201144047 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種於製造樹脂片材時可 繞於輥之捲繞現象，並且以高轉印 .脂片材捲 抒1手將凹凸形狀轅e 脂片材表面之表面形狀轉印樹脂片材之製&树 【先前技術】 &… 作為表面具有凹凸形狀之樹脂片材之 將擠a輥表面之轉印模之形狀轉印至將樹：自擠出 頭中擠出而得到之連續樹脂片材之方法(參 = 開平9.號公報)。該方法為如下方法:將自模= :擠出之連續樹脂片材灸入第-擠壓觀與第二擠壓輕之間 後，以密接於第二擠廢輥之狀態進行搬送，繼而 二 擠壓輥與第三擠壓輥之間。此時，於上述第二擠壓輕之: 面設有轉印模，在將連續樹脂片材失人第―擠 Γ堅親之間時轉印模之凹凸形狀被轉印至連續樹脂片、^ 表面，製造出表面形狀轉印樹脂片材。 【發明内容】 [發明所欲解決之問題] 然而’上述日本專利特開平9_11328號公報記載之技術 中，相對於形成在第二擠遂親之轉印模之v字槽之深度為 40 _，藉由轉印而形成於樹脂片材之棱紋狀花紋之高度 為2 15 pm(參照曰本專利特開平9_丨1328號公報之⑻κ段 之表1之實施例卜句，因而轉印率為5〜37 5%左右，轉印率 低。即，存在無法將轉印親（第二擠壓親）之凹凸形狀以高 154784.doc 201144047 轉印率轉印至樹脂片材之問題。 本發明人發現：藉由將轉印輥溫度設定為相當高，可將 凹凸形狀以高轉印率轉印至樹脂片#之表面。，然而於此 情形時，判；t存在如下問題：如圖13所示，發生樹脂片材 附著捲繞於轉印㈣之捲繞現象。尤其於使用聚碳酸@旨樹 脂作為樹脂片材之構成樹脂時，捲繞現象之發生顯著。 本發明係ϋ於該技術背景而完成，其目的在於提供—種 可抑制樹脂片材對轉印輥之捲繞現象，並且可將凹凸形狀 以高轉印率轉印至樹脂片材表面之表面形狀轉印樹 之製造方法。 [解決問題之手段] 為達成上述目的，本發明提供以下手段。 Π]—種表面形狀轉印樹脂片材之製造方法，其特 於包括： ' 士將樹脂於加熱炫融狀態下自模頭連續地擠出而得到連續 樹脂片材之擠出步驟； 由第-擠壓輥與第二擠壓減人上述連續樹脂片材 一擠壓步驟；及 於上述第一擠壓步驟後，將上述連續樹脂片材以密接於 上述第二擠壓輥之狀態進行搬送之第一搬送步驟； 上述第一擠壓報於表面包含具有複數個凹槽之轉印模， 於上述第-搬送步射，對搬送中之上述連續樹脂片材 之至少一部分進行冷卻。 [2]如前項1之表面形狀轉印樹脂片材之製造方法，其更 包括第二搬送步驟’該第二搬送步驟係於上述第—搬送步 154784.doc 201144047 驟後’將上述連續樹脂片材以使該連續樹脂片材之與上述 第一擠壓輥接觸側之面密接於第三輥之狀態進行搬送。 [3]如前項2之表面形狀轉印樹脂片材之製造方法，其中 於上述第二搬送步驟中，對搬送中之上述連續樹脂片材之 至少一部分進行冷卻。 ' [4]如前項2之表面形狀轉印樹脂片材之製造方法，其中 於上述第二搬送步驟中，對搬送中之上述連續樹 之、自與上述第三親之接觸開始位置與從上述第三輥剝離 之位置之二等分中間位置起直至與上述第三親之接觸開始 位置為止之區域的至少一部分進行冷卻。 、[5]如前項丨至4中任一項之表面形狀轉印樹脂片材之製 造方法，其中於上述第-搬送步驟中，對搬送中之上述連 續樹脂片材之、自與上述第二擠壓輥之接觸開始位置與從 上述第二擠壓輥剝離之位置之二等分中間位置起直至從上 述第二擠壓輥剝離之位置為止之區域的至少一部分進行冷 卻。 7 [6] 如月J頁1至5中{壬一項之表面形狀轉印樹脂片材之製 造方法，其中上述樹脂為聚碳酸酯樹脂。 [7] 如刖項1至6中任一項上述之表面形狀轉印樹脂片材 之製k方法’其中將上述第二擠壓輥之設定溫度設定為相 對於上述樹脂之玻璃轉移溫度Tgfc )高i〇t〜赃之溫 度。 [8] 如別項1至7中任一項之表面形狀轉印樹脂片材之製 k方法其中於將上述轉印模之上述凹槽之剖面形狀中之 154784.doc 201144047 形成1個槽之形成線之長度設為「L」、將上述凹槽之間距 間隔設為「P」時，L/Ρ為1.5〜5。 [9]如則項1至8中任一項之表面形狀轉印樹脂片材之製 k方法，其中上述轉印模之上述凹槽之剖面形狀為大致v 字狀，該大致V字狀凹槽之底部之開度角為1〇。〜8〇〇。 [發明之效果] [1] 之發明中，因由第一擠壓輥與表面包含轉印模之第 -擠壓報炎人連續樹脂片材，於將連續樹脂片材以密接於 第一擠壓親之狀態進行搬送之第一搬送步驟中對搬送中之 連續樹月曰片材之至少一部分進行冷卻，故可將轉印模之凹 凸形狀以高轉印率轉印至樹脂片材，並且可抑制樹脂片材 =繞於第二擠壓輥（轉印輥）之捲繞現象（捲繞問題）之發 [2] 之發明中’因包含於第一搬送步驟後，將連續樹脂 片材以使連續樹脂片材之與第一擠㈣接觸側之面密接於 第三輥之狀態進行搬送之第二搬送步驟，故可製造趣曲小 之表面形狀轉印樹脂片材。 [3] 之發明中’因於第二搬送步驟中，對搬送+之連續 树月曰片材之至7 分進行冷卻，故可製造翹曲更小之表 面形狀轉印樹脂片材。 [4] 之發明中’因於第二搬送步驟中對搬送中之連續 樹月曰片材t自與第二輥之接觸開始位置與從第三輥剝離 之位置之二等分中間位置起直至與第三棍之接觸開始位置 為止之區域之至少-部分進行冷卻，故可製造龜曲得到更 I54784.doc 201144047 進一步抑制之表面形狀轉印樹脂片材。 [5] 之發明中，因於第一搬送步驟中，對搬送中之連續 樹脂片材之、自與上述第二擠壓輥之接觸開始位置與從第 二擠壓輥剝離之位置之二等分中間位置起直至從第二擠壓 輥剝離之位置為止之區域之至少一部分進行冷卻，故可更 加抑制捲繞現象（捲繞問題）之發生。 [6] 之發明中，使用聚碳酸酯樹脂作為樹脂，雖然先前 ^容易發生捲繞現象之構成，但對本發明之製造方法而 舌，即便為此種構成，亦可抑制捲繞現象之發生。 [7] 之發明中’因將第二擠壓輥之設定溫度設定為相對 於上述樹脂之玻璃轉移溫度Tga)高1〇<t〜5〇ec之溫度， 故可將轉印模之凹凸形狀以高轉印率轉印至連續樹脂片 材，並且可更進—步抑制捲繞現象之發生。 [8] 之發明中’轉印模具有L/p之值為} 5〜5之尖銳且深之 槽形狀’雖然先前為容易發生捲繞現象之構成，但對於本 發明之製造方法而言，即使為此種構成，亦可抑制捲繞現 象之發生。 [9] 之發明中，轉印模之凹槽之剖面形狀為大致v字狀， 該大致V字狀凹槽之底部之開度角為10。〜80。，雖然先前為 ^易發生捲繞現象之構成，但對於本發明之製造方法而 。，即便為此種構成，亦可抑制捲繞現象之發生。 【實施方式】 面參照附圖-面說明本發明之表面形狀轉印樹脂片材 1之製造方法。圖1表示本製造方法所使用之製造裝置之— I54784.doc 201144047 例。該製造裝置包含：具有模頭8之擠出機7，於該擠出機 7擠出方向之前方位置上下並列配置之第—擠壓輥u、第 二擠壓輥（轉印輥）12、第三輥13，第一送風裝置7ι，及第 二送風裝置72。於上述第一擠壓輥u之正下方位置配置上 述第二擠壓輥12，於該第二擠壓輥12之正下方位置配置上 述第三輥13。上述第一擠壓輥丨丨之外周面形成為鏡面，上 述第三輥13之外周面形成為鏡面。上述第二擠壓輥12之外 周面形成有複數個凹槽22a(參照圖1〇)。即，上述第二擠壓 輥12於其表面包含轉印模22。本實施形態中，作為上述第 三輥13，採用擠壓輥。 將設置於上述第二擠壓輥12表面之轉印模22之放大剖面 圖（以包含第二擠壓輥之旋轉中心軸之平面切斷而得之放 大剖面圖）示於圖1〇。如此，於上述第二擠壓輥12之表 面，沿輥12之旋轉方向形成複數條剖面形狀為大致v字狀 之凹槽（槽之傾斜面為向外凸起之曲面狀）22a。上述轉印模 22之凹槽22a與自上述擠出機7之模頭8連續地擠出來之連 續樹脂片材2之表面（圖丨中下表面）接觸，於該接觸後之表 面形成剖面形狀為大致V字狀（傾斜面為向外凸起之曲面 狀）之突條部32。 上述第一送風裝置71為向與上述第二擠壓輥12密接地搬 送之狀態之連續樹脂片材之至少一部分（連續樹脂片材之 密接於第二擠壓輥12之區域之至少一部分）吹送空氣之裝 置。 ’ 上述第二送風裝置72為向與上述第三輥13密接地搬送之 154784.doc 201144047 狀態之連續樹脂片材之至少一部分（連續樹脂片材之與第 二輥13密接之區域之至少一部分）吹送空氣之裝置。 使用上述製造裝置以如下方式製造表面形狀轉印樹脂片 L滑id步驟] 將樹脂以加熱熔融狀態自模頭8連續地擠出從而得 續樹脂片材2(參照圖1)。 作為用於將上述樹脂以加熱炼融狀態連續地擠出之模 :::等與通:之擠出成型法所使用之模頭同樣之金屬製τ 單轴擠出機，亦可二：出:用擠出機7。擠出機7可為 熱，融之狀態被送至模頭"後被擠出二：破加 出之樹脂係連續地以片材狀二，、後被擠出。自_8擠 2。 材狀擠出’從而成為連續樹脂片材 連續樹脂片材2為單層 上之夕層。於 熔融狀態擠出時A ’在自模頭8將樹脂以加熱 層以上之多層W 頭8供給1種樹脂並擠出即可，於2 以最& 凊形時，向模頭供給2種以上之榭. 以疊層之狀態共擠出即可 训曰，並 以疊層狀態共擠出之 士於將2種以上之樹脂 公知之2種3層分 塊:如可採用如下方法：使用 二=:歧管模頭來進行_之方法等 續樹月=片材2之厚度F(參照圉9)根據得到之表面 154784.doc 201144047 形狀轉印樹脂片材丨之用途作適當調整即可，例如作為光 擴散板使用時，較佳為將連續樹脂片材2之厚度F設定為 〇. 1〜3.0 mm之範圍，苴中争祛*执中 以Τ更佳為a又疋為0.2〜2.0 mm之範 圍。 作為上述樹脂，雖未作特別限定’但通常可使用藉由加 熱而成為熔融狀態之熱塑性樹脂。作為上述熱塑性樹脂， :作特別限定，例如可舉出苯乙稀系樹脂、丙稀酸系:樹 脂、聚乙烯、聚丙稀、環狀烯烴聚合物樹脂、丙稀猜-丁 二烯-苯乙烯共聚物樹脂（ABS樹脂）' 聚對苯二甲酸乙^酯 (:ET)、聚碳酸酿(PC)等。再者，於可應用於本發明：； 造方法之範圍β ’亦可使用藉由加熱而硬化之熱硬化性樹 脂。 +亦可於上述樹脂中添加光擴散劑、紫外線吸收劑、熱穩 定劑、抗靜電劑等添加劑等。 " 上述光擴散劑可為無機系光擴散劑，亦可為有機系光擴 散劑。作為上述無機系光擴散劑，未作特別限定，例如可 舉出碳酸妈、硫酸鋇、氧化鈦、氫氧化銘、二乳化石夕、無 機玻璃、滑石、雲母、白碳、氧化鎮、氧化辞等無機化合 物之粒子。上述無機系光擴散劑可藉由脂肪酸等表面處理 劑進行表面處理。 又，作為上述有機系光擴散劑，未作特別限定，例如可 舉出笨乙烯系聚合物粒子、丙烯酸系聚合物粒子、矽氧烷 系聚合物粒子等有機化合物粒子。 凡 添加上述光擴散劑時，所添加之光擴散劑之折射率與樹 154784.doc 201144047 脂之折射率之差之絕對值，出 赴^ % ㈣充分確保光擴散效果之觀 ::慮，4常為0.02以上，出於充分確保所得表面形狀轉 P樹脂片材之光透射性之觀點考慮，通常為〇13以下。如 此向樹脂添加光擴散劑時’得到之表面形狀轉印樹脂片材 1例如可作為光擴散板使用。 [第一擠壓步驟] 其次，如圖i所示，於配置在上述擠出機7之擠出方向之 前方位置之第-擠難u與第二擠壓輕12之間使上述連續 樹脂片材2通過，從而以兩擠壓輥u、12夾持連續樹脂片 材2而進行擠壓。此時，因於上述第二擠壓輥^之表面設 有轉印模22，故於上述連續樹脂片材2之一表面轉印有 剖面形狀為大致V字狀（傾斜面為向外凸起之曲面狀）之突 條部32(參照圖11)。上述突條部32以沿上述連續樹脂片材二 之搬送方向（擠出方向）延伸而形成。 上述第一擠壓步驟中，較佳為於第一擠壓輥丨丨與第二擠 壓輥12之間形成樹脂之熔體流（樹脂積存）3，並且將上述熔 體流3之高度E設定為自模頭8擠出之連續樹脂片材2之厚度 F之3倍以上（參照圖9)。如此’藉由將溶體流3之高度e設 定為連續樹脂片材2之厚度F之3倍以上，從而能以更高轉 印率將轉印模22之凹凸形狀轉印至連續樹脂片材2。再 者’上述'熔體流3之高度E較佳為未達15 mm。於高度E為 15 mm以上時，在樹脂片材之與轉印面（形成有突條部32之 面）相反之面出現如圖14所示之滯料紋（木紋狀之樹脂流動 花紋）91，因此欠佳。 154784.doc 11 201144047 上述熔體流3之高度E係指，於連結熔體流]之最高位置 (離第二擠壓親12之旋轉中心最遠之位置）與第：擠壓㈣ 之旋轉中心之假想線κ(第二擠壓輥12之徑方向之線）上的 自上述連續樹脂片材2之上表面位置（相當於連續樹脂片材 2之厚度F部分之上表面位置）至熔體流3之最高之上表面位 置為止的距離（參照圖9)。 再者，上述熔體流3之高度E例如可藉由調節樹脂之擠出 量、擠出線速度、第一擠壓輥U與第二擠壓輥12之間隔等 來進行調整。例如，可藉由增大樹脂之擠出量、減小擠出 線速度、縮小第一擠壓輥n與第二擠壓輥12之間隔等方法 來增大熔體流3之高度E。另外，例如，可藉由減少樹脂之 擠出量、增大擠出線速度、增大第一擠壓報丨丨與第二擠壓 親12之間隔等方法來減小熔體流3之高度e。 上述第一擠壓步驟中’較佳為將上述第二擠壓親12之設 定溫度設定為相對於構成上述連續樹脂片材2之樹脂之玻 璃轉移溫度Tg(°C)高10°C〜5(TC之溫度。藉由將第二擠壓 輥12之設定溫度設定為（Tg+10)eC以上之溫度，從而能以 更高之轉印率將轉印模22之凹凸形狀轉印至連續樹脂片材 2’並且藉由設定為（Tg+50)°C以下之溫度，而可進一步防 止連續樹脂片材2對第二擠壓輥12之捲繞現象（捲繞問題）之 發生。特別地，更佳為將上述第二擠壓輥12之設定溫度設 定為相對於上述樹脂之玻璃轉移溫度TgfC )高15°C〜35°C 之溫度。再者，本說明書中樹脂之玻璃轉移溫度Tg係指添 加上述添加劑前之樹脂之玻璃轉移溫度T g。 154784.doc 201144047 上述第一擠壓輥11之設定溫度未作特別限定，但較佳為 設定為 80°C ~150°C。 作為上述第一擠壓輥11與上述第二擠壓輥12，通常使用 以不鏽鋼、鋼鐵等金屬材料構成之金屬製輥，其直徑通常 為100〜500 mm。使用金屬製輥作為上述第一擠壓輥丨1及〆 或上述第二擠壓輥12時，其表面可被施以例如鍍鉻 '鍍 銅、鍍鎳、鍍鎳-磷等鍍敷處理。 [第一搬送步驟] 其次，將經過上述第一擠壓步驟之連續樹脂片材2以密 接於上述第二擠壓輥12之表面之狀態進行搬送（參照圖1)。 於該第一搬送步驟中，上述連續樹脂片材2從動於第二擠 壓輥12之旋轉而被搬送。 該第一搬送步驟中，藉由自上述第一送風裝置71向第二 擠壓輥12吹送空氣，而強制地冷卻搬送中之連續樹脂片材 2之密接於第二擠壓輥12之區域之至少一部分（參照圖1)。 此時，如圖1所示，較佳為強制地冷卻搬送中之連續樹 脂片材2之、自與第二擠壓輥12之接觸開始位置5丨與從第 二擠壓輥12剝離之位置52之二等分中間位置53起直至從第 二擠壓輥12剝離之位置52為止之區域的至少—部分。於此 情形時，可確保高轉印率，並且可進一步抑制捲繞現象 (捲繞問題）之發生。 圖1所示之實施形態中，作為第一搬送步驟中之強制冷 卻方法，採用自第一送風裝置71向搬送中之連續樹脂片材 2之密接於第二擠壓輥12之區域之至少一部分吹送空氣之 154784.doc -13· 201144047 方法’但未特別限定於這種方法，可代替「吹送空氣」而 採用例如下述丨）、2)等方法。再者，吹送空氣時，該空氣 之溫度較佳為〇°C〜50°C，更佳為l〇°C〜30°C。又，空氣之 吹送壓力較佳為〇.1〜1〇 MPa之範圍。藉由吹送壓力為〇」 MPa以上可提高因冷卻而引起之捲繞現象防止效果，藉由 為10 MPa以下可防止因吹送空氣而引起之樹脂片材變形。 特別地’更佳為空氣之吹送壓力在0.2〜8 MPa之範圍。 1) 吹送霧狀水 霧狀水之溫度較佳為0°c〜5〇0C，更佳為丨〇°c〜3〇t。另 外’霧狀水之吹送壓力較佳為〇1〜1〇 MPa之範圍。藉由吹 送壓力為0.1 MPa以上而可提高冷卻效果，藉由為1〇 Μρ& 以下而可防止因吹送霧狀水而導致之樹脂片材變形。特別 地’霧狀水之吹送壓力更佳為〇 2〜8 MPa之範圍。 2) 與冷卻輥73接觸（參照圖7) 冷卻輥73之設定溫度較佳為3〇〇c 〜15〇〇c ，更佳為 50°C〜130°C。至於冷卻輥73並未特別限定，可與第一擠壓 輥11或第二擠壓輥12同樣，使用例如金屬製輥。 再者，較理想的是上述第一擠壓輥丨丨、第二擠壓輥12具 有溫度調節功能，可調節為期望之溫度。 [第二擠壓步驟] 其次，使經過上述第一搬送步驟之連續樹脂片材2通過 第二擠壓輥12與第三輥13之間，且由兩擠壓輥12、13夾持 連續樹脂片材2來進行擠壓。 作為上述第三輥13，通常使用由不鏽鋼、鋼鐵等金屬材201144047 VI. Description of the Invention: [Technical Field] The present invention relates to a winding phenomenon that can be wound around a roll when manufacturing a resin sheet, and a high-transfer. e The surface shape of the surface of the fat sheet is transferred to a resin sheet. [Previous technique] & As a resin sheet having a concave-convex shape on the surface, the shape of the transfer mold which is pressed onto the surface of the roller is transferred to Tree: A method of extruding a continuous resin sheet from an extrusion head (see = Kaiping No. 9.). The method is as follows: the self-molding =: extruded continuous resin sheet is moxibusted between the first-squeeze view and the second squeezed light, and then conveyed in a state of being in close contact with the second squeezing roller, and then Between the squeeze roller and the third squeeze roller. At this time, in the second extrusion light, the surface is provided with a transfer mold, and when the continuous resin sheet is lost between the first and the crucible, the uneven shape of the transfer mold is transferred to the continuous resin sheet, ^ Surface, manufactured with a surface shape transfer resin sheet. [Problems to be Solved by the Invention] However, in the technique described in Japanese Laid-Open Patent Publication No. Hei 9-11328, the depth of the v-shaped groove formed in the transfer die of the second extrusion is 40 _, The height of the ribbed pattern formed on the resin sheet by transfer is 2 15 pm (refer to the embodiment of Table 1 of the (8) κ section of the Japanese Patent Laid-Open Publication No. Hei 9-丨1328, and thus the transfer rate It is about 5 to 37 5%, and the transfer rate is low. That is, there is a problem that the uneven shape of the transfer parent (second extrusion bond) cannot be transferred to the resin sheet at a transfer rate of 154784.doc 201144047. The inventors have found that by setting the temperature of the transfer roller to be relatively high, the uneven shape can be transferred to the surface of the resin sheet # at a high transfer rate. However, in this case, the following problems occur: As shown in Fig. 13, the winding phenomenon in which the resin sheet adheres to the transfer (four) occurs. Especially when the polycarbonate resin is used as the constituent resin of the resin sheet, the occurrence of the winding phenomenon is remarkable. Completed with technical background, the purpose of which is to provide A method of manufacturing a transfer sheet of a surface sheet to a surface of a resin sheet by transferring a concave-convex shape to a surface of a resin sheet at a high transfer rate. [Means for Solving the Problem] To achieve the above object, The present invention provides the following means: A method for producing a surface shape transfer resin sheet, which comprises: "Sintering the resin continuously from the die in a heated state to obtain a continuous resin sheet. An extrusion step; a pressing step of reducing the continuous resin sheet by the first pressing roller and the second pressing; and after the first pressing step, bonding the continuous resin sheet to the second extrusion a first transporting step of transporting the state of the pressure roller; the first extrusion report comprising a transfer mold having a plurality of grooves on the surface, and at least the step of transporting the continuous resin sheet in the transporting [2] The method for producing a surface shape transfer resin sheet according to the above item 1, further comprising a second transfer step of the second transfer step after the first transfer step 154784.doc 201144047 on The continuous resin sheet is conveyed in a state in which the surface of the continuous resin sheet on the side in contact with the first pressing roll is in close contact with the third roller. [3] The method for producing a surface shape transfer resin sheet according to the above item 2 In the second transfer step, at least a part of the continuous resin sheet in the transfer is cooled. [4] The method for producing a surface shape transfer resin sheet according to the above item 2, wherein the second transfer is performed In the step, the continuous tree in the transfer is from the intermediate position between the contact start position with the third parent and the position separated from the third roller to the contact start position with the third parent. The method for producing a surface shape transfer resin sheet according to any one of the preceding claims, wherein the continuous resin sheet in the transporting step is carried out in the first transport step a region from a position where the contact start position of the second pressing roller and the position where the second pressing roller is peeled off from the intermediate position to the position where the second pressing roller is peeled off At least a part of cooling. [6] The method for producing a surface shape transfer resin sheet according to the first aspect of the present invention, wherein the resin is a polycarbonate resin. [7] The method for producing a surface shape transfer resin sheet according to any one of Items 1 to 6, wherein the setting temperature of the second pressing roller is set to a glass transition temperature Tgfc with respect to the resin; High i〇t ~ 赃 temperature. [8] The method for producing a surface shape transfer resin sheet according to any one of items 1 to 7, wherein the 154784.doc 201144047 of the cross-sectional shape of the groove of the transfer mold is formed into one groove. When the length of the line is "L" and the interval between the grooves is "P", L/Ρ is 1.5 to 5. [9] The method for producing a surface shape transfer resin sheet according to any one of items 1 to 8, wherein a cross-sectional shape of the groove of the transfer mold is substantially v-shaped, the substantially V-shaped concave The opening angle of the bottom of the groove is 1 〇. ~8〇〇. [Effects of the Invention] In the invention of [1], the first squeezing roller and the surface include a first-squeezing squeezing continuous resin sheet of the transfer mold, and the continuous resin sheet is adhered to the first squeezing In the first transport step of transporting in the parent state, at least a part of the continuous tree matte sheet during transport is cooled, so that the uneven shape of the transfer mold can be transferred to the resin sheet at a high transfer rate, and Inhibition of the resin sheet = the winding phenomenon (winding problem) around the second squeezing roller (transfer roller) [2] In the invention, "because it is included in the first transfer step, the continuous resin sheet is The second transfer step of transporting the surface of the continuous resin sheet in contact with the surface on the side of the first extrusion (four) in the third roll is carried out, so that a surface-shaped transfer resin sheet having a small interest can be produced. [3] In the invention, in the second transfer step, the continuous transfer of the continuous ruthenium sheet of the transfer + is cooled to 7 minutes, so that the surface shape transfer resin sheet having a smaller warpage can be produced. [4] In the invention of the fourth embodiment, the continuous transfer of the continuous slab t in the second transfer step from the position where the contact start position with the second roll is separated from the position where the second roll is peeled off is continued until At least part of the area from the contact start position of the third stick is cooled, so that the surface shape transfer resin sheet further suppressed by I54784.doc 201144047 can be produced. [5] In the invention, in the first conveying step, the contact starting position of the continuous resin sheet during the transfer from the second pressing roll and the position separated from the second pressing roll are the second At least a part of the region from the intermediate position to the position where the second squeeze roller is peeled off is cooled, so that the occurrence of the winding phenomenon (winding problem) can be further suppressed. In the invention of the invention, the polycarbonate resin is used as the resin, and the winding phenomenon is likely to occur in the prior art. However, even in the configuration of the tongue of the present invention, the occurrence of the winding phenomenon can be suppressed. In the invention of the seventh aspect, the temperature of the second squeezing roller is set to be higher than the glass transition temperature Tga of the resin by 1 〇 < t 〜 5 〇 ec, so that the unevenness of the transfer mold can be obtained. The shape is transferred to the continuous resin sheet at a high transfer rate, and the occurrence of the winding phenomenon can be further suppressed. In the invention of [8], the "transfer mold has a value of L/p}, and the sharp and deep groove shape of 5 to 5 is a configuration in which the winding phenomenon is likely to occur, but for the manufacturing method of the present invention, Even in such a configuration, the occurrence of the winding phenomenon can be suppressed. In the invention of [9], the cross-sectional shape of the groove of the transfer mold is substantially v-shaped, and the opening angle of the bottom of the substantially V-shaped groove is 10. ~80. Although the structure of the winding phenomenon is easy to occur, it is the manufacturing method of the present invention. Even in such a configuration, the occurrence of the winding phenomenon can be suppressed. [Embodiment] A method of manufacturing the surface shape transfer resin sheet 1 of the present invention will be described with reference to the drawings. Fig. 1 shows an example of a manufacturing apparatus used in the present production method - I54784.doc 201144047. The manufacturing apparatus includes: an extruder 7 having a die 8, and a first pressing roller u and a second pressing roller (transfer roller) 12 arranged side by side in a position before the extrusion direction of the extruder 7 The third roller 13, the first air blowing device 71, and the second air blowing device 72. The second pressing roller 12 is disposed at a position directly below the first pressing roller u, and the third roller 13 is disposed at a position directly below the second pressing roller 12. The outer peripheral surface of the first pressing roll 形成 is formed as a mirror surface, and the outer peripheral surface of the third roll 13 is formed as a mirror surface. The outer peripheral surface of the second pressing roll 12 is formed with a plurality of grooves 22a (see Fig. 1A). That is, the second squeezing roller 12 includes the transfer mold 22 on its surface. In the present embodiment, as the third roller 13, a pressing roller is used. An enlarged cross-sectional view of the transfer mold 22 provided on the surface of the second pressing roll 12 (an enlarged cross-sectional view taken along a plane including the central axis of rotation of the second pressing roll) is shown in Fig. 1A. Thus, on the surface of the second pressing roll 12, a plurality of grooves having a substantially V-shaped cross-sectional shape (the inclined surface of the groove is curved outwardly) is formed in the direction of rotation of the roller 12. The groove 22a of the transfer mold 22 is in contact with the surface (lower surface in the middle) of the continuous resin sheet 2 continuously extruded from the die 8 of the extruder 7, and a cross-sectional shape is formed on the surface after the contact. The ridge portion 32 is substantially V-shaped (the inclined surface is a curved surface that is convex outward). The first air blowing device 71 is configured to blow at least a part of the continuous resin sheet in a state of being closely transported to the second pressing roller 12 (at least a part of a region in which the continuous resin sheet is in close contact with the second pressing roller 12). Air device. The second air blowing device 72 is at least a part of a continuous resin sheet in a state of 154784.doc 201144047 which is conveyed in close contact with the third roller 13 (at least a part of a region of the continuous resin sheet which is in close contact with the second roller 13) A device that blows air. The surface shape transfer resin sheet L was produced by the above-described manufacturing apparatus in the following manner. The resin was continuously extruded from the die 8 in a heat-melted state to continue the resin sheet 2 (refer to Fig. 1). As a mold for continuously extruding the above-mentioned resin in a heated and smelted state::: a metal τ single-axis extruder similar to the one used in the extrusion molding method, or two: : Using extruder 7. The extruder 7 can be heated, and the molten state is sent to the die " after being extruded 2: the broken resin is continuously formed in the form of a sheet, and then extruded. Squeeze from _8. The material is extruded to become a continuous resin sheet. The continuous resin sheet 2 is a layer on a single layer. When extruding in a molten state, A' is supplied from a plurality of W heads 8 of a heating layer or more to the resin from the die 8 and extruded. When 2 is the most & 凊 shape, two types are supplied to the die. In the above, it can be instructed by co-extrusion in the state of lamination, and two types of three layers of two or more kinds of resins are known to be coextruded in a laminated state: if the following method can be used: Two =: the manifold die to carry out the method of continuation of the tree month = the thickness F of the sheet 2 (refer to 圉 9) according to the surface 154784.doc 201144047 obtained shape transfer resin sheet 作 for appropriate adjustment For example, when used as a light diffusing plate, it is preferable to set the thickness F of the continuous resin sheet 2 to a range of 〇. 1 to 3.0 mm, and the 祛 祛 祛 执 执 执 执 执 执 执 执 0.2 0.2 0.2 0.2 0.2 0.2 0.2 A range of 2.0 mm. The resin is not particularly limited, but a thermoplastic resin which is in a molten state by heating can be usually used. The thermoplastic resin is particularly limited, and examples thereof include a styrene-based resin, an acrylic acid-based resin, a polyethylene, a polypropylene, a cyclic olefin polymer resin, and a propylene-butadiene-styrene resin. Copolymer resin (ABS resin) 'polyethylene terephthalate (: ET), polycarbonate (PC), and the like. Further, it can be applied to the present invention: a range of the manufacturing method β ' can also use a thermosetting resin which is hardened by heating. + An additive such as a light diffusing agent, an ultraviolet absorber, a heat stabilizer, or an antistatic agent may be added to the above resin. " The above light diffusing agent may be an inorganic light diffusing agent or an organic light diffusing agent. The inorganic light diffusing agent is not particularly limited, and examples thereof include carbonic acid mother, barium sulfate, titanium oxide, hydrogen hydroxide, emulsified stone, inorganic glass, talc, mica, white carbon, oxidized town, and oxidized word. Particles of inorganic compounds. The above inorganic light diffusing agent can be surface-treated by a surface treating agent such as a fatty acid. In addition, the organic light-diffusing agent is not particularly limited, and examples thereof include organic compound particles such as stupid vinyl polymer particles, acrylic polymer particles, and siloxane polymer particles. When adding the above light diffusing agent, the absolute value of the difference between the refractive index of the added light diffusing agent and the refractive index of the tree 154784.doc 201144047 fat, go to ^% (4) to fully ensure the effect of light diffusion::, 4 It is usually 0.02 or more, and is usually 〇13 or less from the viewpoint of sufficiently ensuring the light transmittance of the obtained surface shape to the P resin sheet. When the light diffusing agent is added to the resin, the obtained surface shape transfer resin sheet 1 can be used, for example, as a light diffusing plate. [First Extrusion Step] Next, as shown in Fig. i, the continuous resin sheet is placed between the first extrusion pressure u and the second extrusion light 12 disposed at the position in the extrusion direction of the extruder 7 described above. The material 2 passes, and the continuous resin sheet 2 is sandwiched by the two pressing rolls u, 12 to be pressed. At this time, since the transfer mold 22 is provided on the surface of the second pressing roll, a cross-sectional shape is substantially V-shaped on one surface of the continuous resin sheet 2 (the inclined surface is outwardly convex) The curved portion 32 of the curved surface (see Fig. 11). The ridge portion 32 is formed to extend in the conveying direction (extrusion direction) of the continuous resin sheet 2. In the above first pressing step, it is preferred to form a melt flow (resin accumulation) 3 of the resin between the first pressing roll 丨丨 and the second pressing roll 12, and to set the height E of the melt stream 3 described above. It is set to be three times or more the thickness F of the continuous resin sheet 2 extruded from the die 8 (refer to FIG. 9). Thus, by setting the height e of the solution stream 3 to be more than three times the thickness F of the continuous resin sheet 2, the uneven shape of the transfer mold 22 can be transferred to the continuous resin sheet at a higher transfer rate. 2. Further, the height E of the above melt stream 3 is preferably less than 15 mm. When the height E is 15 mm or more, a stagnation pattern (resin-like resin flow pattern) as shown in Fig. 14 appears on the opposite side of the resin sheet from the transfer surface (the surface on which the ridge portion 32 is formed). So it is not good. 154784.doc 11 201144047 The height E of the melt stream 3 above refers to the highest position of the joint melt stream (the position farthest from the center of rotation of the second extrusion pro 12) and the center of rotation of the extrusion: (four) The position of the upper surface of the above-mentioned continuous resin sheet 2 (corresponding to the position above the thickness F portion of the continuous resin sheet 2) on the imaginary line κ (the line of the radial direction of the second squeezing roller 12) to the melt The distance from the highest surface position of the stream 3 (see Fig. 9). Further, the height E of the melt stream 3 can be adjusted, for example, by adjusting the extrusion amount of the resin, the extrusion line speed, the interval between the first squeeze roll U and the second squeeze roll 12. For example, the height E of the melt stream 3 can be increased by increasing the amount of extrusion of the resin, reducing the extrusion line speed, and reducing the interval between the first squeeze roll n and the second squeeze roll 12. In addition, for example, the height of the melt stream 3 can be reduced by reducing the amount of extrusion of the resin, increasing the extrusion line speed, increasing the interval between the first extrusion and the second extrusion. e. Preferably, in the first pressing step, the setting temperature of the second pressing member 12 is set to be 10 ° C to 5 ° higher than the glass transition temperature Tg (° C.) of the resin constituting the continuous resin sheet 2 . (The temperature of TC. By setting the set temperature of the second squeeze roll 12 to a temperature of (Tg + 10) eC or more, the uneven shape of the transfer mold 22 can be transferred to the continuous at a higher transfer rate. The resin sheet 2' can be further prevented from occurring in the winding phenomenon (winding problem) of the second pressing roll 12 by the continuous resin sheet 2 by setting the temperature to be (Tg + 50) ° C or less. More preferably, the set temperature of the second pressing roll 12 is set to be 15 ° C to 35 ° C higher than the glass transition temperature TgfC of the resin. Further, the glass transition temperature Tg of the resin in the present specification means the glass transition temperature T g of the resin before the addition of the above additive. 154784.doc 201144047 The set temperature of the first pressing roll 11 is not particularly limited, but is preferably set to 80 ° C to 150 ° C. As the first pressing roll 11 and the second pressing roll 12, a metal roll made of a metal material such as stainless steel or steel is usually used, and its diameter is usually 100 to 500 mm. When a metal roll is used as the first press roll 丨1 and 〆 or the above second press roll 12, the surface thereof may be subjected to a plating treatment such as chrome plating, copper plating, nickel plating, nickel plating-phosphorus plating or the like. [First transporting step] Next, the continuous resin sheet 2 which has passed through the first pressing step is conveyed in a state of being in close contact with the surface of the second pressing roller 12 (see Fig. 1). In the first conveying step, the continuous resin sheet 2 is conveyed by the rotation of the second pressing roll 12. In the first conveying step, air is blown from the first air blowing device 71 to the second pressing roller 12, and the continuous resin sheet 2 in the conveying is forcibly cooled to the region of the second pressing roller 12. At least a part (refer to Figure 1). At this time, as shown in FIG. 1, it is preferable to forcibly cool the position of the continuous resin sheet 2 in the conveyance from the contact start position 5 与 with the second squeeze roll 12 and the position from the second squeeze roll 12 52 bis bisects at least a portion of the region from the intermediate position 53 up to the position 52 where the second squeeze roll 12 is peeled off. In this case, a high transfer rate can be ensured, and the occurrence of a winding phenomenon (winding problem) can be further suppressed. In the embodiment shown in FIG. 1, as the forced cooling method in the first transport step, at least a portion of the region of the continuous resin sheet 2 that is transported from the first air blower 71 in close contact with the second squeeze roller 12 is used. 154784.doc -13· 201144047 The method of blowing air is not particularly limited to such a method, and a method such as the following 丨), 2) may be employed instead of "blowing air". Further, when air is blown, the temperature of the air is preferably 〇 ° C to 50 ° C, more preferably 10 ° C to 30 ° C. Further, the air blowing pressure is preferably in the range of 〇1 to 1 MPa. When the blowing pressure is 〇 MPa or more, the effect of preventing the winding phenomenon due to cooling can be improved, and the resin sheet can be prevented from being deformed by blowing air by 10 MPa or less. In particular, it is more preferable that the air blowing pressure is in the range of 0.2 to 8 MPa. 1) The temperature of the misty water is preferably 0 ° c ~ 5 〇 0 C, more preferably 丨〇 ° c ~ 3 〇 t. Further, the blowing pressure of the misty water is preferably in the range of 〇1 to 1 MPa. The cooling effect can be improved by the blowing pressure of 0.1 MPa or more, and the resin sheet can be prevented from being deformed by blowing the misty water by 1 〇 & ρ & In particular, the blowing pressure of the misty water is more preferably in the range of 〜 2 to 8 MPa. 2) Contact with the cooling roll 73 (refer to Fig. 7) The set temperature of the cooling roll 73 is preferably 3 〇〇 c 〜 15 〇〇 c, more preferably 50 ° C to 130 ° C. The cooling roller 73 is not particularly limited, and a metal roller such as a metal roller can be used similarly to the first pressing roller 11 or the second pressing roller 12. Further, it is preferable that the first squeezing roller 丨丨 and the second squeezing roller 12 have a temperature adjustment function and can be adjusted to a desired temperature. [Second Extrusion Step] Next, the continuous resin sheet 2 that has passed through the first transfer step is passed between the second squeeze roll 12 and the third roll 13, and the continuous resin is sandwiched by the two press rolls 12, 13. Sheet 2 is used for extrusion. As the third roller 13, a metal material such as stainless steel or steel is usually used.
154784.doc iA 201144047 料構成之金屬製輥，其直徑通常為⑽〜_麵。使用金 屬製輥作為上述第三輥13時，其表面可實施例如鍍鉻、鍍 銅、鑛錄、鍍錄·碟等鐘敷處理。較佳為上述第三輥13具 有溫度調節功能’可調節到期望之溫度。 再者’在圖1所示之實施形態中’雖設有此種第二擠壓 步驟’但该第二擠壓步驟並非為必須步驟。例如，如圖 2 4所7F ’’亦可使用配置成第二擠壓輥12與第三輥13分離 狀.vl之構成之製造裝置來製造表面形狀轉印樹脂片材1。 即，於圖2、4所示之實施形態中，由於第二擠壓輥η與第 二輥13分離，故第三輥13並非為擠壓輥。 [第-搬送步驟] 其次，以使上述連續樹脂片材2之於第一擠壓步驟中與 第一擠壓輥11接觸之一側之面密接於第三輕13之表面之狀 態進行搬送。該第二搬送步驟中，上述連續樹脂片材2從 動於第三輥13之旋轉而被搬送。 該第二搬送步驟中，較佳為藉由自上述第二送風裝置72 向第三輥13吹送空氣’⑨而強制地冷卻搬送中之連續樹脂 片材2之密接於第三輥13之區域的至少一部分（參照圖”。 猎由進行該冷卻，可製造翹曲少之表面形狀轉印樹脂片材 又，如圖1所示，更佳為強制地冷卻搬送中之連續樹脂 片材2之、自與第三輥13之接觸開始位置“與從第三輥U 剝離之位置62之二等分中間位置63起直至與第三輥13之接 觸開始位置61為止之區域的至少一部分。於此情形時，可 154784.doc •15- 201144047 製造龜曲進一舟π f到抑制之表面形狀轉印樹脂片材1。 再者，於圖1如-lb 斤不之實施形態中，作為第二搬送步驟中 之強^之冷卻方法’採用自第二送風農置72向搬送中之連 :樹月曰片材2之密接於第三輥13之區域的至少一部分吹送 工氣之方法，但未特別限定於該方法，亦可代替「吹送空 氣」而採用例如下流4、楚；·*、土 S 4, 卜迷3)、4)等方法。再者，於吹送空氣 時’遠空氣之溫度較佳為〇°C~5G°C，更佳為lot〜3〇t。 另外，空氣之吹送壓力較佳為〇·1〜10 MPa之範圍《藉由吹 送壓力為0.1 MPa以上而可提高因冷卻所引起之翹曲防止 效果，藉由為1〇 MPa以下而可防止因吹送空氣所引起之樹 月曰片材變形。特別地’更佳為空氣之吹送壓力為〇 2〜8 MPa之範圍。 3) 吹送霧狀水 霧狀水之溫度較佳為〇〇c〜5(rc，更佳為1(rc〜3(rc。另 外’霧狀水之吹送壓力較佳為OH 〇 MPa之範圍。藉由吹 送壓力為0·1 MPa以上而可提高因冷卻所引起之翹曲防止 效果’藉由為10 MPa以下而可防止因吹送霧狀水所引起之 樹脂片材變形。特別地，更佳為霧狀水之吹送壓力為 0.2〜8 MPa之範圍。 4) 與冷卻輥74接觸（參照圖8) 冷卻輥74之設定溫度較佳為30^501 ，更佳為 50°C〜130°C。作為冷卻輥74未作特別限定，但與第一擠壓 輥11或第二擠壓輥12同樣，可使用例如金屬製輥》再者， 圖8中’冷卻親74按照如下方式進行配置，即，以與搬送 154784.doc •16. 201144047 中之連續樹脂片材2之、自與第三輥13之接觸開始位置“ 與從第三輥13剝離之位置62之二等分中間位置〇起直至從 第三輥13剝離之位置62為止之區域的至少一部分相接觸之 方式進行配置，但亦可按照與從上述二等分中間位置63起 直至與第二親13之接觸開始位置61為止之區域的至少一部 •分相接觸之方式進行配置。 亦可如圖3、5所示般省略上述第二搬送步驟中之強制冷 部（吹送空氣等）。另外，亦可如圖6所示般省略該第二搬送 步驟自身。 於上述第二搬送步驟後，藉由抽取樹脂片材，而得到於 一面以高轉印率轉印有轉印模22之凹凸形狀之表面形狀轉 印樹脂片材1(參照圖u)。 根據本製造方法，當將上述轉印模22之凹槽22a之剖面 形狀（以包含第二擠壓輥12之旋轉中心軸之平面切斷而得 之剖面形狀）中之形成1個槽22a之形成線之長度設為 「L」、將上述凹槽22a之間距間隔設為「p」時（參照圖 10) ’即使凹槽22a具有L/p為1 5〜5之尖銳且深之形狀，亦 可抑制捲繞現象之發生。 如此得到之表面形狀轉印樹脂片材1通常被切成單片 式’用作例如構成液晶顯示裝置之稜鏡片等。另外，作為 樹脂使用添加有光擴散劑之樹脂時，可適合用作光擴散 板。 本製造方法中，上述轉印模22之凹槽22a之間距間隔P未 作特別限定’通常設定為30 μιη〜500 μπι。另外，上述轉印 154784.doc •17- 201144047 模22之凹槽22a之槽深度D未作特別限定，通常設定為3 μΜΟΟ μιη之範圍。上述轉印模以中，相鄰凹槽通常係隔 著間隔d設置成平行狀（參照圖1〇)。該等凹槽m之間距間 隔P、槽深度DW個轉印模整體中不必為固定，於相鄰凹 溝間亦可為不同之構成。 上述間隔d根據得到之表面形狀轉印樹脂片材之用途進 行任意設定即可，間隔d通常設定為1〇 μπι以下。再者，亦 可為不設置上述間隔d(即d=〇)之構成。 作為上述轉印模22之剖面形狀，除圖1〇所示之大致V字 凹槽以外，例如，可例示部分包含大致乂字凹槽之剖面形 狀、大致半圓凹槽、部分包含大致半圓凹槽之剖面形狀 專’但未特別限定於此種剖面形狀。 上述大致V字凹槽22a之底部之開度_角0)通常為 160。以下，根據本製造方法，大致v字凹槽仏於其底部之 開度角Θ為1〇。〜80。之尖銳之槽形狀時，亦能以高轉印率轉 印轉印模22之凹凸形狀。 作為上述大致半圓凹槽，例如’可為將圓柱體於與其中 心拍線非平行之平面切斷時之剖面之任—弧狀之形狀，或 者可為剖面為半橢圓弧狀、或該半橢圓弧狀之一部分為扁 平彎曲狀等形狀。又，採用包含使上述大致半圓凹槽反轉 而成之大致半圓凸槽之形狀、由贿圓弧狀以外之曲線形成 之形狀之情形亦包含於本申請案之申請專利範圍内。又， 作為上述大致半圓凹槽，例如可為圖12⑷所示之具有剖面 形狀之凹槽22a，亦可為圖12〇))所示之具有曲線之剖面形 I54784.doc 201144047 狀之凹槽22a。上述「大致半圓凹槽」亦包含此種大致半 圓形狀之剖面之凹槽。 作為上述轉印模22之製作方法，可舉出在由不鏽鋼、鋼 鐵等製成之轉印輥表面實施例如鍍鉻、鍍銅、鍍鎳、鍍 鎳-磷等鍍敷處理後，使用金剛石車刀或金屬磨石等對該 鍍敷面進行除去加工、雷射加工、或化學蝕刻之方法等， 但不限定於該等方法。 又，上述第二擠壓輥（轉印輥）12之表面形成上述轉印模 22後，例如可於不破壞表面形狀精度之等級實施鍍鉻、鍍 銅、鍍鎳、鍍鎳-磷等鍍敷處理。 再者，只要於不顯著阻礙本發明之效果之範圍内，亦可 使用除上述第一擠壓輥11、第二擠壓輥12、第三輥13以外 還設有其他輥之構成之製造裝置來製造表面形狀轉印樹脂 片材1。作為上述其他輥，例如，可舉出用於將連續樹脂 片材2搬送至第一擠壓輥丨丨之引導輥（接觸輥）、用於預先使 連續樹脂片材2密接於第二擠壓輥12之接觸輥等。 又，上述實施形態中，轉印模22僅設於第二擠壓輥12， 但不特別限定於此種構成，例如亦可為於第二擠壓輥丨之與 第三輕13兩者設置轉印模22之構成。 再者本發明之表面形狀轉印樹脂片材之製造方法並不 特別限定於上述例示之實施形態，只要於請求範圍内、只 要不脫離其精神，則亦容許任何設計之改變。 [實施例] 其次，說明本發明之具體實施例，但本發明不特別限定 154784.doc •19· 201144047 於該等實施例。 (製造裝置A) 準備包含圖3所示構成之製造裝置A。該製造裝置a包 含：具有T型模頭8之擠出機7，第一擠壓輥11，第二擠壓 輥12，第三擠壓輥13，及第一送風裝置71。第一擠壓輥^ 與第三擠壓輥13之表面為鏡面。 第二擠壓輥12如圖1〇所示，於表面包含具有複數個凹槽 22a之轉印模22。該第二擠壓輥12之表面之轉印模22中， 凹槽22a之間距間隔ρ為1〇〇 ，凹槽22a之深度D為1 〇5 μηι ’剖面形狀之形成}個凹槽22&之形成線之長度[為232 μιη，L/P=2.32，間隔 d為 5 μιη ,角度 Θ為 51。（參照圖 1〇)。 〈實施例1> 藉由將聚碳酸酯樹脂（住友DOW公司製「CALIBRE PC 200-30」、根據JIS K 712 1-1987測定得到之玻璃轉移溫度 Tg: 147°C)供給至上述製造裝置Α之螺桿直徑4〇 mm之擠 出機7 ’並經由T型模頭8在模頭溫度260〇c下擠出成片材 狀，從而得到厚度F為〇.8 mm之連續樹脂片材2(擠出步 驟）。 其次’如圓3所示，使該連續樹脂片材2通過上述製造裝 置A之第一擠壓輥Η與第二擠壓輥12之間，藉由用兩擠壓 輥11、12夾持連續樹脂片材2進行擠壓（第一擠壓步驟）。接 著，一邊將連續樹脂片材2以密接於第二擠壓輥12之外周 面之狀態進行搬送，一邊向該搬送中之連續樹脂片材2之 密接於第二擠壓輥12之區域之一部分吹送來自第—送風裝 154784.doc •20· 201144047 置71之空氣（第—搬送步驟）。㈣，使連續樹脂片材2通過 第二擠壓輥12與第三輥13之間，藉由用兩擠壓輥a、U夾 持連續樹脂片材2進行擠壓（第二擠壓步驟）。其次，將連續 樹脂片材2以密接於第三擠壓輥13之外周面之狀態進行搬 送後(第二搬送步驟)’以抽取速度0.91 m/分鐘進行抽取， 由此，得到厚度S為〇.8 mm之表面形狀轉印樹脂片材i(參 照圖11)。 此時，分別設定第二擠壓輥12之設定溫度為180。匚、第 -擠壓輥11之設定溫度為130t、第三擠壓輥13之設定溫 度為150°c。另外，於第一擠壓輥11與第二擠壓親12之間 形成樹脂之熔體流3，調整該熔體流之高度£為6 〇 mm(參 照圖9)。另外，將第一搬送步驟中之自第一送風裝置對 連續樹脂片材2吹送空氣（20。〇之壓力設定為〇 6 Mpa。 再者，如圖3所示，於第一搬送步驟中，進行如下設 疋.自第一送風裝置71對搬送中之連續樹脂片材2之、自 與第二擠壓輥12之接觸開始位置51與從第二擠壓輥12剝離 之位置52之二等分中間位置53起直至從第二擠壓輥12剝離 之位置52為止之區域的一部分吹送空氣。 <比較例1> 於第一搬送步驟中，完全未進行來自第一送風裝置71之 空氣吹送（參照圖13 )’除此以外，與實施例i同樣地製造表 面形狀轉印樹脂材。 其次，基於下述評價法評價如上述般操作得到之表面形 狀轉印樹脂片材之轉印率、翹曲量、以及捲繞現象之發生 154784.doc - 2J - 201144047 程度。將該等評價結果示於表卜 <轉印率評價法> 度設為 「D」 「將得到之表面形狀轉印樹脂片材之突條部32之高 「H」（參照圓U)、將㈣模之凹槽22a之深度設為 時（參照圖10) ’轉印率由下述式⑴求丨。 轉印率（％)=(H/D)X 1 00…⑴ <捲繞現象之發生程度之評價法> 於製造上述表面形狀轉印樹脂片材時，於藉由由第二擠 壓輥(轉印輥)12與第三擠壓輥13夾持連續樹脂片材2進行擠 壓後，考察連續樹脂片材2捲繞於第二擠壓輥12之時間 (移）。表1中，以範圍表示於連續運行中觀察幾分鐘期間捲 繞之時間之最短時間與最長時^可判斷該捲繞時間越 長’則越顯著地發生如圖13所示之對第二擠壓輥12之捲繞 現象。又，可判斷捲繞時間越短，則捲繞現象之發生越得 到抑制。該捲繞時間為0秒時，為完全未發生捲繞之狀態 (參照圖3)。 [表1] 實施例1 比較例1 樹脂之Tg(t) 147 147 第二擠壓輥溫度(°c) 180 180 第一搬送步驟 吹送空氣之溫度(°c) 20 - 空氣之吹送壓力(MPa) 0.6 - 評價 轉印率(％) 93 92 捲繞於第二擠壓輥之時間(秒） 0〜5 6〜10 154784.doc • 22- 201144047 自表1可知，由本發明之製造方法製造之實施例1之表面 烙狀轉印樹脂片材，以高轉印率轉印有轉印模之凹凸形 狀。另外，實施例1中，第二擠壓輥包含L/ρ為2 32、具有 深且尖銳之凹凸形狀之轉印模，而樹脂片材捲繞於第二擠 壓親之捲繞現象之發生程度小。 與此相對’不進行第一搬送步驟中之強制冷卻之比較例 1中，樹脂片材捲繞於第二擠壓輥之捲繞現象之發生程度 大（顯著發生捲繞現象）。 由本發明之製造方法製造之表面形狀轉印樹脂片材，因 以两轉印率轉印有轉印模之凹凸形狀，故適合用作例如稜 鏡片、光擴散板、光偏向構造板、導光板等光學片材，但 未特別限疋於該等用途。其中，上述表面形狀轉印樹脂片 材特別適合於液晶顯示裝置等圖像顯示裝置用之光學片 材。 【圖式簡單說明】 圖1係表示本發明製造方法之一例之概略圖。 圖2係表示本發明製造方法之其他例之概略圖。 圖3係表示本發明製造方法之進而其他例之概略圖。 圖4係表示本發明製造方法之進而其他例之概略圖。 圖5係表示本發明製造方法之進而其他例之概略圖。 圖6係表示本發明製造方法之進而其他例之概略圖。 圖7係表示本發明製造方法之進而其他例之概略圖。 圖8係表示本發明製造方法之進而其他例之概略圖。 圖9係熔體流之高度之定義之說明圖。 I54784.doc -23· 201144047 圖1 〇係第二擠壓輥表面之轉印模之放大剖面圖（以包含 概之旋轉中心軸之平面切斷而得之刮面圖）。 圖11係表示用本發明之製造方法製造之表面形狀轉印樹 月曰片材之—實施形態之剖面圖（圖1〜8之V-V線之剖面圖）。 圖12(a)(b)均表示轉印模之變形例之放大剖面圖（以包含 報之旋轉中心軸之平面切斷而得之刳面圖）。 圖13係表示發生捲繞現象之狀態之概略圖。 圖14係滯料紋之說明圖。 【主要元件符號說明】 2 3 7 8 11 12 13 22 22a 32 51 52 53 表面形狀轉印樹脂片材 連續樹脂片材 熔體流 擠出機 模頭 第一擠壓輥 第二擠壓輥 第三輥 轉印模 凹槽 突條部 連續樹脂片材2之與第二擠壓輥12之接觸開 始位置 連續樹脂片材2從第二擠壓輥12剝離之彳立置 51與52之二等分中間位置 154784.doc • 24- 201144047 61 連續樹脂片材2之與第三 62 連續樹脂片材2之從第三 63 6 1與62之二等分中間位Ϊ 71 第一送風裝置 72 第二送風裝置 73 ' 74 冷卻輥 91 滯料紋 D 凹槽22a之深度 d 間隔 E 熔體流之高度 F 連續樹脂片材2之厚度 H 突條部32之高度 K 假想線 L 形成線之長度 P 凹槽22a之間距間隔 S 厚度 Θ 開度角（頂角） 154784.doc •25-154784.doc iA 201144047 Metal roll made of material, usually diameter (10) ~ _ surface. When a metal roll is used as the third roll 13, the surface thereof may be subjected to a bell coating treatment such as chrome plating, copper plating, mineral recording, plating, or the like. Preferably, the third roller 13 has a temperature adjustment function 'adjustable to a desired temperature. Further, in the embodiment shown in Fig. 1, the second pressing step is provided, but the second pressing step is not an essential step. For example, the surface shape transfer resin sheet 1 can be manufactured by using a manufacturing apparatus configured as a structure in which the second pressing roll 12 and the third roll 13 are separated by a v1. That is, in the embodiment shown in Figs. 2 and 4, since the second squeeze roll η is separated from the second roll 13, the third roll 13 is not a squeeze roll. [First-Transporting Step] Next, the continuous resin sheet 2 is conveyed in a state in which the surface on the side contacting the first pressing roll 11 in the first pressing step is in close contact with the surface of the third light 13. In the second transport step, the continuous resin sheet 2 is transported by the rotation of the third roller 13. In the second transport step, it is preferable that the air is blown from the second air blower 72 to the third roller 13 to forcibly cool the region of the continuous resin sheet 2 that is in the middle of the third roller 13 in the transport. At least a part (refer to the figure). By performing this cooling, a surface shape transfer resin sheet having less warpage can be produced, and as shown in Fig. 1, it is more preferable to forcibly cool the continuous resin sheet 2 in the conveyance. At least a portion of the area from the contact start position with the third roll 13 "two positions from the intermediate position 63 of the position 62 peeled off from the third roll U to the contact start position 61 with the third roll 13". 154784.doc •15- 201144047 Manufactured a tortoise into a boat π f to suppress the surface shape transfer resin sheet 1. Further, in the embodiment of Fig. 1 as a second transfer step, as a second transfer step In the method of cooling from the second air supply unit 72, the method of blowing the gas from at least a portion of the area of the third layer of the tree 2 is not limited. In this method, it is also possible to replace "blowing air". For example, downstream 4, Chu; * *, soil S 4, BU fans 3), 4) and other methods. Further, when the air is blown, the temperature of the far air is preferably 〇 ° C to 5 G ° C, more preferably in the range of 3 to 3 Torr. In addition, the air blowing pressure is preferably in the range of 〇·1 to 10 MPa. The blowing prevention pressure is 0.1 MPa or more, and the warpage preventing effect due to cooling can be improved, and the temperature can be prevented by 1 MPa or less. The sheet of the mooncake caused by blowing air is deformed. In particular, it is more preferable that the air blowing pressure is in the range of 〇 2 to 8 MPa. 3) The temperature of the mist-like water-like water is preferably 〇〇c 5 (rc, more preferably 1 (rc 〜 3 (rc. Further, the blowing pressure of the mist water is preferably in the range of OH 〇 MPa). When the blowing pressure is 0·1 MPa or more, the warpage preventing effect by cooling can be improved. The deformation of the resin sheet caused by the blowing of the mist water can be prevented by 10 MPa or less. In particular, it is better. The blowing pressure for the misty water is in the range of 0.2 to 8 MPa. 4) Contact with the cooling roll 74 (refer to Fig. 8) The setting temperature of the cooling roll 74 is preferably 30^501, more preferably 50°C to 130°C. The cooling roll 74 is not particularly limited, but similarly to the first pressing roll 11 or the second pressing roll 12, for example, a metal roll can be used. Further, in Fig. 8, the 'cooling pro 74 is arranged as follows. In other words, the continuous resin sheet 2 in the transfer 154784.doc • 16. 201144047 is picked up from the intermediate position of the contact start position with the third roll 13 and the position 62 separated from the third roll 13 Arranged so that at least a part of the region from the position 62 where the third roller 13 is peeled off is in contact with each other, but may be followed It is disposed so as to be in contact with at least one of the regions from the second intermediate position 63 to the contact start position 61 of the second parent 13. The second may be omitted as shown in FIGS. The strong cooling unit (blowing air, etc.) in the transporting step. Alternatively, the second transporting step itself may be omitted as shown in Fig. 6. After the second transporting step, the resin sheet is extracted to obtain one side. The surface shape transfer resin sheet 1 having the uneven shape of the transfer mold 22 is transferred at a high transfer rate (see FIG. 9). According to the manufacturing method, the cross-sectional shape of the groove 22a of the transfer mold 22 is The length of the line forming the one groove 22a in the cross-sectional shape obtained by cutting the plane of the central axis of rotation of the second squeeze roll 12 is "L", and the interval between the grooves 22a is set to In the case of "p" (see Fig. 10), even if the groove 22a has a sharp and deep shape in which L/p is 15 to 5, the occurrence of the winding phenomenon can be suppressed. The surface shape transfer resin sheet 1 thus obtained Usually cut into a single piece 'for use as, for example, a liquid crystal display device In addition, when a resin to which a light diffusing agent is added is used as the resin, it can be suitably used as a light diffusing plate. In the present manufacturing method, the distance P between the grooves 22a of the transfer mold 22 is not particularly limited. Usually, the groove depth D of the groove 22a of the die 22 is not particularly limited, and is usually set to a range of 3 μΜΟΟ μηη. The adjacent grooves are generally arranged in parallel along the interval d (refer to FIG. 1A). The distances between the grooves m and the groove depth DW are not necessarily fixed in the entire transfer mold, and adjacent to the concave The grooves can also be of different composition. The interval d may be arbitrarily set depending on the use of the obtained surface shape transfer resin sheet, and the interval d is usually set to 1 μm or less. Further, it is also possible to configure the above-described interval d (i.e., d = 〇). As the cross-sectional shape of the transfer mold 22, in addition to the substantially V-shaped groove shown in FIG. 1A, for example, a cross-sectional shape including a substantially U-shaped groove, a substantially semi-circular groove, and a portion including a substantially semi-circular groove may be exemplified. The cross-sectional shape is specifically 'but is not particularly limited to such a cross-sectional shape. The opening degree _ angle 0 of the bottom of the above substantially V-shaped groove 22a is usually 160. Hereinafter, according to the present manufacturing method, the opening angle Θ of the substantially v-shaped groove at the bottom thereof is 1 〇. ~80. In the case of a sharp groove shape, the uneven shape of the transfer mold 22 can also be transferred at a high transfer rate. As the above-mentioned substantially semicircular groove, for example, 'the shape of the cross section of the cross section when the cylinder is cut in a plane non-parallel to the center line may be a semi-elliptical arc shape, or the semi-ellipse One of the arc shapes is a flat curved shape or the like. Further, the case of a shape including a substantially semicircular groove in which the substantially semicircular groove is reversed and a shape formed by a curve other than a brittle arc is also included in the patent application of the present application. Further, the substantially semicircular groove may be, for example, a groove 22a having a cross-sectional shape as shown in Fig. 12 (4), or may have a curved cross-sectional shape I54784.doc 201144047 as shown in Fig. 12()). . The above-mentioned "substantially semi-circular groove" also includes such a substantially semi-circular shaped groove. As a method of producing the transfer mold 22, a diamond turning tool is used after performing a plating treatment such as chrome plating, copper plating, nickel plating, or nickel-phosphorus plating on a surface of a transfer roller made of stainless steel or steel. The method of removing, processing, or chemical etching the plated surface, such as a metal grindstone, is not limited to these methods. Further, after the transfer die 22 is formed on the surface of the second pressing roller (transfer roller) 12, for example, plating such as chrome plating, copper plating, nickel plating, or nickel-phosphorus plating can be performed without deteriorating the surface shape accuracy. deal with. Further, as long as the effect of the present invention is not significantly impaired, a manufacturing apparatus having a configuration in which other rolls are provided in addition to the first pressing roll 11, the second pressing roll 12, and the third roll 13 may be used. The surface shape transfer resin sheet 1 was produced. As the other roller, for example, a guide roller (contact roller) for conveying the continuous resin sheet 2 to the first pressing roller 、, and a continuous bonding of the continuous resin sheet 2 to the second extrusion may be mentioned. The contact roller of the roller 12 or the like. Further, in the above embodiment, the transfer mold 22 is provided only in the second pressing roll 12, but is not particularly limited to such a configuration, and may be provided, for example, in both the second pressing roll and the third light 13. The composition of the transfer mold 22. Further, the method for producing the surface shape transfer resin sheet of the present invention is not particularly limited to the above-described exemplary embodiments, and any design change is allowed as long as it is within the scope of the request, without departing from the spirit. [Examples] Next, specific examples of the present invention will be described, but the present invention is not particularly limited to 154784.doc • 19· 201144047 in these examples. (Manufacturing Apparatus A) A manufacturing apparatus A including the configuration shown in Fig. 3 was prepared. The manufacturing apparatus a includes an extruder 7 having a T-die 8, a first pressing roll 11, a second pressing roll 12, a third pressing roll 13, and a first blowing device 71. The surfaces of the first squeezing roller ^ and the third squeezing roller 13 are mirror surfaces. The second squeezing roller 12, as shown in Fig. 1A, includes a transfer die 22 having a plurality of grooves 22a on the surface. In the transfer mold 22 of the surface of the second pressing roller 12, the interval ρ between the grooves 22a is 1 〇〇, and the depth D of the groove 22a is 1 〇 5 μηι 'the formation of the cross-sectional shape} a groove 22 & The length of the formed line [is 232 μηη, L/P = 2.32, the interval d is 5 μιη, and the angle Θ is 51. (Refer to Figure 1〇). <Example 1> A polycarbonate resin ("CALIBRE PC 200-30" manufactured by Sumitomo Dow Co., Ltd., and a glass transition temperature Tg: 147 ° C measured according to JIS K 712 1-1987) was supplied to the above-mentioned manufacturing apparatus. The extruder 7' having a screw diameter of 4 mm was extruded into a sheet shape at a die temperature of 260 〇c via a T-die 8, thereby obtaining a continuous resin sheet 2 having a thickness F of 〇.8 mm ( Extrusion step). Next, as shown by the circle 3, the continuous resin sheet 2 is passed between the first pressing roll 上述 and the second pressing roll 12 of the above-described manufacturing apparatus A, and held continuously by the two pressing rolls 11, 12. The resin sheet 2 is pressed (first pressing step). Then, while the continuous resin sheet 2 is conveyed in a state of being in close contact with the outer peripheral surface of the second squeeze roll 12, the continuous resin sheet 2 in the transfer is adhered to a portion of the region of the second squeeze roll 12 Blow air from the first air supply 154784.doc •20· 201144047 (the first transport step). (4) The continuous resin sheet 2 is passed between the second squeeze roll 12 and the third roll 13, and is pressed by sandwiching the continuous resin sheet 2 with the two press rolls a, U (second pressing step) . Then, the continuous resin sheet 2 is conveyed in a state of being in close contact with the outer peripheral surface of the third squeeze roll 13 (second transfer step), and is extracted at an extraction speed of 0.91 m/min, thereby obtaining a thickness S of 〇. .8 mm surface shape transfer resin sheet i (refer to Fig. 11). At this time, the set temperature of the second squeeze roll 12 is set to 180, respectively. The set temperature of the crucible, the first pressing roller 11 was 130 t, and the set temperature of the third pressing roller 13 was 150 °c. Further, a melt stream 3 of a resin is formed between the first squeeze roll 11 and the second press pin 12, and the height of the melt flow is adjusted to be 6 〇 mm (refer to Fig. 9). Further, in the first conveying step, the air is blown from the first air blowing device to the continuous resin sheet 2 (20. The pressure of 〇 is set to 〇6 Mpa. Further, as shown in FIG. 3, in the first conveying step, The following arrangement is made: the first air blowing device 71 pairs the continuous resin sheet 2 in the conveyance from the contact starting position 51 with the second pressing roller 12 and the position 52 separated from the second pressing roller 12 A part of the area from the intermediate position 53 up to the position 52 peeled off from the second squeeze roll 12 is blown. <Comparative Example 1> In the first transfer step, air blowing from the first blower 71 is not performed at all. In the same manner as in the example i, the surface shape transfer resin material was produced. The transfer rate of the surface shape transfer resin sheet obtained as described above was evaluated based on the following evaluation method. The amount of warpage and the occurrence of winding phenomenon 154784.doc - 2J - 201144047 degree. The evaluation results are shown in the table <Transfer rate evaluation method> Degree is set to "D" "The surface shape will be transferred The height of the ridge portion 32 of the printed resin sheet "H" (refer to the circle U) and the depth of the groove 22a of the (four) die are set (see Fig. 10). 'The transfer rate is obtained by the following formula (1). Transfer rate (%) = (H/D) X 1 00 (1) <Evaluation method of the degree of occurrence of the winding phenomenon> When the above surface shape transfer resin sheet is produced, by the second extrusion roller (transfer roller) 12 and the third extrusion After the roll 13 was pressed by the continuous resin sheet 2 and pressed, the time (shift) of the continuous resin sheet 2 wound around the second squeeze roll 12 was examined. In Table 1, the range was observed in a continuous operation for a few minutes. The shortest time and the longest time of the winding can be judged that the longer the winding time is, the more the winding phenomenon of the second pressing roller 12 as shown in Fig. 13 occurs. Further, the winding time can be judged. The shorter the winding, the more the occurrence of the winding phenomenon is suppressed. When the winding time is 0 seconds, the winding state is not generated at all (see Fig. 3). [Table 1] Example 1 Comparative Example 1 Tg of the resin ( t) 147 147 Second squeeze roll temperature (°c) 180 180 First transfer step blowing air temperature (°c) 20 - Air blowing pressure (MPa) 0.6 - Evaluation transfer rate (% 93 92 Time at which the second squeezing roller is wound (seconds) 0 to 5 6 to 10 154784.doc • 22-201144047 From Table 1, it can be seen that the surface of the first embodiment is manufactured by the manufacturing method of the present invention. The resin sheet was transferred with the uneven shape of the transfer mold at a high transfer rate. Further, in the first embodiment, the second squeeze roll contains a transfer mold having a deep and sharp concavo-convex shape with an L/ρ of 2 32. However, the occurrence of the winding phenomenon of the resin sheet wound around the second extrusion is small. On the other hand, in Comparative Example 1 in which the forced cooling in the first transfer step was not performed, the degree of occurrence of the winding phenomenon in which the resin sheet was wound around the second squeeze roll was large (the winding phenomenon remarkably occurred). The surface shape transfer resin sheet produced by the production method of the present invention is suitable for use as, for example, a ruthenium sheet, a light diffusion plate, a light deflection structure plate, and a light guide plate because the uneven shape of the transfer mold is transferred at both transfer rates. Optical sheets, etc., but are not particularly limited to such uses. Among these, the surface shape transfer resin sheet is particularly suitable for an optical sheet for an image display device such as a liquid crystal display device. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view showing an example of a manufacturing method of the present invention. Fig. 2 is a schematic view showing another example of the production method of the present invention. Fig. 3 is a schematic view showing still another example of the production method of the present invention. Fig. 4 is a schematic view showing still another example of the production method of the present invention. Fig. 5 is a schematic view showing still another example of the production method of the present invention. Fig. 6 is a schematic view showing still another example of the production method of the present invention. Fig. 7 is a schematic view showing still another example of the production method of the present invention. Fig. 8 is a schematic view showing still another example of the production method of the present invention. Figure 9 is an illustration of the definition of the height of the melt stream. I54784.doc -23· 201144047 Fig. 1 is an enlarged cross-sectional view of a transfer mold on the surface of a second extrusion roll of a tantalum (a scraped surface obtained by cutting a plane including a central axis of rotation). Fig. 11 is a cross-sectional view showing a surface shape transfer tree of a ruthenium sheet produced by the production method of the present invention (a cross-sectional view taken along line V-V of Figs. 1 to 8). Fig. 12 (a) and (b) each show an enlarged cross-sectional view of a modified example of the transfer mold (a plan view obtained by cutting a plane including the central axis of rotation). Fig. 13 is a schematic view showing a state in which a winding phenomenon occurs. Figure 14 is an explanatory view of the stagnation line. [Main component symbol description] 2 3 7 8 11 12 13 22 22a 32 51 52 53 Surface shape transfer resin sheet continuous resin sheet melt flow extruder die first squeeze roller second squeeze roller third The roll transfer die groove ridge portion of the continuous resin sheet 2 is in contact with the second squeeze roller 12, and the continuous resin sheet 2 is detached from the second squeeze roller 12 by the erecting faces 51 and 52. Intermediate position 154784.doc • 24- 201144047 61 Continuous resin sheet 2 and third 62 continuous resin sheet 2 from the third 63 6 1 and 62 bis divided by the middle position 第一 71 first air blowing device 72 second air supply Device 73' 74 Cooling roller 91 Retentate D Depth of groove 22a d Interval E Height of melt flow F Thickness of continuous resin sheet 2 H Height of ridge 32 K imaginary line L Length of line forming P Groove 22a interval S thickness Θ opening angle (apex angle) 154784.doc •25-