TW201714726A - Method and apparatus for manufacturing surface-structured film - Google Patents

Abstract

Provided are an apparatus and a method for continuously transferring structures onto a film surface with a high accuracy and a low mold cost. This apparatus for manufacturing a surface-structured film in which surface structures including a thermosetting material are provided on a surface of a film is provided with at least: (1) an endless-belt-shaped mold having structures on a surface thereof; (2) a mold conveying means for causing the mold, held by two or more heating rolls, to be conveyed in a circulating manner by rotating the heating rolls; (3) a pressing mechanism provided with at least a nip roll and a nipping means which employs the nip roll and one of the heating rolls of the mold conveying means, the nip roll being arranged parallel to the one heating roll and having a surface covered with a resilient body; (4) a coating unit installed upstream of the pressing mechanism in the conveying direction of the mold; (5) a film supplying means for supplying a film onto a surface of the mold; and (6) a film separating means for separating the film from the surface of the mold.

Description

Method and device for manufacturing surface structure film

The present invention relates to a method of manufacturing a surface structure film by a film transfer surface construction and a manufacturing apparatus therefor. 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, light collection, reflection, and transmission, or an uneven structure film having an ultra-liquid-repellent function or a cell culture property, etc. A microstructured member of micron size to nanometer size is required.

As a method of producing a surface structure film having a fine structure on its surface, there is a method of using a mold having a fine structure formed on its surface, and applying a thermosetting or radiation curable material to a mold or a film before being supplied to the mold. Thereafter, the film is wound into a heated mold to form a fine structure on the coating film while being hardened, and the film is further peeled off from the mold to transfer a fine structure on the surface of the film to obtain a surface structure film.

Patent Document 1 describes a method in which a sol gel of a thermosetting material is applied to a film mold pulled by a roll-to-roll method, and then heat-treated while holding the mold on the substrate, thereby performing the heat treatment on the substrate. The surface transfers the fine structure containing the sol-gel material to the substrate. A fine structure is formed in advance on the surface of the film mold, and a shape is also formed on the surface of the substrate. The structure is almost the same as this fine structure. Since the sol-gel material is applied, it is possible to form a concavo-convex structure having high heat resistance.

Further, Patent Document 2 describes a method in which a film having a radiation curable resin coated on its surface is pressed against an endless belt having a fine structure on its surface, and is irradiated with radiation to form a film surface. After the fine structure, the mold and the film are peeled off to produce a film having a fine structure formed on the surface. It is described that the endless belt uses a copy containing a resin, whereby the cost of the mold can be suppressed.

[Previous Technical Literature] [Patent Literature]

Patent Document 1: Japanese Patent No. 5695804

Patent Document 2: Japanese Laid-Open Patent Publication No. 2008-137282

In the method for producing a fine structure transfer film described in Patent Document 1, since a long film roll is used as a mold, there is a problem that the mold cost is increased. Further, although it can be applied to a single-piece substrate, when applied to a roll-to-roll film, the thermosetting material is peeled off from the substrate by the unhardened lower mold due to shrinkage during heating, and a predetermined surface cannot be formed. Construct such a problem.

Further, in the method for producing a fine structure transfer film described in Patent Document 2, when applied to a material containing a thermosetting material, the thermosetting material is uncured under the hardening due to shrinkage during hardening. The substrate is peeled off, and the problem of a predetermined surface structure cannot be formed.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above problems and to provide an apparatus and method for continuously transferring a fine surface structure containing a thermosetting material on a surface of a film with high precision and inexpensive mold cost.

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

An apparatus for producing a surface structure film, which is a manufacturing apparatus for manufacturing a surface structure film having a surface structure including a thermosetting material on a surface of a film, comprising at least: (1) an endless belt-shaped mold having a surface structure; 2) a mold transfer means for winding the transfer mold to the two or more heat rolls by rotating the heat roller; (3) at least being disposed in parallel with the first heat roller of the mold transfer means; a nip roller whose surface is covered with an elastic body, and a pressurizing mechanism using the heating roller and the nip roller; (4) is provided on the upstream side of the transport mechanism of the mold a coating unit; (5) a film supply means for supplying a film to the surface of the mold; and (6) a film peeling means for peeling off the film of the surface of the mold.

A method for producing a surface structure film, which is characterized by comprising at least the following steps: (1) winding a ring-shaped mold having a surface structure to at least 2 heated One or more heating rolls are used to apply a thermosetting material to the surface of the mold while the mold is being conveyed while heating the mold, and (2) applying a thermosetting material to the surface of the mold State a step of bonding a film from the side of the thermosetting material; (3) a step of pressurizing the film with the film, the thermosetting material, and the mold layer; (4) adding a step of transporting the film after pressing the film, the thermosetting material, and the mold layer while heating, and (5) peeling the surface structure film in a state in which the film and the thermosetting material are in close contact with each other step.

According to the present invention, an endless belt-shaped mold can be applied to produce a surface structure film. Since the step of forming a long film of a roll film shape by the product in the prior art is omitted, the cost of the mold can be reduced. Further, since the film and the mold can be maintained in a laminated state without being peeled off during the hardening process, a highly precise surface structure can be formed.

10‧‧‧Example of a device for manufacturing a surface structure film of the present invention

11‧‧‧ Film

12‧‧

13‧‧‧Hot hardening materials

13a‧‧‧Protrusion

14‧‧‧Layer

15‧‧‧Surface structure film

20‧‧‧Molding means

21‧‧‧1st heating roller

22‧‧‧2nd heating roller

23‧‧‧ Film supply means

23a‧‧‧Rolling roll

23b‧‧‧ Guide roller

24‧‧‧Metal stripping means

24a‧‧‧ peeling roller

25a‧‧‧ winding roller

25b‧‧‧ Guide roller

27‧‧‧ Pressurizing mechanism

27a‧‧‧Pressure

28‧‧‧Clamping roller

29‧‧‧Measure means

30‧‧‧ Coating unit

31‧‧‧Slit mode

32‧‧‧Support roller

35‧‧‧End detection sensor

36‧‧‧ Controller

40‧‧‧Example of a device for manufacturing a surface structure film of the present invention

41‧‧‧ Pressurizing unit

45‧‧‧Example of a device for manufacturing a surface structure film of the present invention

46‧‧‧Flating means

50‧‧‧Example of a device for manufacturing a surface structure film of the present invention

51‧‧‧ Pressing mechanism

52, 53‧‧‧ Roll

54‧‧‧Ring belt

60‧‧‧Example of a device for manufacturing a surface structure film of the present invention

66a~66d‧‧‧heating roller

70‧‧‧Example of a device for manufacturing a surface structure film of the present invention

71‧‧‧2nd mode transfer means

72, 73‧‧‧heating roller

74‧‧‧Slit mode

75‧‧‧heating unit

77‧‧‧Film contact points

78, 79‧‧‧heating roller

80‧‧

81‧‧‧Surface structure film

100‧‧‧Example of a mold manufacturing apparatus applied to a manufacturing apparatus of a surface structure film of the present invention

101‧‧‧Mold

102‧‧‧film

110‧‧‧Rolling roll

120‧‧‧heating roller

121‧‧‧Clamping roller

130‧‧‧Cooling roller

140‧‧‧ peeling roller

150‧‧‧ winding roller

Fig. 1 is a schematic view showing an example of a manufacturing apparatus of a surface structure film of the present invention as seen from a cross section.

Fig. 2 is a schematic view showing an example of a manufacturing apparatus of the surface structure film of the present invention as seen from a cross section.

Fig. 3 is a schematic view showing an example of a manufacturing apparatus of the surface structure film of the present invention as seen from a cross section.

Fig. 4 is a schematic view showing an example of a manufacturing apparatus of the surface structure film of the present invention as seen from a cross section.

Fig. 5 is a schematic view showing an example of a manufacturing apparatus of the surface structure film of the present invention as seen from a cross section.

Fig. 6 is a schematic view showing an example of a manufacturing apparatus of the surface structure film of the present invention as seen from a cross section.

Fig. 7 is a schematic view showing an example of an apparatus for manufacturing a mold applied to the surface structure film of the present invention from a cross section.

Fig. 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.

Fig. 9 is a photograph of the surface of the surface structure film produced in Example 1 observed by an electron microscope.

[Formation of the Invention]

The apparatus for producing a surface structure film of the present invention is a device including at least a member having an endless belt-shaped mold having a surface structure, and being wound by a rotary heating roller to be wound around two or more of the heating rollers. The mold transporting means for the mold includes at least a nip roller disposed in parallel with one of the mold transporting means, and having a surface covered with an elastic body, and a rolling means using the heat roller and the nip roller a pressurizing mechanism; a coating unit provided upstream of the pressurizing mechanism in the transport direction of the mold; a film supply means for supplying a film to the surface of the mold; and a film for peeling off the film for peeling off the surface of the mold means.

Fig. 1 is a schematic view showing an example of a manufacturing apparatus of a surface structure film of the present invention as seen from a cross section. The apparatus 10 for manufacturing a surface structure film is an example of a device in which a surface structure film 15 having a structure including a thermosetting material 13 is formed on the surface of the film 11.

As shown in Fig. 1, the apparatus 10 for manufacturing a surface structure film of the present invention comprises: an endless belt-shaped mold 12; and the mold 12 is suspended on the first heating roll. 21 and the second heating roller 22 are the mold transporting means 20 for winding and transporting; the pressurizing mechanism 27 for pressing the nip roller 28 arranged in parallel with the first heating roller 21 against the first heating roller 21; A coating unit 30 that applies a thermosetting material to the surface; a film supply means 23 that supplies the film 11 to the surface of the mold 12; and a film peeling means 24 that peels the surface structure film 15 from the mold 12. The outline of each structure is as follows.

The mold transporting means 20 includes a first heating roller 21, a second heating roller 22, and a driving portion that rotates the two rollers or the first heating roller 21. When only the first heating roller 21 is rotationally driven, the second heating roller 22 is held rotatably and rotated by friction with the die 20. Further, the first heating roller 21 and the second heating roller 22 include heating means. The heating means is preferably a structure that is heated from the inside of the roll. However, an infrared heating heater or an induction heating device may be provided in the vicinity of the outer surface of the roll to promote heating from the outer surface of the roll.

The pressurizing mechanism 27 is a mechanism that can press the nip roller 28 against the first heating roller 21 with a uniform pressure in the width direction, and applies the structure in which the outer surface of the core layer is coated with the elastic body in the nip roller 28, and the core layer is Both ends of the bearing are rotatably supported by the bearing. The nip roller 28 is opened and closed by the stroke of the pressurizing mechanism 27, and is pressed or released in a state where the mold 12, the thermosetting material 13, and the film 11 are laminated. In addition, the nip roller 28 can have a temperature adjustment mechanism depending on the desired process or film material.

The film supply means 23 includes one or a plurality of take-up rolls 23a for winding a film from a film wound into a roll shape, and a guide roll 23b for aligning the conveyance path of the film 11, and the film 11 is wound. After being wound around the nip roller, the pressurizing portion 27a is carried.

The film peeling means 24 includes one or a plurality of peeling rolls 24a for peeling off the surface structure film 15 including the laminated body of the film 11 and the thermosetting material from the mold 12, and the surface structure film 15 to be peeled off The winding roller 25a wound in a roll shape and a guide roller 25b for aligning the conveying path of the surface structure film 15 are also provided.

The coating unit 30 may be a thermosetting material 13 capable of continuously and uniformly discharging a coating material in the width direction. For example, it may be a combination of a discharge die 31 including a slit die 31 as shown in the drawing. A constructor such as a liquid supply mechanism that can continuously supply a predetermined amount of coating liquid. Further, in order to maintain the interval between the discharge front end surface of the slit die and the mold with high precision, the support roller 32 may be disposed on the opposite side of the application of the mold. It is preferable to provide a position adjustment mechanism that can adjust the position of the applicator to the left and right with high resolution.

The endless belt-shaped mold 12 forms an endless belt of surface construction. Since it is wound around a roll during conveyance, it is preferable to have flexibility. Further, in order to uniformly pressurize and heat it, a material having a uniform thickness is preferable. As the shape, in consideration of the deformation time or the hardening time of the thermosetting material, a surface structure having a height difference of 1 mm or less is preferable. Further, since it is heated during transportation, it is preferably a material that can withstand the heating temperature.

A series of forming operations of the manufacturing apparatus 10 based on the surface structure film are as follows. The mold 12 is wound and conveyed by the first heating roller 21 and the second heating roller 22, and is heated to a predetermined temperature. Then, the thermosetting material 13 is applied to the surface of the mold 12 by the coating unit 30. In addition, the molding film 11 wound up by the take-up roll 23a as the film supply means 23 is supplied to the surface of the mold 12 in the pressurizing portion 27a. Using the pressurizing mechanism 27 In the state where the mold 12, the thermosetting material 13, and the film 11 are laminated, the pressurizing portion 27a is pressed. The thermosetting material is heated and slowly hardened immediately after coating, but is pressurized by the pressurizing mechanism 27 in a state where the hardening is not completely completed, thereby putting the thermosetting material into the surface formed on the mold 12. Among the surface structures, heat energy is further continuously received on the surface of the heat roller 21, so that hardening can be promoted. By promoting hardening, the thermosetting material is brought into close contact with the film and begins to become less likely to be peeled off. In this state, the laminated body 14 of the mold, the thermosetting material, and the film is transferred to the second heating roller 22, and the thermosetting material further receives thermal energy from the surface of the heated roller to complete the curing reaction of the thermosetting material. When the hardening of the thermosetting material is completed, the thermosetting material adheres to the mold 12 and the film 11 in a firm state. Next, the side of the mold 12 and the side of the surface structure film 15 on which the film 11 and the thermosetting material are laminated are separated by the peeling roller 24a as the film peeling means 24. The surface structure of the surface structure film is the opposite shape of the mold surface structure. After the peeling, the thermosetting material is applied to the surface of the mold 12 again. On the other hand, the surface structure film 15 is wound by the winding roller 25a. The above actions are continuously performed.

The surface structure including the thermosetting material can be formed on the surface of the film 11 by the above-described device structure and operation. The thermosetting material is not a film 11 which is a base material, but is applied to a previously heated mold to be slightly hardened to maintain fluidity before pressurization, and is set to an appropriate elastic modulus. The shape (high filling property) into which the resin is pressed and the shape (high flatness) of the film on the surface of the mold are obtained, and a fine surface structure is obtained with high precision. Here, the high filling property of the resin means Clamping is performed with respect to a pressure at which the modulus of elasticity of the thermosetting material is sufficiently high to cause the resin to flow to the gap of the structure formed on the surface of the mold. Further, the high flatness means that the inflow of the resin toward the end portion in the nip width direction or the conveyance direction during pressurization is suppressed, and a uniform thickness is obtained in both the width direction and the conveyance direction.

Further, it is possible to obtain a sufficiently long distance between the heating rolls by applying an endless belt-shaped mold, and further adding a heating device between the rolls to ensure a sufficient resin hardening time. Thereby, the application range of the high speed or thermosetting material can be increased. The endless belt-shaped mold can be managed by changing the mold at the time of deterioration or when a defect occurs, and since it is not thrown away like a roll-shaped mold, the cost of the mold can be reduced.

Next, the structure of each part will be described in detail with reference to Fig. 1 .

The first heating roller 21 constituting the mold transporting means 20 receives the load at the time of nip, and therefore requires strength and processing accuracy, and further includes heating means. Examples of the material include steel or fiber reinforced resin, ceramics, and aluminum alloy. Further, as the heating means, a configuration may be adopted in which a cartridge heater or an induction heating device is provided by making the inside hollow, or a flow path is internally processed to allow oil or water, steam or the like to flow from the inside of the roller. Heat up. Further, it is also possible to adopt a configuration in which an infrared heating heater or an induction heating device is provided in the vicinity of the outer surface of the roller to heat the outer surface of the roller.

The processing accuracy of the first heating roller 21 is preferably 0.03 mm or less in accordance with the cylinder tolerance defined in JIS B 0621 (Revised Year 1984). The circular run-out tolerance is 0.03 mm or less. When these values become too large, a partial gap is formed between the first heating roller 21 and the nip roller 28 at the time of rolling, so that the laminated body 14 cannot be uniformly pressed and the shape of the transferred surface structure is formed. The case of mutation. Further, the surface roughness of the roll is preferably 0.2 μm or less in accordance with the arithmetic mean roughness Ra defined in JIS B 0601 (Revised 2001). This is because when Ra exceeds 0.2 μm, the shape of the first heating roller 21 is transferred to the back surface of the mold 12, and the film is further transferred to the surface structure of the film 11.

It is preferable to apply a high hardness film such as hard chrome plating, ceramic thermal spraying, or diamond-like carbon coating to the surface of the first heating roller 21 . This is because the first heating roller 21 is always in contact with the mold 12 and receives the pressing force based on the nip roller 28 through the laminated body 14, so that the surface thereof is very easily worn, if the surface of the first heating roller 21 If there is abrasion or damage, there is a problem that the shape of the surface structure is changed as described above or the shape of the surface of the roll is transferred.

On the other hand, the second heating roller 22 also includes a heating means. The material and the heating means are the same as those of the first heating roller. The processing accuracy of the second heating roller 22 is preferably 0.05 mm or less in accordance with the cylindrical tolerance defined in JIS B 0621 (Revised 1984), and the circumferential deflection tolerance is 0.05 mm or less. When these values are too large, there is a case where the conveyance precision is lowered, and there is a possibility that unevenness in the width direction or excessive meandering occurs in the laminated body 14 or the mold 12. The surface roughness of the second heating roller 22 is the same as that of the first heating roller, and it is preferable that the arithmetic mean roughness Ra defined by JIS B 0601 (Revised 2001) is 0.2 μm or less. If Ra exceeds 0.2 μm, There is a possibility that the heat conduction to the mold becomes insufficient. Further, the material is also the same as the first heating roller 21, and it is preferable to apply a high hardness film such as hard chrome plating, ceramic thermal spraying, or a diamond-like carbon coating. This is because damage or wear due to contact with the mold is prevented.

Then, the ends of the rolls are rotatably supported by a rolling bearing or the like. The first heating roller 21 is coupled to a driving means such as a motor (not shown), and is rotatable while controlling the speed. Further, the second heating roller 22 preferably passes through the die 12 and is rotated by the driving force of the first heating roller 21. In terms of speed, it is preferably carried out in the range of 1 to 30 m/min, and productivity can be improved while transferring the surface structure with high precision.

Further, it is preferable to provide the mold meandering mechanism to stably convey the mold 12. A preferred embodiment of the mode-snake suppression mechanism is as shown in Fig. 1, in the transport path of the mold 12, having an end detecting sensor 35 for detecting the position of the end of the mold 12; and for detecting based on the detected The value controls the movement of the second heating roller 22 to adjust the controller 36 of the transport position of the mold 12.

As the moving means of the second heating roller 22, it is preferable that the angle of the second heating roller 22 can be adjusted in the conveying direction of the die 12, respectively. It is preferable to adopt a configuration in which the angle of the second heating roller in the direction in which the mold is conveyed is adjusted so that the tension is lowered in the direction in which the movement is desired based on the value from the end detecting sensor. By providing the meandering suppression mechanism of the above-described mold 12, it is possible to suppress the meandering of the mold due to thermal deformation, and it is possible to realize stable conveyance and molding operation of the mold 12. Further, it is preferable that the second heating roller 22 presses the non-surface structural surface of the mold 12 with a constant load by a pressing means such as an air cylinder. Since the mold undergoes dimensional changes as the temperature changes, the above configuration is effective for maintaining a certain tension.

Further, the thermosetting material may be applied during the mold transporting process and then heated by another heating means to pressurize to promote hardening of the thermosetting material. Fig. 2 is a schematic view showing an example of a manufacturing apparatus 40 for viewing a surface structure film from an example of an apparatus in which a heating unit is added. By setting the heating unit 41 at the position immediately after the application, the hardening of the thermosetting material immediately after the application is started, and in a state of being hardened to some extent, the film 11 is laminated by the pressurizing mechanism 27. Pressure. The expansion of the end portion in the width direction of the material during pressurization is suppressed, and the thickness of the thermosetting material film after pressurization can be made uniform in the width direction. In the heating unit 41, the thermosetting material may be heated, and the heating unit 41 such as an infrared heater may be separately provided, and the heating roller may be brought into contact with the non-coated side of the mold 12 to conduct heat conduction. Heated structure.

Further, a flattening means for flattening the coated surface of the thermosetting material may be provided between the press and the thermosetting material 13 during the mold transfer. Fig. 3 is a schematic view showing an example of a device for adding a flattening means 46, and a manufacturing apparatus 45 for viewing a surface structure film from a cross section. The flattening means 46 is a structure for flattening the coated surface having irregularities, and is preferably a structure having an edge abutting on the coated surface. Further, it is preferable to have a mechanism or structure in which the edge portion can abut against the coated surface in a state in which a uniform pressure is maintained in the width direction of the mold 12 or a uniform distance from the surface of the mold 12 is maintained.

In addition to this, the flattening means 46 may include means for removing or recovering the remaining thermosetting material 13 due to the flattening of the coated surface. By removing or recovering the remaining thermosetting material 13, continuous flattening can be continuously performed, and the thermosetting material 13 can be prevented. Go to the uncoated side of mold 12. The means for removing or recovering is preferably a suction nozzle system connected to a vacuum pump or the like, but may be a method of mechanically removing the remaining liquid by a doctor blade, and is not particularly limited.

Further, a pressing mechanism for adhering the film 11 to the thermosetting material may be provided between the pressurization of the thermosetting material and the heating during the mold transfer. Fig. 4 is a schematic view showing an example of a device for adding a pressing mechanism, and a manufacturing apparatus 50 for viewing a surface structure film from a cross section. The pressing mechanism 51 is an example of a mechanism for pressing the laminated body 14 pressurized by the pressurizing mechanism 27 by the endless belt 54 on the surface of the first heating roller 21 . The endless belt 54 is suspended by the rollers 52 and 53, and follows the conveyance of the laminated body 14, and the endless belt 54 is rotated by friction with the film 11. The rollers 52, 53 are kept free to rotate. Preferably, the endless belt 54 is heated, and preferably the temperature adjustment mechanism is also provided in the rolls 52, 53. The material of the endless belt 54 is preferably a resin that does not damage the film 11, but may be a metal strip such as stainless steel. According to the above configuration, the laminated body 14 after the pressurization can press the film 11 against the thermosetting material 13 while heating, thereby promoting the hardening of the thermosetting material 13, and promoting the thermosetting material 13 to the mold. The filling of the surface structure of 12 and the adhesion of the film 11 and the thermosetting material 13 to the film 11 are performed.

Further, in order to promote the hardening of the thermosetting material 13 after pressurization during the mold transfer, a heating roll may be added to the mold transfer means. Fig. 5 is a schematic view showing an example of a manufacturing apparatus 60 for viewing a surface structure film from a cross section, as an example of an apparatus in which three or more heating rolls are added to a mold transporting means. The heating rollers 66a, 66b, 66c, and 66d are provided as conveying means, and the first heating roller 21 and the laminated body are provided in the same manner as in the fourth embodiment. Pressing mechanism 51 for 14. By the configuration in which the heating rollers 66a to 66d and the pressing mechanism 51 are added, the adhesion between the film 11 and the thermosetting material 13 can be maintained and the curing can be promoted. Therefore, the mold transfer method illustrated in Fig. 1 or Fig. 2 cannot be used. A fully hardened material is effective.

Here, the pressurizing mechanism 27 will be described with reference to the first drawing. The pressurizing mechanism 27 is constituted by a nip roller 28 and a mechanism that presses the first heating roller 21 disposed in parallel with each other. The nip roller 28 is configured to cover the outer surface of the core layer with an elastic body. The core layer requires strength and processing precision, and for example, steel or fiber reinforced resin, ceramics, aluminum alloy, or the like can be applied. Further, in the layer in which the elastic system is deformed by the pressure, a resin layer or an elastomer material typified by rubber is preferably used. The core layer is rotatably supported by bearings at both end portions thereof, and the bearing is connected to a pressing means 29 such as a cylinder. The nip roller 28 is opened and closed by the stroke of the pressing means 29, and the laminated body 14 is pressed or released.

In addition, the nip roller 28 can have a temperature adjustment mechanism depending on the desired process or film material. As the temperature adjustment mechanism, a configuration may be adopted in which a cartridge heater or an induction heating device is buried in a hollow interior of the roller, or a flow path is internally processed to allow a heat medium such as oil or water or steam to flow from the roller. Heated inside. Further, it is also possible to adopt a configuration in which an infrared heating heater is provided in the vicinity of the outer surface of the roller to heat the outer surface of the roller.

The machining accuracy of the nip roller 28 is preferably 0.03 mm or less in accordance with the cylindrical tolerance defined in JIS B 0621 (Revised 1984), and the circumferential deflection tolerance is 0.03 mm or less. When these values become too large, a partial gap is formed between the first heating roller 21 and the nip roller 28 at the time of rolling, because In this case, the laminated body 14 cannot be pressed in the width direction with a uniform force, and the laminated body 14 cannot be uniformly pressed, and the shape of the transferred surface structure is mutated. Further, the surface roughness of the elastomer is preferably 1.6 μm or less in accordance with the arithmetic mean roughness Ra defined in JIS B 0601 (Revised 2001). This is because if Ra exceeds 1.6 μm, the surface shape of the elastic body may be transferred to the back surface of the film 11 when pressed.

The heat resistance of the elastic body of the nip roller 28 is preferably a heat resistant temperature of 160 ° C or higher, and more preferably a heat resistant temperature of 180 ° C or higher. Here, the heat-resistant temperature is determined by the temperature at which the rate of change in tensile strength when the temperature is left at this temperature for more than 10%.

As a material of the elastomer, for example, an oxime rubber or EPDM (ethylene-propylene-diene rubber), chloroprene rubber, CSM (chlorosulfonated polyethylene rubber), or ethyl urethane can be used. Rubber, NBR (nitrile rubber), hard rubber, etc. A higher modulus of elasticity and hardness are required, and a hard pressure-resistant resin (for example, a polyester resin) which improves toughness can be used. The rubber hardness of the elastomer is preferably in the range of 70 to 97° in accordance with ASTM D2240:2005 (Shore D) specifications. This is because if the hardness is less than 70°, the amount of deformation of the elastic body becomes large, and the pressure contact width with the film 11 becomes excessively large, and the pressure required to form the structure cannot be ensured. Further, if the hardness exceeds 97°. Then, the amount of deformation of the layer is rather small, the pressure contact width becomes too small, and there is a case where the pressing time required for the transfer surface structure cannot be ensured.

The driving means of the nip roller 28 is preferably connected to the end of the first heating roller 21 by a chain or a belt, and can be rotated in conjunction with the first heating roller 21. Alternatively, the motor may be independently rotated by using a motor that can be synchronized with the speed of the first heating roller 21, but it may be configured to be freely rotatable and rotated by friction with the film 11.

The film supply means 23 is composed of a take-up roll 23a and one or a plurality of guide rolls 23b provided for the conveyance path of the alignment film 11, but it is preferable that the guide roll 23b is provided with a tension detecting mechanism to The tension becomes a certain way to control the torque of the guide roller 23a. The film 11 is wound around the nip roller 28 and conveyed to the pressurizing portion 27a. However, a roll that flattens the wrinkles may be provided immediately before the winding.

The film peeling means 24 is formed by winding the surface structure film 15 from the mold 12 by the peeling roller 24a, winding the roll 25a in a roll shape, or one or a plurality of guide rolls 25b. The guide roller 25b is provided with a tension detecting mechanism that controls the torque of the winding roller 25a so that the tension becomes constant. In addition, the surface structure film 15 is not necessarily wound into a roll shape, and may be provided in a single sheet shape while being cut into a sheet shape during conveyance while holding the end portion in the width direction. Further, a cooling mechanism may be provided on the inner surface of the peeling roller 24a. It is also possible to perform cooling before winding the heated surface structure film 15. Further, a cooling device such as a jet may be provided in the transfer process from the peeling roller to the winding to cool the surface structure film 15. It is possible to suppress wrinkles or planarity defects caused by temperature changes in the surface structure film 15 after winding by cooling to room temperature before winding.

The coating unit 30 is provided with a slit die 31 and a coating material supply mechanism connected thereto on the upstream side of the pressurizing portion 27a during the conveyance of the die 12. The slit die 31 is configured to form a surface structure in the mold 12. The surface of the thermosetting material 13 is applied to face to face. In order to form a uniform coating film, it is preferable to maintain the interval between the slit die 31 and the die 12 with high precision and uniformity, and it is preferable to support the die from the face opposite to the face on which the surface structure is formed as shown in the figure. The support roller 32 is configured in a manner. Further, the support roller 32 is preferably provided with a temperature adjustment mechanism internally in such a manner that the mold temperature can be controlled to a predetermined temperature when the mold is contacted. Here, it is preferable that the interval between the slit die 31 and the die 12 is controlled so that the distance between the discharge surface of the slit die 31 and the surface of the die 12 can be controlled at an interval of 10 μm to 500 μm. Further, the interval accuracy in the width direction is preferably 10 μm or less, and more preferably 3 μm or less. Further, in order to achieve the accuracy of the present invention, the straightness and the rotational deflection of the support roller 32 are preferably 5 μm or less, more preferably 1 μm or less. Further, although the coating method using the slit die is exemplified here, other coating methods may be employed.

Further, the coating unit for heating the curable material may be further applied so that a layer of a thermosetting material can be formed on both surfaces of the film 11. Fig. 6 is a schematic view showing a manufacturing apparatus 70 for viewing a surface structure film from a cross section, showing an example of a device for forming a layer containing a thermosetting material on both surfaces. The second mold transporting means 71 is provided in parallel with the mold transporting means 20. The second mold 80 constituting the second mold transporting means 71 may or may not be provided with a surface structure on its surface. In the absence of a surface structure, a flat surface of the thermosetting material can be obtained. The second mold transporting means 71 is disposed in the vicinity of the first heating roller 21, and the heating rollers 72 and 73 are disposed so that the second mold 80 comes into contact with the film 11, and the second mold 80 is suspended by the two rollers. The slit die 74 constituting the second coating unit is provided on the upstream side of the mold transfer step from the film contact point 77 during the conveyance of the second mold. In addition, in the narrow A heating unit 75 is disposed between the slit die 74 and the film contact point 77. Further, after passing through the first heating roller 21, the heating rolls 78 and 79 can be pressed a plurality of times, and the curing of the thermosetting material and the adhesion of the film 11 and the thermosetting material can be promoted. The heating roller 73 is provided at a position where the film conveyed to the second heating roller 22 is opposed to each other. The surface structure film 81 is peeled off from the mold 12 by the heating roller 72, and is wound around a winding roller. Since the surface structure film 81 is a layer in which a thermosetting material is formed on both surfaces, warpage deformation of the film accompanying shrinkage of the thermosetting material can be suppressed, and planarity can be improved.

The endless belt-shaped mold 12 is formed into an endless belt of surface construction. As the material, in consideration of high strength and thermal conductivity, a metal such as nickel or steel, stainless steel or copper may be used, but a resin is preferable in consideration of peelability from a thermosetting material. In the case of a resin, in order to obtain higher peelability, a thermoplastic material having a surface energy of 25 mN/m or less is preferred. As the material, a polyolefin-based material can be preferably exemplified. In order to improve the planarity as a mold, it may be bonded to a biaxially oriented polyethylene terephthalate film (PET).

As a method of producing the mold 12 having a surface structure, a method of pressing a mold on the surface of the thermoplastic film to form a shape can be applied. The method of pressing the mold on the surface of the thermoplastic film to form a shape presses the thermoplastic film against the mold in a heated state, and forms a structure opposite to the structure formed on the surface of the mold on the surface of the thermoplastic film. For example, it can be manufactured by a process of passing through a mold manufacturing apparatus as shown in Fig. 7. Fig. 7 is a cross-sectional view showing an example of an apparatus for manufacturing the mold 12 using the endless belt-shaped mold 101.

In the example shown in Figure 7, the film 102 is from the take-up roll The 110 is pulled out and supplied to the surface of the heated endless belt-shaped mold 101 having a surface structure by means of the heat roller 120. The surface structure of the mold 101 is formed into almost the same shape as the surface structure of the finally desired surface structure film 15. The mold 101 is heated by the heating roller 120 just prior to contact with the film. The film 102 that is continuously supplied is held down by the surface of the mold 101 by the nip roller 121, and the film 102 is formed in a structure opposite to the surface structure of the mold 101.

Thereafter, the film 102 is conveyed to the outer surface position of the cooling roll 130 in a state in which it is in close contact with the mold 101. The film 102 is cooled by heat conduction through the mold 101 by the cooling roll 130, and then peeled off from the mold 101 by the peeling roll 140, and the film is wound around the winding roll 150. By such a process, a roll-shaped mold is obtained. The mold 12 shown in Fig. 1 is cut into an appropriate length according to the device to be applied, and is processed into an endless belt shape by treatment with a tape fixing end portion or the like from the inner surface side.

Moreover, as a processing method applied to the surface of the mold 101, a method of directly performing cutting or laser processing on the surface of the metal strip, and directly performing cutting or laser processing on the gold plating film formed on the surface of the metal strip may be mentioned. In the method, a method of applying electrical casting to a cylindrical original plate having a fine structure on the inner surface thereof, and a method of continuously adhering a thin plate having a fine structural surface to the surface of the metal tape are used. Further, a method of abutting and welding end portions of a metal plate having a predetermined thickness and length to each other may be mentioned.

Further, as the surface structure of the mold 12, it is suitable to dispersely arrange the concave shape. This is because the pressure can be received on the flat surface of the mold when pressurized, so that the pressure is concentrated at the tip end of the shape and the possibility of deformation at the tip is low. As the concave shape, it is preferably at a pitch of 100 nm. ~1 mm is arranged in the shape of a cylindrical recess having a diameter of 10 nm to 1 mm and a height of 10 nm to 0.5 mm, more preferably a height of 1 μm to 500 μm. However, it is not limited thereto, and may be a conical or pyramidal depression. Further, for example, the grooves may be arranged in a plurality of stripes, or the convex shapes may be arranged in a dispersed manner.

Moreover, the second mold 80 used in the case where the thermosetting material is formed on both surfaces as shown in Fig. 6 may be the same structure, material, and manufacturing method as the mold 12. Further, it may be a flat material having no surface structure.

Next, a method of producing the surface structure film of the present invention will be described. The method for producing a surface structure film of the present invention is characterized in that a surface structure film is produced by at least including a step of winding an endless belt-shaped mold having a surface structure to at least two or more heated a heating roller that applies a thermosetting material to the surface of the mold while the mold is being conveyed while heating the mold, and applies a thermosetting material to the surface of the mold to remove heat. a step of bonding a film on the side of the curable material; a step of pressurizing the film with the film, the thermosetting material, and the mold layer; and the film after pressing, the heat hardening a step of transporting the material and the mold layer while heating, and a step of peeling off the surface structure film in a state in which the film and the thermosetting material are in close contact with each other.

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

In the preparation stage, the film 11 is pulled out by the take-up roll 23a so as to pass along the die 12 and pass through the peeling roll 24a to become the winding roll 25a. The state of winding.

Then, while the film 11 is conveyed by the driving means, the first heating roller 21 and the second heating roller 22 are actuated to adjust the temperature until the surface temperature of the two heating rollers reaches a predetermined temperature. The condition of the surface temperature of the two heating rolls depends on the material of the thermosetting material 13 to be applied, the heat resistance of the film 11, the shape of the surface structure of the mold 12, the aspect ratio, and the like, but is usually set at 80 ° C to 200 ° C. between. In the case where the mold is a resin, the surface temperature of the heat roller is preferably 20 ° C or more lower than the glass transition temperature of the mold. This is because the shape deformation of the surface structure of the mold can be suppressed. Further, as shown in Fig. 2, a heating unit 41 may be provided between the coating unit 30 and the pressurizing portion 27a to heat the mold. At this time, the set temperature of the heating unit 41 can be set such that the thermosetting material 13 is in a suitable hardened state in the pressurizing portion 27a. By being in a suitable hardened state, the expansion of the end portion in the width direction of the material during pressurization is suppressed, and the thickness of the thermosetting material film after pressurization can be made uniform in the width direction.

When the surface temperature of the first heating roller 21 and the second heating roller 22 reaches the set value, the coating unit 30 is actuated simultaneously with the conveyance of the film 11 at the molding speed, and the thermosetting material 13 is applied simultaneously to the mold 12 to be closed. The nip roller 28 presses the film 11 and the die 12 with the first heating roller 21 and the nip roller 28, and forms a shape opposite to the surface structure of the die 12 to the thermosetting material 13. The condition at this time depends on the mechanical properties of the thermosetting material 13 to be applied, the shape of the surface structure of the mold 12, the aspect ratio, and the like. However, it is preferable to set the film forming speed to 1 to 30 m/min. The nip pressure is in the range of 10 MPa or more and 100 MPa or less.

In addition, as shown in Fig. 3, it can be applied to the coating unit 30 to A flattening means 46 is provided between the pressing portions 27a to planarize the coated surface immediately after the application of the thermosetting material 13. It is difficult to completely flatten, but by narrowing the size of the unevenness on the coated surface, it becomes easy to promote the subsequent adhesion to the film 11.

The thermosetting material 13 to be applied may be any of an inorganic material and an organic material, and is considered to be an organic material having a low curing temperature in consideration of 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, an anthrone resin, a polyurethane, or the like can be suitably used. Among them, a two-liquid-curable fluorenone rubber which can widely select the viscosity at the time of coating, the hardness at the time of hardening, and the like can be suitably used.

When the nip pressure is less than 10 MPa, the fine structure is transferred, and the resin may not be sufficiently deformed completely to cause molding failure. Further, at a temperature exceeding 100 MPa, there is a case where the shape of the mold is deformed; and the strength is designed, the apparatus becomes large, and the cost becomes a problem.

The thermosetting material 13 is heated by heat conduction from the mold 12, and is pressed by the first heating roller 21 and the nip roller 28 to be filled in the surface structure of the mold 12. Then, the film 11 that has passed through the pressurizing portion 27a, the thermosetting material 13, and the laminated body 14 of the mold 12 are conveyed to the second heating roller 22 while maintaining the temperature. Here, the mold 12 is further heated, and the thermosetting material 13 is also heated by heat conduction from the mold 12 to be hardened. Thereafter, the film is peeled off by a peeling roller 24a as a film peeling means. Further, as shown in Fig. 4, the laminated body 14 can be pressed from the side of the film 11 by the endless belt 54 on the surface of the first heating roller 21. The hardening of the thermosetting material 13 and the adhesion of the film 11 and the thermosetting material 13 can be promoted.

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

Further, as shown in Fig. 6, the coating unit for heating the curable material may be further chased, and a layer of a thermosetting material may be formed on both surfaces of the film 11. The material or coating thickness of the applied thermosetting material is preferably equal to the thermosetting material 13 formed on the opposite side. Further, it is preferable that the set temperatures of the heating rolls 72, 73 or other additional heating rolls are equal to the heating setting on the side of the thermosetting material 13. This is because in the surface structure film 81, the amount of heat shrinkage on both surfaces of the film is made equal to suppress warpage of the film, and the flatness is improved.

The film 11 preferably has strength and heat resistance to such an extent that it does not deform even during curing or shrinkage of the thermosetting material, and specifically, it preferably contains polyethylene terephthalate or poly Polyester resin such as ethylene 2,6-naphthalenedicarboxylate, polytrimethylene terephthalate or polybutylene terephthalate, polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene Polyolefin resin such as polymethylpentene, polyamine resin, polyimide resin, polyether resin, polyester amide resin, polyether ester resin, acrylic resin, polyamine A resin such as a formate resin, a polycarbonate resin, or a polyvinyl chloride resin.

An example of the form of the produced surface structure film is shown in Fig. 8. Fig. 8 is a perspective view showing a region in which the surface structural film 15 is cut. The surface structure film 15 is coated with a thermosetting material 13 on the surface of the film 11, and has a structure formed on the surface layer. As a manufacturer suitable for applying the present invention The preferred structure of the method is that the columnar or tapered protrusions 13a are arranged in a distributed manner, but are not limited thereto. The shape of the surface structure is preferably a columnar convex shape having a diameter of 10 nm to 1 mm and a height of 10 nm to 0.5 mm at a pitch of 100 nm to 1 mm, and more preferably a height of 1 μm to 500 μm. However, it is not limited thereto, and may be a convex shape having a conical shape or a pyramid shape. Further, for example, it may be a stripe shape, or a recessed shape may be disposed.

[Examples]

[Example 1]

The film 11 is a biaxially oriented polyethylene terephthalate film (trade name "LUMIRROR" (registered trademark), S10, manufactured by Toray Industries, Inc.) having a thickness of 100 μm. The width is set to 300mm.

The mold 12 is a film comprising a methylpentene polymer having a thickness of 100 μm, a length of 3 m, and a width of 320 mm (Opulent, manufactured by Mitsui Chemicals, Inc.), and the surface structure is formed using the surface of the thermoplastic film shown in FIG. A device that holds the mold to form a shape. The surface structure was a concave shape in which the height was 50 μm, the diameter was 40 μm, and the pitch was 120 μm.

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

The apparatus shown in Fig. 1 is used as a manufacturing apparatus of the surface structure film, and the first and second heating rolls 21 and 22 are made of a cylindrical core material containing carbon steel, and a hard chrome plating is performed on the surface. Applicator. The outer diameter of the central portion of the support die 12 was set to 400 mm, and the length in the width direction was set to 340 mm. The surface temperatures of the two heated rolls were heated to 160 °C.

The slit die 31 has a discharge width of 290 mm and a slit width of 100 μm was applied so as to have a coating thickness of 20 μm when applied to a flat surface.

The peeling roller 24a which is a film peeling means has a structure in which an outer diameter is 400 mm and a length in the width direction is 340 mm, and a cooling core is passed through a hollow core material containing carbon steel. The temperature of the cooling water was set to 30 °C.

The supply of the film 11 to the mold 12 was performed by a film wound into a roll shape, and the winding tension was set to 30N.

The film of the surface structure film 15 is peeled off from the die 12 by the winding tension 30N, and is wound into a film roll.

The mold 12 was spun and conveyed at a speed of 2 m/min. The first and second heating rolls are held so as to apply a tension 30N to the mold 12.

The nip roll 28 was made of a cylindrical core material having an outer diameter of 160 mm and containing a carbon steel, and a surface having a pressure width of 290 mm was covered with a polyester resin (hardness: Shore D80°) as an elastomer. The pressing means uses a hydraulic cylinder to apply a pressing force of 100 kN to the nip roller 28. At this time, after the contact width B between the nip roller 28 and the film 11 was confirmed using a pressure measurement film (Prescale, manufactured by Fujifilm Co., Ltd.), the pressure was 6 mm over the entire width, and the pressure applied to the film 2 for molding was about 50 MPa. It is uniform in the width direction.

The molding operation is continuously performed, and as a result, the surface shape of the mold 12 can be transferred to the thermosetting material 13 almost 100%. Fig. 9 shows the results of observing the surface of the surface structure film with a scanning electron microscope.

[Example 2] The film 11 and the mold 12 were the same as those described in Example 1.

As the thermosetting material 13, a two-liquid hardening type ketone rubber is used. Glue (trade name RBL-9101-05, manufactured by Dow Corning Dongli Co., Ltd.).

The apparatus shown in FIG. 3 is used as a manufacturing apparatus of the surface structure film, and the first and second heating rolls 21 and 22 are made of a cylindrical core material containing carbon steel, and a hard chrome plating is performed on the surface. Applicator. The outer diameter of the central portion of the support die 12 was set to 400 mm, and the width direction was set to 340 mm. The surface temperature of the first heating roller 21 was heated to 160 ° C, and the surface temperature of the second heating roller 22 was heated to 90 ° C.

The slit die 31 has a discharge width of 290 mm and a slit width of 100 μm, and is applied so as to have a coating thickness of 25 μm when applied to a flat surface. The flattening means 46 uses a dialing blade including a stainless steel dialing width of 320 mm, and the shortest distance between the surface of the die 12 and the dialing blade is 20 μm.

The remaining liquid system dispensed by the scraping blade was recovered by a suction nozzle disposed above the dialing blade and connected to the vacuum pump with a suction width of 320 mm and a slit width of 200 μm. The suction pressure of the suction nozzle was set to 10 kPa using a pressure regulator.

The peeling roller 24a which is a film peeling means has a structure in which an outer diameter is 400 mm and a length in the width direction is 340 mm, and a cooling core is passed through a hollow core material containing carbon steel. The temperature of the cooling water was set to 30 °C.

The supply of the film 11 to the mold 12 was performed by a film wound into a roll shape, and the winding tension was set to 30N.

The film of the surface structure film 15 is peeled off from the die 12 by the winding tension 30N, and is wound into a film roll.

The mold 12 was spun and conveyed at a speed of 2 m/min. The first and second heating rolls are held so as to apply a tension 30N to the mold 12.

The nip roll 28 was made of a cylindrical core material having an outer diameter of 160 mm and containing a carbon steel, and a surface having a pressure width of 290 mm was covered with a polyester resin (hardness: Shore D80°) as an elastomer. The pressing means uses a hydraulic cylinder to apply a pressing force of 100 kN to the nip roller 28.

By continuously performing the molding operation, the surface shape of the mold 12 can be transferred to the thermosetting material almost 100%, and the coating surface can be flattened immediately after coating, and the adhesion between the film 11 and the thermosetting material 13 can be achieved. Also good.

10‧‧‧Example of a device for manufacturing a surface structure film of the present invention

11‧‧‧ Film

12‧‧

13‧‧‧Hot hardening materials

14‧‧‧Layer

15‧‧‧Surface structure film

20‧‧‧Molding means

21‧‧‧1st heating roller

22‧‧‧2nd heating roller

23‧‧‧ Film supply means

23a‧‧‧Rolling roll

23b‧‧‧ Guide roller

24‧‧‧Metal stripping means

24a‧‧‧ peeling roller

25a‧‧‧ winding roller

25b‧‧‧ Guide roller

27‧‧‧ Pressurizing mechanism

27a‧‧‧Pressure

28‧‧‧Clamping roller

29‧‧‧Measure means

30‧‧‧ Coating unit

31‧‧‧Slit mode

32‧‧‧Support roller

35‧‧‧End detection sensor

36‧‧‧ Controller

Claims (14)

An apparatus for producing a surface structure film, which is a manufacturing apparatus for manufacturing a surface structure film having a surface structure including a thermosetting material on a surface of a film, comprising at least: (1) an endless belt-shaped mold having a surface structure; 2) a mold transporting means for winding the winding roller to the two or more of the heating rollers by rotating the heating roller; (3) at least being disposed in parallel with the first heating roller of the mold transporting means; a nip roller whose surface is covered with an elastic body, and a pressurizing mechanism using the heating roller and the nip roller; (4) is disposed on the upstream side of the pressurizing mechanism in the transport direction of the mold a coating unit; (5) a film supply means for supplying a film to the surface of the mold; and (6) a film peeling means for peeling off the film on the surface of the mold. The apparatus for producing a surface structure film according to claim 1, wherein a heating means for heating the mold is provided between the coating unit and the first heating roller. The apparatus for producing a surface structure film according to claim 1 or 2, wherein a flattening means for flattening a material applied to the surface of the mold is provided between the coating unit and the pressurizing mechanism. The apparatus for manufacturing a surface structure film according to any one of claims 1 to 3, wherein a mechanism capable of pressing the first heating roller is provided on an outer circumferential surface of the first heating roller. The apparatus for producing a surface structural film according to any one of claims 1 to 4, wherein the annular ribbon-shaped molding resin. The apparatus for manufacturing a surface structural film according to any one of claims 1 to 5, There is provided a transfer unit for transferring a layer of a thermosetting material to a surface on the opposite side of the surface of the film having the surface structure. A method for producing a surface structure film, which is characterized by comprising at least the following steps: (1) winding a ring-shaped mold having a surface structure to at least 2 heated One or more heating rolls are used to apply a thermosetting material to the surface of the mold while the mold is being conveyed while heating the mold, and (2) applying a thermosetting material to the surface of the mold a step of laminating a film from the side of the thermosetting material; (3) a step of pressurizing the film, the thermosetting material, and the mold layer by a nip roll; (4) a step of transporting the film after pressing the film, the thermosetting material, and the mold layer while heating, and (5) peeling off the surface of the film and the thermosetting material from the mold The step of constructing the film. The method of producing a surface structure film according to claim 7, wherein after the step of applying the thermosetting material to the surface of the mold, the mold is heated before the step of bonding the film from the side of the thermosetting material. The method for producing a surface structure film according to claim 7 or 8, wherein after the step of pressurizing the film with the film, the thermosetting material, and the mold layer, the mold roll is used The heating roller is pressed from the film side in a state of being wound around the heating roller. Method for producing surface structure film according to any one of claims 7 to 9 After the step of applying the thermosetting material to the surface of the mold, the coated surface of the thermosetting material is planarized before the step of bonding the film from the side of the thermosetting material. The method of producing a surface structural film according to any one of claims 7 to 10, wherein the endless belt-shaped molding resin. A method of producing a surface-constituting film according to claim 11, wherein the endless belt-shaped mold comprises a thermoplastic film produced by a method of pressing a mold on a surface of the thermoplastic film to form a shape. A method of producing a surface structural film according to claim 11 or 12, wherein the temperature of the heating roller during heating is lower than the glass transition temperature of the mold by 20 degrees or more. The method for producing a surface structure film according to any one of claims 7 to 13, further comprising: a surface on a side opposite to a surface structure on which the surface structure film is formed during the winding conveyance of the mold, the transfer heat A transfer unit for a layer of a hardenable material.