KR20180104591A - Method and apparatus for manufacturing surface structure film - Google Patents

Abstract

A manufacturing apparatus for producing a surface structure film having a surface structure including a thermosetting material on a surface of a film, comprising: (1) an endless belt-shaped mold having a structure formed on a surface thereof; and (2) (3) a nip roll which is disposed in parallel with one heating roll in the mold transporting means and whose surface is covered with an elastic body, and a heating roll (4) a coating unit for a mold for applying a material to a surface of the mold on which the surface structure is formed, which is provided on the upstream side of the pressing mechanism in the conveying direction of the mold, (5) a film supply means for supplying a film to the surface of the mold, (6) a film supply means disposed on the upstream side of the pressing mechanism in the film transport direction and in contact with the mold And the coating unit for the film for applying the material, the (7) at least having a film peeling means for peeling the film of the surface of the mold.

Description

Method and apparatus for manufacturing surface structure film

The present invention relates to a method for producing a surface structure film by transferring a surface structure to a film and an apparatus for producing the same. The surface structure film obtained by the method of the present invention can be used as an optical film having an optical function such as diffusion, condensation, reflection, and transmission, or a microstructure having a micron size to nano size Is used as a member required for its surface.

A method of producing a surface structure film having a fine structure on its surface, comprising the steps of applying a thermosetting or radiation-curing material to a mold or a film before feeding the mold using a mold having a fine structure on its surface, There is a method of forming a fine structure on a coating film by surrounding the film and curing it and further peeling the film from the mold to transfer a fine structure to the surface of the film to obtain a surface structure film.

Patent Document 1 discloses a method of transferring a fine structure made of a sol-gel material to a substrate by applying a sol-gel, which is a thermosetting material, onto a film mold drawn out by a roll-to-roll process and then performing heat treatment while pressing the mold against the substrate have. A fine structure is previously formed on the surface of the film mold, and a structure almost the same as that of the fine structure is formed on the surface of the substrate. Since a sol-gel material is applied, a concave-convex structure having relatively high heat resistance can be formed.

Patent Document 2 discloses a method of forming a fine structure on the surface of a film by irradiating the film with the radiation curable resin applied on the surface in advance while pressing the film against the endless belt having the fine structure formed on the surface thereof, A method for producing a film having a structure formed on its surface is disclosed. It is described that the endless belt uses a replica made of resin, whereby the mold cost can be suppressed.

Reference 3 also discloses a method in which after a concave-convex structure is formed by softening a raw material thermoplastic resin by a first heating roll, the foamed material is foamed on the second heating roll by heating and laminated on a disk having a convexo-concave structure Method is described. It is described that the temperatures of the first heating roll and the second heating roll can be set individually in accordance with the used disc and the foamed material. By this, it is possible to form the concave-convex structure on the disc and the foaming and lamination of the foamed material, So that it can be performed by the operation.

Japanese Patent No. 5695804 Japanese Patent Application Laid-Open No. 2008-137282 Japanese Patent Application Laid-Open No. 2001-277354

However, in the method of producing a microstructure transfer film described in Patent Document 1, there is a problem that mold cost is increased because a long film roll is used as a mold. When applied to a roll-to-roll film, it is possible to form a predetermined surface structure by peeling the mold and the substrate while the thermosetting material is uncured due to shrinkage upon heating There was a problem that there was not. Further, even if the film can be cured without being peeled off, the cured material can not be sufficiently filled up to the inside of the pattern formed on the mold surface in the state where the film and the mold are laminated, resulting in a problem that the transferred pattern shape becomes defective .

Further, in the method of manufacturing a 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, There is a problem that it can not be formed. Further, since the flatness of the thermosetting material applied to the mold surface is poor, there is a problem that the thermosetting material adheres poorly to the substrate in the laminated state with the substrate, and the thermosetting material is not uniformly transferred onto the substrate.

Further, in the method of manufacturing a microstructure transfer film described in Patent Document 3, the first heating roll and the second heating roll need to be at a high temperature together, and the maintenance of the concave-convex structure of the disc as the thermoplastic resin, A cooling roll for cooling the product is required in addition to the two heating rolls, resulting in a problem that the equipment is increased in size.

An object of the present invention is to solve the above problem and to provide an apparatus and a method for continuously and uniformly transferring a fine surface structure including a thermosetting material to a film surface with high precision and inexpensive mold cost.

The present invention is the following production method and apparatus.

A production apparatus for producing a surface structure film having a surface structure including a thermosetting material on a surface of a film,

(1) an endless belt-shaped mold having a surface structure formed thereon,

(2) a mold conveying means for conveying the mold surrounding two or more heating rolls by rotating the heating roll by a main conveyance;

(3) a nip roll which is disposed in parallel with the first heating roll in the mold conveying means and whose surface is covered with an elastic body, and a pressurizing mechanism including at least the pressurizing means using the heating roll and the nip roll,

(4) a mold application unit for applying a material to a surface of the mold on which the surface structure of the mold is formed, which is provided on the upstream side of the pressing mechanism in the conveying direction of the mold,

(5) film supply means for supplying a film to the surface of the mold,

(6) a film application unit arranged on the upstream side of the pressing mechanism in the film transport direction and for applying a material to a surface of the film in contact with the mold,

(7) a film peeling means for peeling the film on the surface of the mold.

A method of making a surface structure film comprising a thermosetting material,

(1) A mold conveying unit for main-conveying the mold while heating at least two heating rolls heated by the endless belt-shaped mold having the surface structure formed thereon, wherein the thermosetting material A is applied to the surface of the mold fair,

(2) a step of applying a thermosetting material B to the surface of the film,

(3) a step of bonding the mold and the film so that the thermosetting material A and the thermosetting material B are in contact with each other

(4) a step of pressing the film, the thermosetting material A, the thermosetting material B, and the mold in a laminated state by a nip roll

(5) a step of transporting the film after the press, the thermosetting material A, the thermosetting material B, and the mold in a laminated state while heating,

(6) A process for producing a surface structure film, which comprises at least a step of peeling the film and a surface structure film composed of the thermosetting material A and the thermosetting material B from the mold.

(Effects of the Invention)

According to the present invention, the surface structure film can be manufactured by applying an endless belt-shaped mold. It is possible to omit the step of manufacturing a long roll-shaped mold for each product as in the prior art, thereby reducing the cost of the mold. In addition, even in the curing process, the film and the mold can be kept in a laminated state without being peeled off, and the cured material and the film can be uniformly adhered to each other, so that a highly precise surface structure can be formed.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view showing an example of an apparatus for producing a surface structure film of the present invention, seen from a cross section;
2 is a schematic view showing an example of an apparatus for producing a surface structure film of the present invention, which is seen from a cross section.
3 is a schematic view showing an example of an apparatus for producing a surface structure film of the present invention, which is seen from a cross section.
4 is a schematic view of an example of an apparatus for producing a surface structure film of the present invention, as seen from a cross section;
5 is a schematic view of an example of an apparatus for producing a surface structure film of the present invention, as seen from a cross-section.
6 is a schematic view showing an example of an apparatus for producing a surface structure film of the present invention, which is seen from a cross section.
7 is a schematic view of an example of an apparatus for producing a mold applied to the surface structure film according to the present invention, as seen from a cross-section.
8 is a perspective view showing an example of a surface structure film produced by the method for producing a surface structure film of the present invention.
9 is a photograph of the surface of the surface structure film produced by Example 1, observed by an electron microscope.

An apparatus for producing a surface structure film according to the present invention comprises a mold having an endless belt having a surface structure formed thereon, a mold conveying means for conveying the mold surrounding two or more heating rolls by rotating the heating roll, A nip roll which is disposed in parallel with the first heating roll in the first heating roll and whose surface is covered with an elastic body, a pressing mechanism including at least the heating roll and the pressing means using the nip roll, A film supply unit for supplying a film to a surface of the mold, the film supply unit being provided on the upstream side of the mold and for applying a material to a surface of the mold on which the surface structure is formed; A coating unit for a film for applying a material to a surface of the film which is in contact with the mold, and a peeling unit for peeling the film on the surface of the mold Having a film separation means at least a production apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view showing an example of an apparatus for producing a surface structure film of the present invention, seen from a cross section; An apparatus 10 for producing a surface structure film is an example of an apparatus for forming a surface structure film 15 in which a structure made of a thermosetting material A 13 and a thermosetting material B 13 'is formed on a surface of a film 11 . The thermosetting material A and the thermosetting material B are preferably made of the same material from the viewpoint of adhesiveness when they are bonded, but they are not necessarily the same material, and they are mixed with each other at the interface of both materials, You can choose a material that can be used.

1, the apparatus 10 for manufacturing a surface structure film of the present invention comprises an endless belt-shaped mold 12, a mold 12, a first heating roll 21 and a second heating roll 22, And a nip roll 28 disposed in parallel with the first heating roll 21 to press the first heating roll 21 against the first heating roll 21, A coating unit 30 for applying a thermosetting material A 13 to the surface of the mold 12; a film supply unit 23 for supplying the film 11 to the surface of the mold 12; A film application unit 33 for applying a thermosetting material B 13 'to the surface of the film 11 on the contact side of the mold 12, and a film peeling for peeling the surface structure film 15 from the mold 12 Means (24). The outline of each configuration is as follows.

The mold conveying means 20 includes a first heating roll 21 and a second heating roll 22 and a driving unit for rotating both rolls or the first heating roll 21. When only the first heating roll 21 is rotationally driven, the second heating roll 22 rotates by friction with the mold 20 while keeping it freely rotatable. In addition, the first heating roll 21 and the second heating roll 22 include heating means. As the heating means, a structure of heating from the inside of the roll is preferable, but an infrared heating heater or an induction heating device may be provided near the outer surface of the roll to accelerate the heating from the outer surface of the roll.

The pressing mechanism 27 is a mechanism capable of pressing the nip roll 28 at a uniform pressure in the widthwise direction with respect to the first heating roll 21. The nip roll 28 has a structure in which an outer surface of the deep layer is covered with an elastic body And the core layer is rotatably supported at its both ends by bearings. The nip roll 28 is opened or closed by the stroke of the pressing mechanism 27 and is pressed or bonded in a state in which the mold 12, the thermosetting material A 13, the thermosetting material B 13 ' Open. In addition, the nip roll 28 may have a temperature control mechanism in accordance with the desired process or film material.

An unwinding roll 23a for unwinding the film from the film wound in the form of a roll as the film supply means 23 and one or more guide rolls 23b for matching the conveying path of the film 11, 11 are made to adhere to the nip roll, and then are brought into the pressing portion 27a.

A peeling roll 24a for peeling the surface structure film 15 as a laminate composed of the film 11, the thermosetting material A 13 and the thermosetting material B 13 'from the mold 12 as the film peeling means 24, A take-up roll 25a for winding the peeled surface structure film 15 into a roll shape and a guide roll 25b so as to match the conveying path of the surface structure film 15.

The mold application unit 30 may be any material that can continuously and uniformly discharge the thermosetting material A 13 as a coating material in the width direction. For example, the mold application unit 30 may be continuously provided with a discharger made of a slit die 31 A liquid delivery mechanism capable of supplying a predetermined amount of the coating liquid, and the like. The support roll 32 may be disposed on the opposite side of the application surface of the mold in order to keep the end of the discharge line of the slit die and the gap between the molds with high accuracy. It is preferable to provide a position adjusting mechanism capable of adjusting the position of the applicator with high resolution from left to right.

Although only one coating unit is shown in the drawing, a plurality of coating units for a mold may be formed. The flatness of the coated surface may be lowered due to the influence of the surface structure of the mold 12. In this case, flatness can be improved by applying a plurality of coating steps.

As in the case of the coating unit for a mold, the film coating unit 33 may be any material as long as it can continuously and uniformly discharge the thermosetting material B (13 ') as a coating material in the width direction. For example, 34), and a liquid-delivery mechanism capable of continuously supplying a predetermined amount of the coating liquid. Further, the support roll 35 may be disposed on the opposite side of the application of the mold in order to maintain a high accuracy in the distance between the end of the discharge line of the slit die and the mold. It is preferable to provide a position adjusting mechanism capable of adjusting the position of the applicator with high resolution from left to right.

The mold 12 in the form of an endless belt is an endless belt having a surface structure of unevenness. It should be flexible because it will stick to the roll during transportation. Further, a thin and uniform thickness material is preferable for uniformly pressing and heating. As the shape, a surface structure having a height difference of 1 mm or less is preferable in consideration of a deformation time and a curing time of a thermosetting material to be applied. Further, a material which can withstand the heating temperature is preferable because it is heated during transportation.

A series of molding operations by the apparatus 10 for producing a surface structure film is as follows. The mold 12 is conveyed by the first heating roll 21 and the second heating roll 22 and heated to a predetermined temperature. The thermosetting material A 13 is applied to the surface of the mold 12 by the mold application unit 30. The thermosetting material B 13 'is applied to the surface of the molding film 11 released from the unwinding roll 23a as the film supply means 23 by the film application unit 33. And is supplied to the surface of the mold 12 at the pressing portion 27a. Is pressed by the pressing portion 27a in a state in which the mold 12, the thermosetting material A 13, the thermosetting material B 13 'and the film 11 are laminated by the pressing mechanism 27. The thermosetting material A 13 is heated immediately after the application and is gradually cured. However, when the thermosetting material A 13 is pressed by the pressurizing mechanism 27 in a state where the curing is not completely completed, The thermosetting material A 13 is introduced into the heating roll 21 at the same time as it receives thermal energy from the surface of the heating roll 21, thereby further accelerating the curing. On the other hand, unevenness may occur on the coated surface of the thermosetting material A 13 due to the concavo-convex structure imparted to the surface of the mold 12. However, when the mold 12 and the film 11 are bonded, The thermosetting material A 13 and the thermosetting material B 13 'flow to fill the concave portion of the coated surface of the thermosetting material A 13 as a result, , And the film (11) without any gap between the layers.

The thermosetting materials A 13 and B 13 'receive thermal energy from the mold 12 and are accelerated in curing so that the film 11 starts to come into close contact with the film 11 and is not easily peeled off. In this state, the mold 12, the thermosetting materials A 13 and B 13 ', and the laminate 14 of the film 11 are conveyed to the second heating roll 22, and the thermosetting material A 13 and B 13 'receive more thermal energy to complete the curing reaction of the thermoset material. When the curing of the thermosetting material is completed, the adhesion of the thermosetting material A (13) and B (13 ') to the mold 12 and the film 11 becomes strong. Subsequently, the surface of the mold 12 and the surface structure film 15 in which the film 11 and the thermosetting materials A 13 and B 13 'are laminated by the peeling roll 24a as the film peeling means 24, . The surface structure of the surface structure film 15 becomes an inverted shape of the mold surface structure. After peeling, the surface of the mold 12 is coated with the thermosetting material A 13 again. On the other hand, the surface structure film 15 is wound by the winding roll 25a. The above operation is continuously performed.

The surface structure including the thermosetting material can be formed on the surface of the film 11 by the above device configuration and operation. By applying the thermosetting material to both the film 11 to be the base material and the preheated mold 12, the uneven shape of the surface structure of the mold 12 is cured to some extent by heating to obtain a thermosetting material A The resin into the concave portion of the surface structure of the mold 12 at the time of pressurization (a high filling state) is formed by the combination of the thermosetting material A 13 and the thermosetting material B 13 ' (High flatness) as a film on the surface of the mold can be obtained, and a fine surface structure can be obtained with high accuracy. 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 modulus of elasticity of the thermosetting material A (13). In addition, the high level of flatness suppresses the inflow of the resin into the resin in the nip width direction and in the transport direction at the time of pressurization, so that a uniform thickness can be obtained in both the width direction and the transport direction.

Further, by applying the mold of the endless belt shape, it is possible to secure a sufficiently long distance between the heating rolls and, in some cases, to further secure a resin curing time by further adding a heating device between the rolls. This makes it possible to increase the speed of application and the range of application of the thermosetting material. The mold of the endless belt shape can be managed so as to replace the mold at the time of deterioration or at the time of occurrence of defects. Since the mold is not used for the same time as the roll film mold, the mold cost can be kept low.

Next, the configuration of each unit will be described in detail with reference to Fig.

Since the first heating roll 21 constituting the mold conveying means 20 is subjected to a load at the nip, it is required to have strength and processing accuracy, and further includes a heating means. Examples of the material include steel, fiber-reinforced resin, ceramics, aluminum alloy, and the like. As the heating means, a structure in which a cartridge heater or an induction heating device is provided with a hollow inside, or a flow of oil, water, steam or the like is flowed through the inside of the flow path to heat the inside of the roll. Alternatively, an infrared heating heater or an induction heating device may be provided near the outer surface of the roll to heat it from the outer surface of the roll.

The machining accuracy of the first heating roll 21 is preferably 0.03 mm or less in the cylindrical tolerance defined by JIS B 0621 (revised 1984), and 0.03 mm or less in the circumferential shake tolerance. If these values are excessively large, a partial gap is generated between the first heating roll 21 and the nip roll 28 at the time of pressing, the multilayer body 14 can not be pressed uniformly, There is a case where the shape may cause a deviation. In addition, the surface roughness of the roll is preferably not more than 0.2 탆 in terms of an arithmetic average roughness (Ra) defined in JIS B 0601 (revision 2001). If the Ra exceeds 0.2 탆, the shape of the first heating roll 21 may be transferred to the back surface of the mold 12, and may be transferred to the surface structure of the film 11.

The surface of the first heating roll 21 is preferably subjected to a hard chromium plating process, a ceramic spray process, a diamond-like carbon coating process or the like. The first heating roll 21 is always in contact with the mold 12 and receives a pressing force by the nip roll 28 through the multilayer body 14 so that the surface thereof is very likely to be abraded, 21 are worn or scratched, problems such as the shape deviation of the surface structure and the transfer of the shape of the roll surface may occur as described above.

On the other hand, the second heating roll 22 also includes a heating means. The material and the heating means are the same as the first heating roll. The processing accuracy of the second heating roll 22 is preferably 0.05 mm or less in the cylindrical degree tolerance defined in JIS B 0621 (revised 1984), and 0.05 mm or less in the circumferential shake tolerance. If these values are excessively large, the conveying accuracy may be lowered, and there is a possibility that unevenness in tension in the width direction of the laminate 14 or the mold 12 or excessive meandering may occur. The surface roughness of the second heating roll 22 is preferably 0.2 탆 or less in terms of an arithmetic mean roughness (Ra) defined in JIS B 0601 (revised 2001), similarly to the first heating roll. If Ra exceeds 0.2 탆, the thermal conductivity to the mold may be insufficient. It is preferable that the material is also subjected to hard chromium plating, ceramic spraying, diamond hard coating, carbon coating, or the like in the same manner as the first heating roll 21. This is to prevent scratches and abrasion due to contact with the mold.

The ends of the respective rolls are rotatably supported by a rolling bearing or the like. The first heating roll 21 is connected to driving means such as a motor (not shown), and is rotatable 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. The speed is preferably in the range of 1 to 30 m / min, and the productivity can be increased while transferring the surface structure with high accuracy.

In addition, it is preferable that the mold serpentine correction mechanism is provided in order to stably transfer the mold 12. 1, an end detecting sensor 36 for detecting the position of the end portion of the mold 12 in the conveying path of the mold 12 and an end detecting sensor 36 for detecting the position of the end portion of the mold 12, And a controller 37 for controlling the transport position of the mold 12 by controlling the movement of the second heating roll 22.

As the moving means of the second heating roll 22, it is preferable that the angle of the second heating roll 22 can be adjusted with respect to the feeding direction of the mold 12, respectively. It is preferable that the angle of the second heating roll with respect to the mold conveying direction is adjusted so that the tension is lowered in the direction to be moved based on the value from the end portion detection sensor 36. [ By providing the meandering suppressing mechanism of the mold 12, it is possible to suppress the meandering of the mold 12 due to the thermal deformation, and realize the conveying and forming operation of the stable mold 12. The second heating roll 22 is preferably pressed against the surface of the mold 12 at a constant load by an urging means such as an air cylinder. Since the mold causes a dimensional change in accordance with the temperature change, the above structure is effective for maintaining a constant tension.

The curing of the thermosetting material A 13 may be promoted by heating the thermosetting material A 13 by a separate heating unit between the application and pressurization of the thermosetting material A 13 in the process of transferring the mold. Fig. 2 shows an example of a device to which a heating unit is added, and is a schematic view of a surface structure film production apparatus 40 as viewed from the end. Curing of the thermosetting material A 13 immediately after the application of the thermosetting material A 13 is started by providing the heating unit 41 at a position immediately after the application of the heating unit 41. The film 11 is laminated by the pressurizing mechanism 27 Lt; / RTI > It is possible to suppress the spreading of the end portions in the width direction of the material at the time of pressurization and to make the thickness of the thermosetting material film after pressing uniform in the width direction. The heating unit 41 may be of any type as long as it can heat the thermosetting material A 13 and may be provided separately from the heating unit 41 such as an infrared heater, And heat it by heat conduction.

Further, a planarization means may be provided for planarizing the application surface of the thermosetting material A between the application and pressing of the thermosetting material A 13 in the process of transferring the mold. 3 is a schematic view showing an example of a device to which the planarization means 46 is added, which is a cross-sectional view of the apparatus 45 for manufacturing a surface structure film. The planarization means 46 is a structure for planarizing the coated surface having irregularities, and is preferably a structure having an edge contacting the coated surface. It is also preferable that the edge portion has a mechanism or structure capable of contacting the application surface in a state in which the edge portion maintains a uniform pressure in the width direction of the mold 12 or a uniform distance from the surface of the mold 12.

In addition, a pressing mechanism for pressing the thermosetting material A 13 and B 13 'in the process of conveying the mold and pressing the film 11 against the thermosetting material during heating may be provided. Fig. 4 is a schematic view showing an example of a device to which a pressing mechanism is added, which is a cross-sectional view of the apparatus 50 for producing a surface structure film. The pressing mechanism 51 is an example of a mechanism for pressing the laminated body 14 pressed by the pressing mechanism 27 with the endless belt 54 on the surface of the first heating roll 21. [ The endless belt 54 is suspended on the rolls 52 and 53 and following the conveyance of the laminated body 14, the endless belt 54 is rotated by friction with the film 11. The rolls 52 and 53 are rotatably held. It is preferable that the endless belt 54 is heated, and it is preferable that the rolls 52 and 53 are also provided with a temperature adjusting mechanism. The material of the endless belt 54 is preferably a resin so as not to warp against the film 11, but a metal belt such as stainless steel may be used. With the above configuration, the film 11 is pressed against the thermosetting materials A 13 and B 13 'while the laminated body 14 after the pressurization is heated, whereby the thermosetting materials A 13 and B 13' The filling of the thermosetting material A 13 on the surface structure of the mold 12 and the adhesion of the film 11 and the thermosetting material B 13 'can be promoted while accelerating the curing of the film 11 and the thermosetting material B 13'.

In addition, a heating roll may be added to the mold conveying means to accelerate the curing of the thermosetting material A (13), B (13 ') after pressurization in the mold conveying process. Fig. 5 is a schematic view showing an example of a device in which three or more heating rolls are added to the mold conveying means, and the device 60 for manufacturing a surface structure film is viewed from the end. The heating rolls 66a, 66b, 66c and 66d are provided as the conveying means and a pressing mechanism 51 for pressing the first heating roll 21 and the laminated body 14 is provided as in Fig. Since the configuration in which the heating rolls 66a to 66d and the pressing mechanism 51 are further added enables the curing to be promoted while keeping the adhesion between the film 11 and the thermosetting material B 13 ' The mold conveying means illustrated in Fig. 2 is effective for a material having insufficient curing.

Here, the pressurizing mechanism 27 will be described with reference to Fig. The pressurizing mechanism 27 is constituted by a mechanism for pressing against the nip roll 28 and the first heating roll 21 arranged in parallel to this. 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 required to have strength and machining accuracy. For example, steel, fiber reinforced resin, ceramics, aluminum alloy, etc. are applied. The elastic body is a layer which is deformed by a pressing force, and a resin layer or an elastomer material typified by rubber is preferably applied. The core layer is rotatably supported at its both ends by bearings, and the bearing is connected to a pressing means 29 such as a cylinder. The nip roll 28 is opened or closed by the stroke of the pressing means 29 to press or open the laminated body 14. [

In addition, the nip roll 28 may have a temperature control mechanism in accordance with the desired process or film material. As the temperature regulating mechanism, there may be employed a structure in which the inside of the roll is hollow and the cartridge heater or induction heating apparatus is embedded, or the flow path is internally processed so that the oil, water, steam or the like is flowed and heated from inside the roll. Alternatively, an infrared heat heater may be provided near the outer surface of the roll to heat it from the outer surface of the roll.

The machining precision of the nip roll 28 is preferably 0.03 mm or less in the cylindrical tolerance defined by JIS B 0621 (revised 1984), and 0.03 mm or less in the circumferential shake tolerance. If these values are excessively large, a partial gap is generated between the first heating roll 21 and the nip roll 28 at the time of pressing, so that the laminate body 14 can not be pressed with a uniform force in the width direction, The resultant laminate 14 can not be pressed uniformly, which may cause a deviation in the shape of the surface structure to be transferred. Further, the surface roughness of the elastic body is preferably an arithmetic average roughness (Ra) defined by JIS B 0601 (revision 2001) of 1.6 탆 or less. If the Ra exceeds 1.6 탆, the surface shape of the elastic body may be transferred to the back surface of the film 11 at the time of pressing.

The heat resistance of the elastic body of the nip roll 28 preferably has a heat resistant temperature of 160 DEG C or more and preferably has a heat resistant temperature of 180 DEG C or more. Here, the heat-resistant temperature is a temperature at which the rate of change of the 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) . When a higher elastic modulus and hardness are required, a lightly pressure resistant resin (for example, a polyester resin) having improved toughness can be used. The rubber hardness of the elastomer is preferably in the range of 70 to 97 degrees according to the ASTM D2240: 2005 (Shore D) standard. When the hardness is less than 70 deg., The deformation amount of the elastic body becomes large and the pressure contact width with the film 11 becomes excessively large. As a result, the pressure required for forming the structure may not be secured. On the other hand, The deformation amount of the layer becomes small and the pressure contact width becomes too small, so that the pressing time necessary 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 by a chain or belt or the like and is allowed to rotate in conjunction with the first heating roll 21, And the speed may be rotated independently by using a synchronous motor or the like, but it may be rotated by friction with the film 11 in a rotatable structure.

The film feeding means 23 is constituted by the unwinding roll 23a and one or more guide rolls 23b provided so as to fit the conveying path of the film 11 but the guide roll 23b is provided with a tension detecting mechanism So that the rotation torque of the guide roll 23a is controlled so that the tension is constant. The film 11 is adhered to the nip roll 28 and then conveyed to the pressurizing portion 27a. However, the roll 11 may be provided just before sticking.

The film peeling means 24 is constituted by a take-up roll 25a for peeling the surface structure film 15 from the mold 12 by the peeling roll 24a and winding up the film in the form of a roll and one or more guide rolls The guide roll 25b is preferably provided with a tension detecting mechanism so as to control the rotation torque of the winding roll 25a so that the tension becomes constant. The surface structure film 15 is not necessarily wound in a roll shape, but may be provided with a mechanism that cuts the sheet shape into a sheet shape in the transporting process 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. The heated surface structure film 15 may be cooled before being wound. Further, the surface structure film 15 may be cooled by providing a cooling device such as an air jet during the conveying process before winding from the peeling roll. It is possible to suppress wrinkles and poor planarity which may be caused by the temperature change in the surface structure film 15 after winding by cooling to room temperature before winding.

The mold application unit 30 is provided with a slit die 31 and a coating material supply mechanism connected to the slit die 31 on the upstream side of the pressing portion 27a in the process of transferring the mold 12. The slit die 31 opposes the surface on which the surface structure of the mold 12 is formed so that the thermosetting material A 13 can be applied. It is preferable that the gap between the slit die 31 and the mold 12 be maintained uniformly with high accuracy in order to form a uniform coating film. As shown in the figure, the support roll 32 is provided on the opposite side It is preferable to arrange to support the mold from the surface. In addition, it is preferable that the support roll 32 is provided with a temperature adjusting mechanism therein so as to control the mold temperature to a predetermined temperature at the time of mold contact. Here, the distance between the discharge surface of the slit die 31 and the surface of the mold 12 can be controlled at an interval of 10 mu m to 500 mu m with respect to the gap between the slit die 31 and the mold 12 . The accuracy of the interval in the width direction is preferably 10 占 퐉 or less, and more preferably 3 占 퐉 or less. Further, in order to realize the precision in the present invention, the straightness and rotation of the support roll 32 are preferably 5 占 퐉 or less, and more preferably 1 占 퐉 or less. Although a coating method using a slit die is illustrated here, other coating methods may be used.

 The film application unit 33 is provided with an applicator and a coating material supply mechanism connected to the applicator on the upstream side of the pressing portion 27a in the process of conveying the film 11, A similar slit die or the like may be used. In this case, it is preferable that the interval between the slit die 34 and the film 11 is maintained uniformly in the width direction with high accuracy, and it is preferable to dispose the support roll 35 as shown in the figure. The distance between the slit die 34 and the film 11 and the distance between the discharge surface of the slit die 34 and the surface of the film 11 can be controlled at intervals of 10 to 500 占 퐉 . The accuracy of the interval in the width direction is preferably 10 占 퐉 or less, and more preferably 3 占 퐉 or less. Further, in order to realize the precision in the present invention, the straightness and the rotational shake of the support roll 35 are preferably 5 占 퐉 or less, and more preferably 1 占 퐉 or less. Although a coating method using a slit die is illustrated here, other coating methods may be used.

A transfer unit and a coating unit for a mold of a thermosetting material may be further added to form a layer of a thermosetting material on both sides of the film 11. [ Fig. 6 shows an example of a device for forming a layer containing a thermosetting material on both sides, and is a schematic view of an apparatus 70 for producing a surface structure film as seen from an end face. The second mold transfer means 71 constituting the transfer unit is provided in parallel with the mold transfer means 20. [ The surface of the second mold 80 constituting the second mold transfer means 71 may be provided with a surface structure or may not be provided. When there is no surface structure, a flat surface of a thermosetting material is obtained. The second mold conveying means 71 arranges the heating rolls 72 and 73 so that the second mold 80 comes into contact with the film 11 in the vicinity of the mold 12 away from the first heating roll 21 , And the second mold 80 is suspended on both rolls. The slit die 74 constituting the second mold application unit is installed upstream of the film contact point 77 in the process of conveying the second mold in the mold conveying process. Further, the heating unit 75 is provided between the slit die 74 and the film contact point 77. After passing through the first heating roll 21, it may be pressed plural times by the heating rolls 78, 79, and the curing of the thermosetting material and the adhesion of the film 11 and the thermosetting material can be promoted. A heating roll (73) is provided at a position opposed to the second heating roll (22) with the film conveyed therebetween. The surface structure film 81 is peeled off from the mold 12 by the heating roll 72 and wound around a winding roll. The surface structure film 81 can improve the planarity by suppressing warpage of the film due to shrinkage of the thermosetting material in order to form a layer of the thermosetting material on both sides.

The endless belt-shaped mold 12 is an endless belt having a surface structure processed. Materials such as nickel, steel, stainless steel, and copper may be used in consideration of high strength and thermal conductivity, but resins are preferable in view of peelability from a thermosetting material. In the case of a resin, a thermoplastic material having a surface energy of 25 mN / m or less is preferable so as to obtain higher releasability. As the material, a polyolefin-based material is preferably exemplified. It may be bonded to a biaxially stretched polyethylene terephthalate film (PET) in order to improve planarity as a mold.

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

In the example shown in Fig. 7, the film 102 is taken out from the unwinding roll 110 and supplied to the surface of the endless belt-shaped metal mold 101 having the heated surface structure by the heating roll 120. [ The surface structure of the mold 101 is formed in a shape almost identical to 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 contact with the film. The film 102 supplied continuously is pressed against the surface structure of the mold 101 by the nip roll 121 to form an inverted structure of the surface structure of the mold 101 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 metal mold 101. The film 102 is cooled by heat conduction through the mold 101 by the cooling roll 130 and then peeled from the mold 101 by the peeling roll 140 and the film is wound on the winding roll 150 . By this process, a roll-shaped mold is obtained. The mold 12 shown in Fig. 1 is cut into an appropriate length according to the apparatus to be applied, and the end portion is fixed to the inner surface side with tape to form an endless belt shape.

Examples of the processing method to be performed on the surface of the metal mold 101 include a method of directly cutting or laser machining the surface of the metal belt, a method of directly cutting or laser processing the plated film formed on the surface of the metal belt, A method of electroforming a circular cylindrical disk having a structure on the inner surface thereof, and a method of continuously attaching a thin plate having a microstructured surface to the surface of a metal belt. A method of butt-welding the end portions of the metal plate having a predetermined thickness and length may also be mentioned.

As the surface structure of the mold 12, it is preferable that the depressed shape is disposed discretely. This is because it is possible to receive pressure from the flat surface of the mold at the time of pressurization, and it is unlikely that the pressure is concentrated at the tip of the shape and causes deformation at the tip. As for the depressed shape, a shape having a columnar depression of a diameter of 10 nm to 1 mm and a height of 10 nm to 0.5 mm is arranged at a pitch of 100 nm to 1 mm, and more preferably a height of 1 to 500 m desirable. However, the present invention is not limited to this, but may be a concave or convex shape. Further, for example, a plurality of grooves may be arranged in a stripe shape or a convex shape may be disposed discretely.

The second mold 80 used for forming the thermosetting material on both sides shown in Fig. 6 may be the same in constitution, material, and manufacturing method as the mold 12. Further, it may be a flat one without a surface structure.

Next, a method for producing the surface structure film of the present invention will be described. A method of manufacturing a surface structure film according to the present invention is a method for manufacturing a surface structure film, which comprises a mold conveying section for main-conveying an endless belt-shaped mold having a surface structure formed by surrounding at least two heated rolls heated by heating, A step of applying a thermosetting material A to the surface of the film, a step of bonding the mold and the film so that the thermosetting material A and the thermosetting material B are in contact with each other, the film, the thermosetting material A , The step of pressing the thermosetting material B and the mold with the nip roll in a laminated state, the step of conveying the film after the press, the thermosetting material A, the thermosetting material B, and the mold in a laminated state while heating , A film having a surface structure composed of the thermosetting material A and the thermosetting material B And the step of stripping from the mold characterized in that for producing a surface structure film by including at least.

Next, a manufacturing method will be described with reference to Figs. 1 to 6. Fig.

As a preparation step, the film 11 is taken out from the unwinding roll 23a, and is wound on the winding roll 25a via the peeling roll 24a along the mold 12.

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 temperature of both heating rolls reaches a predetermined temperature . The condition of the surface temperature of both heating rolls depends on the material of the thermosetting material A 13 and B 13 'to be applied, the heat resistance of the film 11, the shape and the aspect ratio of the surface structure of the mold 12, And is usually set between 80 ° C and 200 ° C. When the mold is a resin, it is preferable that the surface temperature of the heating roll is 20 DEG C or more lower than the glass transition temperature of the resin constituting the mold. This is because the deformation of the shape of the surface structure of the mold can be suppressed. Further, as shown in Fig. 2, the mold may be heated by providing the heating unit 41 between the mold application unit 30 and the pressing portion 27a. At this time, it is preferable that the set temperature of the heating unit 41 is set so that the thermosetting material A 13 is properly cured at the pressing portion 27a. It is possible to suppress the spreading of the end portions in the width direction of the material at the time of pressing so that the thickness of the thermosetting material film after pressing can be made uniform in the width direction.

When the surface temperature of the first heating roll 21 and the second heating roll 22 reaches the set value, the film 11 is conveyed at the forming speed and at the same time the mold application unit 30 and the film application unit 33 to start the application of the thermosetting material A 13 to the mold 12 and the application of the thermosetting material B 13 'to the film 11 while closing the nip roll 28, The film 11 and the mold 12 are pressed by the roll 21 and the nip roll 28 to form an inverted shape of the surface structure of the mold 12 in the thermosetting material A 13. The thermosetting material A 13 and the thermosetting material B 13 'are brought into contact with each other and pressed so that the thermosetting material B 13' is adhered to the concavo-convex portion of the applied surface of the thermosetting material A 13, Is charged. The conditions at this time depend on the mechanical properties of the thermosetting materials A and B to be applied, the shape of the surface structure of the mold 12, and the aspect ratio, but the forming speed of the film is 1 to 30 m / min, And is preferably set in a range of 100 MPa or less. 3, a planarizing means 46 may be provided between the coating unit 30 for the mold and the pressing portion 27a, and the coating surface immediately after the coating of the thermosetting material A may be flattened in advance. Though complete planarization is difficult, the size of the unevenness of the application surface is made small, and the subsequent thermosetting material B (13 ') is easily filled in the uneven surface.

As the thermosetting materials A and B to be applied, an inorganic material or an organic material may be used, but an organic material having a relatively low curing temperature is preferable in consideration of the heat resistance of the film 11. [ For example, a phenol resin, a urea resin (urea resin), a melamine resin, an epoxy resin, an unsaturated polyester, a silicone resin and a polyurethane are suitably used. Further, a two-component curing type silicone rubber which can widely select viscosity, hardness at the time of curing, etc., is suitably used.

When the nip pressure is less than 10 MPa, when the microstructure is transferred, the resin may not be fully deformed sufficiently, resulting in a molding failure. If the pressure exceeds 100 MPa, the shape of the mold may be deformed, and the cost may become a problem due to the large size of the device due to the strength design.

The thermosetting material A 13 is heated by the heat conduction from the mold 12 and is filled in the surface structure of the mold 12 by being pressed by the first heating roll 21 and the nip roll 28. The laminated body 14 having the film 11, the thermosetting material, and the mold 12 laminated thereon, which has passed through the pressing portion 27a, is conveyed to the second heating roll 22 while maintaining the temperature. Here, the mold 12 is further heated, and the thermosetting materials A 13 and B 13 'are all heated by the heat conduction from the mold 12 to advance the curing. Thereafter, it is peeled off by the peeling roll 24a which is a film peeling means. 4, the laminate body 14 may be pressed from the film 11 side by using the endless belt 54 on the surface of the first heating roll 21. Curing of the thermosetting materials A 13 and B 13 'and adhesion between the thermosetting material A 13 and the film 11 can be promoted.

Subsequently, the surface structure film 15 (15) in which the film 11 and the thermosetting material A (13), B (13 ') are laminated in close contact with each other by the peeling roll 24a as the film peeling means on the surface of the second heating roll 22 ) Is peeled from the mold (12). The peeled surface structure film 15 is wound on the winding roll 25a.

6, a transfer unit and a coating unit for a mold of a thermosetting material may be further added so that a layer of the thermosetting material can be transferred to both sides of the film 11. [ It is preferable that the material and the coating thickness of the thermosetting material to be applied are equal to those of the thermosetting material A 13 formed on the opposite surface. It is also preferable to set the set temperatures of the heating rolls 72 and 73 and other additional heating rolls to be equal to the heating setting of the side of the thermosetting material A 13. This is to suppress the warpage of the film and improve the planarity by making the amount of heat shrinkage of both surfaces of the surface structure film 81 equal.

As the film 11, it is preferable that the film 11 has strength and heat resistance so as not to be deformed even in conveying or curing shrinkage of a thermosetting material, and specifically, polyethylene terephthalate, polyethylene-2,6-naphthalate, polypropylene terephthalate, Polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene and the like, polyamide resins, polyimide resins, polyether resins , A polyester amide resin, a polyetherester resin, an acrylic resin, a polyurethane resin, a polycarbonate resin, a polyvinyl chloride resin, or the like.

An example of the shape of the surface structure film thus produced is shown in Fig. Fig. 8 is a perspective view showing one section of the surface structure film 15 cut out. In the surface structure film 15, a pattern layer 13a including a thermosetting material is coated on the surface of the film 11, and a structure is formed on the surface layer. As a preferred structure to which the production method of the present invention is suitably applied, it is preferable that discrete dished pits or protrusions, protrusions of a cone or pyramid shape, stripes, or recesses are disposed discretely, It is not limited thereto. The pitch of the pattern is preferably 100 nm to 1 mm, and the height of the pattern is preferably 100 nm to 500 m.

Example

[Example 1]

The film 11 was made of a 100 μm thick film (trade name: "Lumirror" (registered trademark), S10, manufactured by Toray Kabushiki Kaisha) comprising biaxially stretched polyethylene terephthalate. The width was 300 mm.

A film (100 μm in length, 3 m in length and 320 mm in width) made of methylpentene polymer (manufactured by Mitsui Chemicals, Inc.) was used as the mold 12, and the thermoplastic resin film To form a shape by pressing a mold against the surface of the mold. As the surface structure, the isosceles triangle has a wave shape in which the height of the isosceles triangle is 12.5 mu m, the apex angle is 90 degrees, and the pitch is 25 mu m.

Two liquid curable silicone rubbers (trade name: 7-6830, manufactured by Toray Dow Corning Co., Ltd.) were used as the thermosetting materials A 13 and B 13 ', and two liquids were mixed and stirred and then defoamed.

The apparatus shown in Fig. 1 is used as the apparatus for producing the surface structure film. In the first and second heating rolls 21 and 22, a cartridge heater is embedded in a cylindrical core made of carbon steel, and hard chromium plating is applied to the surface I used something. The outer diameter of the central portion supporting the mold 12 was 400 mm and the length in the width direction was 340 mm. The surface temperature of the first heating roll 21 was heated to 120 캜 and the surface temperature of the second heating roll 22 was heated to 160 캜.

A thermosetting material A (13) was applied on the surface of the mold 12 so that the coating thickness became 10 占 퐉 when the slit die 31 having a discharge width of 290 mm and a slit width of 100 占 퐉 was applied to a flat surface .

A thermosetting material B 13 'was coated on the surface of the film 11 so as to have a thickness of 20 μm using a slit die 34 having a discharge width of 290 mm and a slit width of 200 μm.

The peeling roll 24a, which is a film peeling means, has an outer diameter of 400 mm and a length in the width direction of 340 mm, and a hollow core made of carbon steel has a structure capable of flowing cooling water therein. The temperature of the cooling water was 30 占 폚.

The feeding of the film 11 to the mold 12 was performed from the roll-wound film, and the pulling tension was set to 30N.

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

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

The nip roll 28 was made of a polyester resin (hardness: Shore D80 deg.) As an elastic body coated on its surface so as to have a pressing width of 290 mm on the surface of a cylindrical core made of carbon steel having an outer diameter of 160 mm. A pressing force of 100 kN was applied to the nip roll 28 using a hydraulic cylinder. At this time, the contact width B between the nip roll 28 and the film 11 was measured using a pressure measuring film (Freescale, manufactured by Fuji Film Co., Ltd.) to find that the total width was 6 mm, The applied pressure was about 50 MPa and was uniform in the width direction.

As a result of the continuous molding operation, the thermosetting material B (13 ') on the film 11 is bonded to the thermosetting material A (13) on the mold 12 and bonded to the thermosetting material A (13) 12 could be almost 100% transferred. Fig. 9 shows the results of observing the surface of the surface structure film with a scanning electron microscope.

[Example 2]

The same film as that described in Example 1 was used for the film 11 and the mold 12.

Two liquid curable silicone rubbers (trade name: RBL-9101-05, manufactured by Dow Corning Toray Co., Ltd.) were used as the thermosetting materials A 13 and B 13 ', and two liquids were mixed and stirred and then defoamed did.

The apparatus shown in Fig. 3 is used as the apparatus for producing the surface structure film. In the first and second heating rolls 21 and 22, a cartridge heater is embedded in a cylindrical core made of carbon steel and hard chromium plating is applied to the surface I used something. The outer diameter of the central portion supporting the mold 12 was 400 mm and the length in the width direction was 340 mm. The surface temperature of the first heating roll 21 was heated to 70 캜 and the surface temperature of the second heating roll 22 was heated to 150 캜.

The slit die 31 had a discharge width of 290 mm and a slit width of 100 占 퐉, and the thermosetting material A (13) was applied so as to have a coating thickness of 25 占 퐉 when it was applied to a flat surface. A thermosetting material B (13 ') was applied on the surface of the film (11) so as to have a thickness of 10 mu m using a slit die (34) having a discharge width of 290 mm and a slit width of 200 mu m.

A scraping blade of a scraping width of 320 mm made of stainless steel was used as the flattening means 46 and the shortest distance between the surface of the mold 12 and the scraping blade was kept at 20 占 퐉.

The surplus liquid scraped by the scraping blade was disposed above the scraping blade and recovered from a suction nozzle connected to a vacuum pump having a suction width of 320 mm and a slit width of 200 mu m. The suction pressure of the suction nozzle was set to -10 kPa by the pressure regulator.

The peeling roll 24a, which is a film peeling means, has an outer diameter of 400 mm and a length in the width direction of 340 mm, and a hollow core made of carbon steel has a structure capable of flowing cooling water therein. The temperature of the cooling water was 30 占 폚.

The feeding of the film 11 to the mold 12 was performed from the roll-wound film, and the pulling tension was set to 30N.

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

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

The nip roll 28 was made of a polyester resin (hardness: Shore D 80 °) coated on the surface with a pressing width of 290 mm as an elastic body on the surface of a cylindrical core made of carbon steel with an outer diameter of 160 mm. A pressing force of 100 kN was applied to the nip roll 28 using a hydraulic cylinder.

As a result of the continuous molding operation, the thermosetting material B (13 ') on the film 11 is bonded to the thermosetting material A (13) on the mold 12 and bonded to the thermosetting material A (13) 12 could be almost 100% transferred.

10: Production apparatus of surface structure film of the present invention
11: Film
12: Mold
13: Thermosetting material A
13 ': Thermosetting material B
13a: pattern layer
14:
15: Surface structure film
20: Mold conveying means
21: first heating roll
22: second heating roll
23: Film feeding means
23a: unwinding roll
23b: guide roll
24: Film peeling means
24a: peeling roll
25a: winding roll
25b: guide roll
27: Pressurizing device
27a:
28: Nip roll
29: Compression means
30: Application unit for mold
31: Slit die
32: Support roll
33: Film application unit
34: Slit die
35: Support roll
36: End detection sensor
37: Controller
40: Production apparatus of surface structure film of the present invention
41: Heating unit
45: Manufacturing apparatus of surface structure film of the present invention
46: Planarizing means
50: Production apparatus of surface structure film of the present invention
51:
52, 53: Roll
54: Endless belt
60: Production apparatus of surface structure film of the present invention
66a to 66d:
70: Production 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: Production apparatus for a mold applied to an apparatus for producing a surface structure film of the present invention
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 production apparatus for producing a surface structure film having a surface structure including a thermosetting material on a surface of a film,
(1) an endless belt-shaped mold having a surface structure formed thereon,
(2) a mold conveying means for conveying the mold surrounding two or more heating rolls by rotating the heating roll by a main conveyance;
(3) a nip roll which is disposed in parallel with the first heating roll in the mold conveying means and whose surface is covered with an elastic body, and a pressing mechanism including at least the pressing roll using the heating roll and the nip roll,
(4) a mold application unit for applying a material to the surface of the mold on which the surface structure is formed, the mold application unit being provided on the upstream side of the pressing mechanism in the conveying direction of the mold,
(5) film supply means for supplying a film to the surface of the mold,
(6) a film application unit arranged on the upstream side of the pressing mechanism in the film transport direction, for applying a material to a surface of the film in contact with the mold,
(7) An apparatus for producing a surface structure film, comprising at least a film peeling means for peeling a film on the surface of the mold. The method according to claim 1,
And heating means for heating the mold between the mold application unit and the first heating roll. 3. The method according to claim 1 or 2,
And planarizing means for flattening the material applied to the mold surface between the mold application unit and the pressing mechanism. 4. The method according to any one of claims 1 to 3,
And a pressing mechanism capable of being pressed against the first heating roll on the outer circumferential surface of the first heating roll. 5. The method according to any one of claims 1 to 4,
Wherein the endless belt-shaped mold is a resin. 6. The method according to any one of claims 1 to 5,
Further comprising a transfer unit for transferring the layer of the thermosetting material to a surface of the film opposite to the surface having the surface structure. A method of making a surface structure film comprising a thermosetting material,
(1) A thermosetting material A is coated on the surface of the mold in an endless belt-shaped mold having a surface structure formed by enclosing at least two heated rolls heated by the mold, fair,
(2) a step of applying a thermosetting material B to the surface of the film,
(3) joining the mold and the film so that the thermosetting material A and the thermosetting material B are in contact with each other,
(4) a step of pressing the film, the thermosetting material A, the thermosetting material B, and the mold in a laminated state by a nip roll,
(5) a step of transporting the film after the press, the thermosetting material A, the thermosetting material B, and the mold in a laminated state while heating,
(6) A process for producing a surface structure film, comprising at least a step of peeling the film and a surface structure film composed of the thermosetting material A and the thermosetting material B from the mold. 8. The method of claim 7,
Wherein the mold is heated before the step of bonding the film on the side of the thermosetting material A after the step of applying the thermosetting material A to the surface of the mold. 9. The method according to claim 7 or 8,
Wherein the coating surface of the thermosetting material (A) is planarized before the step of bonding the film on the side of the thermosetting material (A) after the step of coating the surface of the mold with the thermosetting material (A). 10. The method according to any one of claims 7 to 9,
After the step of pressing the film, the thermosetting material A, the thermosetting material B, and the mold in a laminated state by a nip roll, To the surface of the film. 11. The method according to any one of claims 7 to 10,
Wherein the endless belt-shaped mold is a resin. 12. The method of claim 11,
Wherein the endless belt-shaped mold is a thermoplastic resin film produced by a method of pressing a mold against the surface of a thermoplastic resin film to form a shape. 13. The method according to claim 11 or 12,
Wherein the surface temperature of the heating roll during heating is 20 占 폚 or more lower than the glass transition temperature of the resin constituting the mold. 14. The method according to any one of claims 7 to 13,
Wherein a layer of a thermosetting material is transferred onto the surface of the surface structure film on the opposite side where the surface structure is formed.

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