, the surface shape of the elastic body may be transferred to the back surface of the film 11 during pressing.

  The heat resistance of the elastic body of the nip roll 28 is preferably one having a heat resistant temperature of 160 ° C. or higher, more preferably one having a heat resistant temperature of 180 ° C. or higher. Here, the heat resistant temperature is determined by the temperature at which the rate of change in tensile strength when left at that temperature for 24 hours exceeds 10%.

  As the material of the elastic body, for example, when rubber is used, silicone rubber, EPDM (ethylene propylene diene rubber), neoprene, CSM (chlorosulfonated polyethylene rubber), urethane rubber, NBR (nitrile rubber), ebonite and the like are used. Can be used. Further, it is possible to use a hard pressure resistant resin (for example, a polyester resin) having a higher elastic modulus and hardness and improved toughness. The rubber hardness of the elastic body is preferably in the range of 70 to 97 ° according to ASTM D2240: 2005 (Shore D) standard. If the hardness is less than 70 °, the amount of deformation of the elastic body becomes large, the pressure contact width with the film 11 becomes too large, and the pressure necessary for forming the structure may not be secured. If the angle exceeds 97 °, the amount of deformation of the layer becomes small, and the pressure contact width becomes too small, so that the pressing time required for transferring the surface structure may not be secured.

  The driving means of the nip roll 28 is connected to the end of the first heating roll 21 with a chain or a belt so that it can rotate in conjunction with the first heating roll 21, or Although it is preferable to rotate independently using a motor or the like that can synchronize the speed, it may have a rotatable structure and may be rotated by friction with the film 11.

  The film supply means 23 includes an unwinding roll 23a and one or a plurality of guide rolls 23b installed so as to match the transport path of the film 11, and the guide roll 23b includes a tension detection mechanism. It is preferable to control the rotational torque of the guide roll 23a so that the tension is constant. The film 11 is held by the nip roll 28 and then conveyed to the pressure unit 27a, but a wrinkle stretching roll may be installed just before the film 11 is held.

  The film peeling means 24 is composed of a winding roll 25a that winds up the surface structure film 15 from the mold 12 by the peeling roll 24a and then wound into a roll, and one or a plurality of guide rolls 25b. The guide roll 25b is preferably provided with a tension detection mechanism to control the rotational torque of the take-up roll 25a so that the tension is constant. Moreover, the surface structure film 15 does not necessarily need to be wound in a roll shape, and may be provided with a mechanism that cuts into a sheet shape during the conveyance process and collects it in a single sheet shape while grasping the end portion in the width direction. Further, a cooling mechanism may be provided on the inner surface of the peeling roll 24a. You may cool before heating the surface structure film 15 heated. Moreover, you may cool the surface structure film 15 by providing cooling devices, such as air blowing, in the conveyance process before winding up from a peeling roll. By cooling to room temperature before winding, in the surface structure film 15 after winding, wrinkles and flatness defects that may occur due to temperature changes can be suppressed.

  The coating unit 30 includes a slit die 31 and a coating material supply mechanism connected to the slit die 31 on the upstream side of the pressurizing unit 27 a in the process of transporting the mold 12. The slit die 31 is opposed to the surface on which the surface structure of the mold 12 is formed so that the thermosetting material 13 can be applied. In order to form a uniform coating film, it is preferable that the gap between the slit die 31 and the mold 12 be maintained uniformly with high accuracy. As shown in the figure, the support roll 32 is opposite to the surface on which the surface structure is formed. It is preferable to arrange so that the mold is supported from the side surface. The support roll 32 is preferably provided with a temperature control mechanism inside so that the mold temperature can be controlled to a predetermined temperature when contacting the mold. Here, it is preferable that the distance between the slit die 31 and the mold 12 be controlled so that the distance between the discharge surface of the slit die 31 and the surface of the mold 12 is 10 μm to 500 μm. Further, the accuracy of the interval in the width direction is preferably 10 μm or less, more preferably 3 μm or less. In order to achieve the accuracy in the present invention, the straightness and rotational runout of the support roll 32 are preferably 5 μm or less, more preferably 1 μm or less. In addition, although the application | coating system using a slit die is illustrated here, the other application | coating system may be sufficient.

  A thermosetting material coating unit may be further added so that layers of the thermosetting material can be formed on both sides of the film 11. FIG. 6 shows an example of an apparatus for forming a layer made of a thermosetting material on both sides, and is a schematic view of a surface structure film manufacturing apparatus 70 as seen from a cross section. A second mold conveying means 71 is provided in parallel with the mold conveying means 20. The second mold 80 constituting the second mold conveying means 71 may or may not have a surface structure on the surface. In the absence of a surface structure, a flat thermoset surface is obtained. The second mold conveying means 71 is provided with heating rolls 72 and 73 so that the second mold 80 comes into contact with the film 11 in the vicinity where the mold 12 is separated from the first heating roll 21. The second mold 80 is suspended. The slit die 74 constituting the second coating unit is provided on the upstream side of the mold conveyance process from the film contact point 77 in the second mold conveyance process. A heating unit 75 is provided between the slit die 74 and the film contact point 77. Moreover, after passing the 1st heating roll 21, you may pinch several times with the heating rolls 78 and 79, and accelerate | stimulate hardening of thermosetting material and adhesion | attachment of the film 11 and thermosetting material. Can do. A heating roll 73 is provided at a position opposite to the film to be conveyed to the second heating roll 22. The surface structure film 81 is peeled off from the mold 12 by the heating roll 72 and wound on the winding roll. Since the surface structure film 81 forms layers of the thermosetting material on both sides, the warp deformation of the film accompanying the shrinkage of the thermosetting material can be suppressed, and the planarity can be improved.

  The endless belt-shaped mold 12 is an endless belt whose surface structure is processed. The material may be a metal such as nickel, steel, stainless steel, or copper in consideration of high strength and thermal conductivity, but is preferably a resin in consideration of peelability from the thermosetting material. In the case of a resin, a thermoplastic material having a surface energy of 25 mN / m or less is preferable so that higher peelability can be obtained. Preferred examples of the material include polyolefin-based materials. In order to improve the flatness as a mold, it may be bonded to a biaxially stretched polyethylene terephthalate film (PET).

  As a method for producing the mold 12 having the surface structure, a method of forming a shape by pressing a mold against the surface of the thermoplastic film may be applied. In the method of forming a shape by pressing a mold against the surface of the thermoplastic film, the thermoplastic film is pressed against the mold in a heated state, and the reverse structure of the structure formed on the surface of the mold is applied to the thermoplastic film. Form on the surface. For example, it can be manufactured by a process via a mold manufacturing apparatus as shown in FIG. FIG. 7 is a cross-sectional view showing an example of an apparatus for manufacturing the mold 12 using the endless belt-shaped mold 101.

  In the example shown in FIG. 7, the film 102 is drawn out from the unwinding roll 110 and supplied to the surface of the endless belt-shaped mold 101 having a heated surface structure by the heating roll 120. The surface structure of the mold 101 is almost the same as the surface structure of the surface structure film 15 to be finally obtained. The mold 101 is heated by the heating roll 120 immediately before coming into contact with the film. The surface structure of the mold 101 is pressed against the continuously supplied film 102 by the nip roll 121, and a structure in which the surface structure of the mold 101 is reversed is formed on the film 102.

  Thereafter, the film 102 is conveyed to the outer surface position of the cooling roll 130 while being in close contact with the mold 101. The film 102 is cooled by heat conduction through the mold 101 by the cooling roll 130, and then peeled off from the mold 101 by the peeling roll 140, and the film is taken up by the winding roll 150. By such a process, a roll film mold is obtained. The mold 12 shown in FIG. 1 is cut into an appropriate length according to the apparatus to be applied, and is processed into an endless belt shape by fixing the end portion with tape from the inner surface side.

  In addition, as a processing method applied to the surface of the mold 101, a method of performing cutting or laser processing directly on the surface of the metal belt, a method of performing cutting or laser processing directly on the plating film formed on the surface of the metal belt, Examples thereof include a method in which electroforming is performed on a cylindrical original plate having a structure on the inner surface, and a method in which a thin plate having a microstructure surface is continuously pasted on the surface of a metal belt. Moreover, the method of butt-welding the edge parts of a metal plate with predetermined thickness and length etc. is mentioned.

  Further, as the surface structure of the mold 12, a structure in which the concave shapes are discretely arranged is suitable. This is because pressure can be received on the mold flat surface during pressurization, so that pressure is concentrated on the tip of the shape and the possibility of causing deformation at the tip is low. The recess shape is preferably a shape in which cylindrical recesses having a diameter of 10 nm to 1 mm and a height of 10 nm to 0.5 mm are arranged with a pitch of 100 nm to 1 mm, more preferably a height of 1 μm to 500 μm. However, the present invention is not limited to this, and a conical or pyramidal dent may be used. Furthermore, for example, a plurality of grooves may be arranged in stripes, or convex shapes may be discretely arranged.

  Note that the second mold 80 used when the thermosetting material is formed on both surfaces shown in FIG. 6 may have the same configuration, material, and manufacturing method as the mold 12. It may be flat without a surface structure.

  Next, the manufacturing method of the surface structure film of this invention is demonstrated. The method for producing a surface structure film according to the present invention includes a mold conveyance in which an endless belt-shaped mold with a surface structure formed is held by at least two heated rolls so that the mold is conveyed while being heated. Part, a step of applying a thermosetting material to the surface of the mold, a step of bonding a film from the thermosetting material side with the thermosetting material applied to the surface of the mold, the film, the thermosetting A step of pressing the material and the mold with a nip roll in a stacked state, a step of transporting the film after pressing, the thermosetting material, and the mold in a stacked state, the film and the Fewer steps for peeling off the surface structure film in which the thermosetting material is in close contact with the mold. By including, characterized by producing a surface structure film.

  Next, a manufacturing method will be described with reference to FIGS.

  As a preparatory stage, the film 11 is pulled out from the unwinding roll 23a, is placed on the mold 12, and is wound up by the winding roll 25a through the peeling roll 24a.

  Subsequently, the first heating roll 21 and the second heating roll 22 are operated while the film 11 is conveyed by the driving means, and the temperature is adjusted until the surface temperatures of the both heating rolls reach a predetermined temperature. The conditions of the surface temperature of both heating rolls depend on the material of the thermosetting material 13 to be applied, the heat resistance of the film 11, the shape of the surface structure of the mold 12, the aspect ratio, etc., but usually between 80 ° C and 200 ° C. Set by. When the mold is a resin, the surface temperature of the heating roll is preferably 20 ° C. or lower than the glass transition temperature of the mold. This is because deformation of the shape of the surface structure of the mold can be suppressed. In addition, as shown in FIG. 2, a heating unit 41 may be installed between the coating unit 30 and the pressure unit 27a to heat the mold. At this time, the set temperature of the heating unit 41 is preferably set so that the thermosetting material 13 is properly cured in the pressure unit 27a. By setting it to an appropriate cured state, it is possible to suppress the spread of the end portion in the width direction of the material at the time of pressurization and make the thickness of the thermosetting material film after the pressurization uniform in the width direction.

  When the surface temperatures of the first heating roll 21 and the second heating roll 22 reach the set values, the film 11 is transported at the molding speed, and at the same time, the coating unit 30 is operated and the thermosetting material 13 to the mold 12 is operated. At the same time, the nip roll 28 is closed, and the film 11 and the mold 12 are pressurized by the first heating roll 21 and the nip roll 28, and a reverse shape of the surface structure of the mold 12 is formed in the thermosetting material 13. The conditions at this time depend on the mechanical characteristics of the thermosetting material 13 to be applied, the shape of the surface structure of the mold 12, the aspect ratio, etc., but the film forming speed is 1 to 30 m / min, and the nip pressure is 10 MPa or more. It is preferable to set in the range of 100 MPa or less.

  Further, as shown in FIG. 3, a flattening means 46 may be installed between the coating unit 30 and the pressure unit 27a, and the coating surface immediately after the thermosetting material 13 is coated may be planarized in advance. Good. Although complete flattening is difficult, reducing the size of the unevenness of the coated surface facilitates subsequent adhesion with the film 11.

  As the thermosetting material 13 to be applied, either an inorganic material or an organic material may be used, but considering the heat resistance of the film 11, an organic material having a relatively low curing temperature is suitable. For example, phenol resin, urea resin (urea resin), melamine resin, epoxy resin, unsaturated polyester, silicone resin, polyurethane and the like are preferably used. Among these, a two-component curable silicone rubber that can widely select the viscosity at the time of application and the hardness at the time of curing is preferably used.

  When the nip pressure is less than 10 MPa, when the fine structure is transferred, the resin may not be sufficiently deformed, resulting in molding failure. Further, if it exceeds 100 MPa, the shape of the mold may be deformed, and the apparatus may become large due to the strength design, which may cause a problem of cost.

  The thermosetting material 13 is heated by heat conduction from the mold 12 and is sandwiched between the first heating roll 21 and the nip roll 28 to fill the surface structure of the mold 12. And the laminated body 14 by which the film 11, the thermosetting material 13, and the mold 12 which passed the pressurization part 27a were laminated | stacked is conveyed to the 2nd heating roll 22, maintaining temperature substantially. Here, the mold 12 is further heated, and the thermosetting material 13 is also heated by heat conduction from the mold 12, so that the curing progresses. Then, it peels with the peeling roll 24a which is a film peeling means. In addition, as shown in FIG. 4, the laminate 14 may be pressed from the film 11 side using an endless belt 54 on the surface of the first heating roll 21. Curing of the thermosetting material 13 and adhesion between the film 11 and the thermosetting material 13 can be promoted.

  Next, on the surface of the second heating roll 22, the surface structure film 15 in which the film 11 and the thermosetting material 13 are adhered and laminated is peeled from the mold 12 by a peeling roll 24 a serving as a film peeling means. The peeled surface structure film 15 is wound up by a winding roll 25a.

  Further, as shown in FIG. 6, a thermosetting material coating unit may be further added so that layers of the thermosetting material can be formed on both surfaces of the film 11. It is preferable that the material and application thickness of the thermosetting material to be applied are the same as those of the thermosetting material 13 formed on the opposite surface. Further, the set temperature of the heating rolls 72 and 73 and other heating rolls to be added is preferably equal to the heating setting on the thermosetting material 13 side. This is because, in the surface structure film 81, the amount of heat shrinkage on both sides of the film is made equal to suppress the warp of the film and improve the flatness.

  The film 11 preferably has strength and heat resistance so as not to be deformed even during conveyance or curing shrinkage of a thermosetting material, and specifically, preferably polyethylene terephthalate, polyethylene-2,6-naphthalate, polypropylene terephthalate. Polyester resins such as polybutylene terephthalate, polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene and polymethylpentene, polyamide resins, polyimide resins, polyether resins, polyesteramide resins, polyethers Some are made of ester resin, acrylic resin, polyurethane resin, polycarbonate resin, or polyvinyl chloride resin.

  An example of the form of the manufactured surface structure film is shown in FIG. FIG. 8 is a perspective view in which a region of the surface structure film 15 is cut out. In the surface structure film 15, the surface of the film 11 is covered with the thermosetting material 13, and the structure is formed on the surface layer. A preferable structure to which the manufacturing method of the present invention is preferably applied is a structure in which columnar or conical protrusions 13a are discretely arranged, but is not limited thereto. The surface structure preferably has a cylindrical convex shape with a diameter of 10 nm to 1 mm and a height of 10 nm to 0.5 mm and a pitch of 100 nm to 1 mm, more preferably a height of 1 μm to 500 μm. However, the shape is not limited to this, and may be a cone or a pyramid convex shape. Furthermore, for example, it may be a stripe shape or may have a concave shape discretely arranged.

[Example 1]
As the film 11, a biaxially oriented polyethylene terephthalate film (trade name “Lumirror” (registered trademark), S10, manufactured by Toray Industries, Inc.) having a thickness of 100 μm was used. The width was 300 mm.

  For the mold 12, a film made of methylpentene polymer having a thickness of 100 μm, a length of 3 m, and a width of 320 mm (Opylan, manufactured by Mitsui Chemicals, Inc.) is applied, and the surface structure is formed by the surface of the thermoplastic film shown in FIG. The apparatus which shape | molds a shape by pressing a metal mold | die was used. The surface structure is a concave shape arranged squarely with a height of 50 μm, a diameter of 40 μm, and a pitch of 120 μm.

  As the thermosetting material 13, a two-component curable silicone rubber (trade name: 7-6830, manufactured by Toray Dow Corning Co., Ltd.) was used.

  The apparatus shown in FIG. 1 is used as a surface structure film manufacturing apparatus, and the first and second heating rolls 21 and 22 have a cartridge heater built in a cylindrical core material made of carbon steel, and hard chrome plating is applied to the surface. What was done was used. The outer diameter of the central portion that supports the mold 12 was 400 mm, and the length in the width direction was 340 mm. The surface temperature of both heating rolls was heated to 160 ° C.

  The slit die 31 had a discharge width of 290 mm and a slit width of 100 μm, and was applied so that the coating thickness was 20 μm when applied to a flat surface.

  The peeling roll 24a, which is a film peeling means, has an outer diameter of 400 mm and a width direction length of 340 mm, and has a structure in which cooling water can flow inside a hollow core made of carbon steel. The temperature of the cooling water was 30 ° C.

  Supply of the film 11 to the mold 12 was performed from a film wound in a roll shape, and the unwinding tension was set to 30N.

  The film of the surface structure film 15 was peeled off from the mold 12 with a winding tension of 30 N and wound up as a film roll.

  The mold 12 was circulated and conveyed at a speed of 2 m / min. The first and second heating rolls were held so that a tension of 30 N was applied to the mold 12.

  As the nip roll 28, a cylindrical core material made of carbon steel having an outer diameter of 160 mm and a surface coated with a polyester resin (hardness: Shore D80 °) as an elastic body with a pressure width of 290 mm was used. A pressing force of 100 kN was applied to the nip roll 28 using a hydraulic cylinder as the pressing means. At this time, when the contact width B between the nip roll 28 and the film 11 was confirmed using a pressure measurement film (Prescale, manufactured by Fuji Film Co., Ltd.), the total width was 6 mm, and the pressure applied to the molding film 2 was The pressure was about 50 MPa, which was uniform in the width direction.

As a result of continuously performing the molding operation, the surface shape of the mold 12 was transferred to the thermosetting material 13 by almost 100%. FIG. 9 shows the result of observing the surface of the surface structure film with a scanning electron microscope.
[Example 2]
The same film 11 and mold 12 as described in Example 1 were used.

  As the thermosetting material 13, a two-component curable silicone rubber (trade name RBL-9101-05, manufactured by Toray Dow Corning Co., Ltd.) was used.

  The apparatus shown in FIG. 3 is used as a surface structure film manufacturing apparatus, and the first and second heating rolls 21 and 22 have a cartridge heater built in a cylindrical core material made of carbon steel, and hard chrome plating is applied to the surface. What was done was used. The outer diameter of the central portion that supports the mold 12 was 400 mm, and the length in the width direction was 340 mm. The surface temperature of the 1st heating roll 21 was heated to 160 degreeC, and the surface temperature of the 2nd heating roll 22 was heated to 90 degreeC.

  The slit die 31 had a discharge width of 290 mm and a slit width of 100 μm, and was applied so that the coating thickness was 25 μm when applied to a flat surface. As the flattening means 46, a scraping blade made of stainless steel with a scraping width of 320 mm was used and held so that the shortest distance between the surface of the mold 12 and the scraping blade was 20 μm.

  The surplus liquid scraped off by the scraping blade was disposed above the scraping blade and collected by a suction nozzle having a suction width of 320 mm and a slit width of 200 μm connected to a vacuum pump. The suction pressure of the suction nozzle was set to −10 kPa using a pressure regulator.

  The peeling roll 24a, which is a film peeling means, has an outer diameter of 400 mm and a width direction length of 340 mm, and has a structure in which cooling water can flow inside a hollow core made of carbon steel. The temperature of the cooling water was 30 ° C.

  Supply of the film 11 to the mold 12 was performed from a film wound in a roll shape, and the unwinding tension was set to 30N.

  The film of the surface structure film 15 was peeled off from the mold 12 with a winding tension of 30 N and wound up as a film roll.

  The mold 12 was circulated and conveyed at a speed of 2 m / min. The first and second heating rolls were held so that a tension of 30 N was applied to the mold 12.

  As the nip roll 28, a cylindrical core material made of carbon steel having an outer diameter of 160 mm and a surface coated with a polyester resin (hardness: Shore D80 °) as an elastic body with a pressure width of 290 mm was used. A pressing force of 100 kN was applied to the nip roll 28 using a hydraulic cylinder as the pressing means.

  As a result of continuously performing the molding operation, the surface shape of the mold 12 can be transferred to the thermosetting material almost 100%, and the application surface is flattened immediately after application, so that the film 11 and the thermosetting material are transferred. The adhesion of 13 was also good.

10: Example of production apparatus for surface structure film of the present invention 11: Film 12: Mold 13: Thermosetting material 13a: Protrusion 14: Laminate 15: Surface structure film 20: Mold conveying means 21: First heating roll 22 : Second heating roll 23: film supply means 23a: unwinding roll 23b: guide roll 24: film peeling means 24a: peeling roll 25a: take-up roll 25b: guide roll 27: pressure mechanism 27a: pressure unit 28: Nip roll 29: Pressing means 30: Coating unit 31: Slit die 32: Support roll 35: Edge detection sensor 36: Controller 40: Example of surface structure film manufacturing apparatus 41 of the present invention 41: Heating unit 45: Surface structure of the present invention Example 46 of film production apparatus: Flattening means 50: Example 51 of production apparatus for surface structure film of the present invention: Pressing Mechanisms 52, 53: Roll 54: Endless belt 60: Examples of manufacturing apparatus for surface structure film of the present invention 66a to 66d: Heating roll 70: Example of manufacturing apparatus of surface structure film of the present invention 71: Second mold conveying means 72, 73: Heating roll 74: Slit die 75: Heating unit 77: Film contact point 78, 79: Heating roll 80: Mold 81: Surface structure film 100: Manufacture of a mold to be applied to the surface structure film manufacturing apparatus of the present invention Example of apparatus 101: mold 102: film 110: unwinding roll 120: heating roll 121: nip roll 130: cooling roll 140: peeling roll 150: winding roll

Claims (14)

A manufacturing apparatus for manufacturing a surface structure film having a surface structure including a thermosetting material on the surface of the film,
(1) an endless belt-shaped mold having a surface structure formed thereon;
(2) Mold conveying means for rotating and conveying the mold held by two or more heating rolls by rotating the heating roll;
(3) A pressurizing mechanism including at least a nip roll disposed in parallel with the first heating roll in the mold conveying unit and having a surface covered with an elastic body, and a pressing unit using the heating roll and the nip roll. When,
(4) a coating unit installed on the upstream side in the conveyance direction of the mold from the pressure mechanism;
(5) film supply means for supplying a film to the surface of the mold;
(6) film peeling means for peeling the film on the surface of the mold;
An apparatus for producing a surface structure film comprising at least   The apparatus for producing a surface structure film according to claim 1, further comprising heating means for heating the mold between the coating unit and the first heating roll.   The surface structure film according to claim 1, further comprising a flattening unit for flattening a material applied to the mold surface between the coating unit and the pressurizing mechanism. apparatus.   The apparatus for producing a surface structure film according to any one of claims 1 to 3, further comprising a mechanism capable of pressing the outer peripheral surface of the first heating roll against the first heating roll.   The apparatus for producing a surface structure film according to any one of claims 1 to 4, wherein the endless belt-shaped mold is a resin.   The surface according to any one of claims 1 to 5, further comprising a transfer unit for transferring a layer of a thermosetting material to a surface opposite to the surface having the surface structure of the film. Structural film manufacturing equipment. A method for producing a surface structure film, comprising:
(1) In a mold conveyance section that circulates the mold while heating it by holding the endless belt-shaped mold on which the surface structure is formed on at least two heated rolls, on the surface of the mold Applying a thermosetting material;
(2) A step of bonding a film from the thermosetting material side in a state where a thermosetting material is applied to the mold surface;
(3) a step of pressing the film, the thermosetting material, and the mold with a nip roll in a laminated state;
(4) A step of conveying the film after pressurization, the thermosetting material, and the mold while heating in a stacked state,
(5) The process of peeling the surface structure film which is the state which the said film and the said thermosetting material contact | adhered from the said mold,
A method for producing a surface structure film, comprising at least   8. The surface structure film according to claim 7, wherein the mold is heated after the step of applying a thermosetting material to the surface of the mold and before the step of laminating the film from the thermosetting material side. Manufacturing method.   After the step of pressing the film, the thermosetting material, and the mold with a nip roll in a laminated state, the film is pressed against the heating roll from the film side in a state where the mold is held by the heating roll. The method for producing a surface structure film according to claim 7 or 8, wherein:   The application surface of the thermosetting material is flattened after the step of applying a thermosetting material to the surface of the mold and before the step of laminating a film from the thermosetting material side. Item 10. A method for producing a surface structure film according to any one of Items 7 to 9.   The method for producing a surface structure film according to claim 7, wherein the endless belt-shaped mold is a resin.   12. The method for producing a surface structure film according to claim 11, wherein the endless belt-shaped mold comprises a thermoplastic film produced by a method of forming a shape by pressing a mold against the surface of the thermoplastic film.   The method for producing a surface structure film according to claim 11 or 12, wherein the temperature of the heating roll during heating is 20 degrees or more lower than the glass transition temperature of the mold.   14. A transfer unit for transferring a layer of a thermosetting material to a surface on the opposite side of the surface structure film on which the surface structure is formed, in the process of circular conveyance of the mold. The manufacturing method of the surface structure film in any one of.

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