TW201940307A - Method for producing a shaped sheet - Google Patents

Abstract

According to one embodiment of the present invention, there is provided a method for manufacturing a shaped sheet, the method having: a step for using a sheet-form material including a support and a resin layer, and using the same mold to shape a relief pattern on the resin layer and position information for the purpose of cutting; and a step for detecting the position information and performing cutting. In detection of the position information, a material for which L* in the CIE-Lab color system is less than 28 is used as an underlay during cutting of the sheet-form material that was shaped through the shaping step.

Description

Manufacturing method of shaped sheet

The present disclosure relates to a method for manufacturing a shaped sheet.

In the production of shaped patterns such as a microlens array (MLA), in order to improve productivity, a roll-to-roll method is sometimes used.
When the above pattern is produced by a roll-to-roll method, the sheet rolled out from the roll is given an uneven shape, and then the sheet is cut (punched) to obtain a part having a specific size having the above pattern.
As a method of manufacturing a known pattern, for example, there are those described in Japanese Patent Application Laid-Open No. 2017-149033 or Japanese Patent Application Laid-Open No. 2012-203244.

Japanese Patent Application Laid-Open No. 2017-149033 describes a method for manufacturing a stencil, which includes a stencil manufacturing process and peeling off an ultraviolet curable resin hardened on a surface pattern layer of a master from the master to form a stencil. A stencil of a reverse surface pattern layer corresponding to the surface pattern layer of the master plate; and a shape modification process, which uses the warm wind to heat the reverse surface pattern layer formed on the stencil plate to The shape-repairing process of reversing the shape of the surface pattern layer generated during release is performed.

Japanese Unexamined Patent Publication No. 2012-203244 describes a concave-convex sheet characterized in that a concave-convex pattern is formed on the surface of a band-shaped sheet, At least both end portions in the width direction are formed by forming a high convex strip portion higher than the convex portion of the uneven pattern along the longitudinal direction of the sheet.

During the punching process in the conventional roll-to-roll method, the position information is printed separately from the forming, and the positioning of the punching process is performed by reading the position information. However, depending on these aspects, the punching position may be shifted due to the shift of the printing position.
In addition, in the conventional technology, it is also described that the position information is formed by shaping (Japanese Patent Application Laid-Open No. 2017-149033 and Japanese Patent Application Laid-Open No. 2012-203244). In these aspects, the location information The contrast is low, and it is difficult to detect the position information. As a result, the punching accuracy is reduced, and the punching position may sometimes be shifted on the obtained shaped sheet.

The problem to be solved by the embodiments of the present invention is to provide a method for manufacturing a shaped sheet having high punching accuracy and suppressed displacement of the punching position on the obtained shaped sheet.

The following solutions are included in the solutions for solving the above problems.
<1> A method for producing a shaped sheet, comprising: using a sheet-like material having a support and a resin layer; forming the concave-convex shape of the resin layer using the same mold; and forming the position information for cutting. The process of cutting; and the process of cutting by detecting the above position information,
In the detection of the above-mentioned position information, as a cushion material when cutting the sheet-like material that is shaped by the above-mentioned forming process, a component with an L ^{* of} less than 28 in the CIE-Lab color system is used.
<2> The method for manufacturing a shaped sheet according to the above <1>, wherein the position information is a positioning mark.
<3> The method for manufacturing a shaped sheet according to the above <1> or <2>, wherein the position information is a boundary portion between a formation range and an unformed range of the uneven shape on the resin layer.
<4> The method for producing a shaped sheet according to any one of <1> to <3>, wherein the mat is a black member.
<5> The method for producing a shaped sheet according to any one of <1> to <4>, wherein the uneven shape is a lens shape.
<6> The manufacturing method of the shaped sheet as described in said <5> whose maximum value of the lens pitch of the said lens shape is 200 micrometers or less.
<7> The method for producing a shaped sheet according to any one of <1> to <6>, wherein the support has a light transmittance of 85% or more at a wavelength of 400 nm to 700 nm.
<8> The method for manufacturing a shaped sheet according to any one of <1> to <7>, wherein after detecting the position information, the position information is used to correct the posture of the sheet-like material or the position of the sheet-like material. At least one of the rotation angles of the area to be cut in the cutting process.
[Inventive effect]

According to an embodiment of the present invention, there is provided a method for manufacturing a shaped sheet having high punching accuracy and suppressed displacement of the punching position on the obtained shaped sheet.

Hereinafter, the contents of this disclosure will be described in detail. The constituent elements described below may be described based on the representative embodiments of the present disclosure, but the present disclosure is not limited to these embodiments.
In addition, in this specification, "~" is shown as a numerical range, and the numerical value described before and after is used as a meaning which includes a lower limit and an upper limit.
In addition, the term "process" in this specification includes not only an independent process, but even if it cannot be clearly distinguished from other processes, as long as the purpose required for the process is achieved, this term is also included. In addition, in this disclosure, "mass%" has the same meaning as "weight%", and "mass parts" has the same meaning as "weight parts".
Moreover, in the present disclosure, a combination of two or more preferred aspects is a better aspect.
Hereinafter, the present disclosure will be described in detail.

(Manufacturing method of shaped sheet)
The method for manufacturing a shaped sheet according to the present disclosure includes: using a sheet-like material having a support body and a resin layer, using the same mold to form the concave-convex shape of the above-mentioned resin layer and the forming process of cutting position information; And the process of cutting by detecting the position information, and in the detection of the position information, the CIE-Lab color is used as a cushion material when cutting the sheet-like material that is shaped by the forming process. Parts with L ^* less than 28 in the system.

As a result of intensive research conducted by the present inventors, it is found that, according to the manufacturing method of the present disclosure, the punching accuracy of the obtained part is high and the displacement of the punching position on the obtained shaped sheet is suppressed.
Specifically, it is considered that by performing the shaping of the uneven shape and the position information for cutting using the same mold, it is considered that the positional position and the position of the uneven shape are prevented from shifting.
It is considered that in the detection of the position information, as a cushion material when the sheet-like material that is shaped by the forming process is cut, a component with an L ^{* of} less than 28 in the CIE-Lab color system is used. Therefore, the contrast of the position information is increased, and the readability according to the punching machine is excellent, so the punching accuracy of the obtained part is high and the shift of the punching position on the obtained shaped sheet is suppressed.
Hereinafter, details of each constituent element in the manufacturing method of the present disclosure will be described.

＜ Shaping process ＞
The manufacturing method of the shaped sheet of the present disclosure includes a manufacturing process of forming a concave-convex shape of the above-mentioned resin layer and a position information for cutting by using the same mold using a sheet-like material having a support and a resin layer. Shape process).

[Forming method]
The forming method used in the forming process in the present disclosure is not particularly limited as long as it is a method of providing a concave-convex shape by pressing a mold on a resin layer, and a known forming method can be used.
For example, a method of inserting a sheet-like material between an embossing roll (roller die) and a roll on which a mold is formed to impart a concave-convex shape to a resin layer can be mentioned.
In this case, the shape of the mold having the uneven shape and the position information on the embossing roll, or the mold having the uneven shape may be mentioned, and the shape of the uneven shape itself is detected as the position information in the cutting process described later. kind.

Specifically, for example, an inverse shape using a concave-convex shape such as a lens shape on the surface and an inverse shape according to the required position information are used. The embossing roller of the embossing roller has a support body and a resin layer between the embossing roller and the nip roller.
By the nip, the reversed shape of the uneven shape formed on the surface of the embossing roller and the positional information according to need are transferred to the surface of the resin layer.
After the transfer, the resin layer is cured by ultraviolet curing, thermal curing, or the like, and the resin layer and the support are peeled off from the embossing roller, thereby shaping the sheet-like material. The hardening method may be selected according to the composition of the resin layer.

-2P method-
The hardening of the resin layer can be performed by a 2P method.
The 2P method is a method of applying a curable resin as a resin layer to a support, winding it around a roll formed with a mold, and curing the resin layer by irradiating ultraviolet (UV) light or the like while being wound, to form After the reversed shape of the concave-convex pattern of the mold roll is transferred to the resin layer in the sheet-like material, the transferred sheet-like material is peeled from the mold roll, and the peeled strip-shaped uneven sheet is rolled by a roll The take-up device is wound in a roll shape.

-Shaping position-
When the convex-convex shape provided is a lens shape described later, as for the above-mentioned shape, as shown in FIG. 1 described later, the arrangement direction of the lenses in the concave-convex shape may be a direction that is not parallel to or orthogonal to the conveyance direction of the sheet-like material For forming, as shown in FIG. 3 described later, the arrangement direction of the lenses in the concave-convex shape may be set to be a direction orthogonal to the conveying direction of the sheet-like material, and the arrangement of the lenses in the concave-convex shape may be performed. The direction is shaped to be parallel to the conveyance direction of the sheet-like material.
In the present disclosure, the arrangement direction of lenses refers to the direction of a straight line connecting the vertices of each lens in such a way that the density of the lenses contained in the straight line becomes the largest in the microlens array, and in cylindrical lenses, it means The plane included in the apex of each cylindrical lens is a direction orthogonal to the longitudinal direction of each cylindrical lens.

[Uneven shape]
The shape of the unevenness provided is preferably a fine shape. For example, in the case of a concave-convex shape in which recesses are continuous with respect to a reference surface, the maximum value of the interval between adjacent recesses and depressions is preferably 300 μm or less. For example, the reference surface When the concave and convex shapes of the concave portion and the convex portion are alternately repeated, the maximum value of the interval between adjacent concave and convex portions is more preferably 300 μm or less.
The shape of the unevenness to be imparted is not particularly limited, and a lens shape is preferred.
Examples of the lens shape include a hemispherical lens shape (micro lens), a semi-cylindrical lens shape (cylindrical lens), and the like.
In addition, as the formed concave-convex shape, a shape in which the above microlenses or cylindrical lenses are continuously arranged is preferable, and a microlens array is more preferable.
The arrangement in the microlens array is not particularly limited, and it can be arranged in a square lattice or a honeycomb structure.

When the uneven shape is a lens shape, the maximum value of the lens pitch is preferably 200 μm or less, and more preferably 160 μm or less.
The minimum value of the lens pitch is not particularly limited, but is preferably 5 μm or more.
In the present disclosure, the lens pitch indicates the distance between the vertices of the lens shape from each other.
When the lens pitch is small as described above, the accuracy of position alignment during punching processing becomes important. In the manufacturing method of the shaped sheet of the present disclosure, the punching accuracy of the obtained shaped sheet is high and the displacement of the punching position on the obtained shaped sheet is suppressed, so it is suitable for such lenses Production of lenticular uneven shapes with small pitch.

[Location Information]
As the position information, a positioning mark formed by using the same mold as the above-mentioned forming of the uneven shape may be used, and a part of the uneven shape may be used as the position information. It is preferable that a boundary portion of the range is used as position information.

-Location markers-
The positioning mark is not particularly limited, and a convex ○ type (cylindrical convex shape), a convex ● type (cylindrical convex shape), a convex triangular shape (triangular columnar convex shape), and a convex cross shape are used for the sheet-like material. And so on.
When forming by the embossing roller, the positioning marks are formed on the embossing roller, and thus a concave ○ type (hollow cylindrical concave), a concave ● type (hollow cylindrical concave), and a concave △ are formed. (Hollow triangular column-shaped concave), concave cross-shaped mold.
The size, shape, etc. of the positioning marks are not particularly limited, and can be changed according to the device used.
It is preferable that the positioning mark is formed at a position where no uneven shape is formed.
From the viewpoint of detection, it is preferable that the size of the positioning mark (the diameter of the circle circumscribed with the positioning mark) is 5 mm or less. The lower limit of the size of the positioning mark is not particularly limited, but from the viewpoint of detection, it is preferably 0.1 mm or more.
These positioning marks may be used alone or in combination of two or more.
For example, as shown in FIG. 1 which will be described later, a case where a convex ○ type positioning mark and a convex cross type positioning mark are used in combination is exemplified.

-Boundary part-
In addition, when the boundary portion between the formation range and the non-formation range of the uneven shape is used as the position information, the shape of the boundary portion is not particularly limited as long as it is a detectable shape. (For example, the four corners described by the arrow L in FIG. 2 described later) and the like.

[Sheet-like material]
The sheet-like material used in the present disclosure includes a support and a resin layer.

-Support body-
As the support, a sheet-shaped or film-shaped support is preferred.
Moreover, as a support body, a resin base material is mentioned preferably from a viewpoint of high temperature elongation.
Examples of the resin substrate include polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), and acrylonitrile-benzene Polyester resins such as ethylene copolymer resin (AS resin), polypropylene resin, polyethylene resin, polyethylene terephthalate resin (PET), ethylene glycol modified polyethylene terephthalate resin (PETG), Polyvinyl chloride resin (PVC), thermoplastic elastomers or copolymers thereof, cycloolefin polymers, etc.
Considering the ease of melt extrusion, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), and polyethylene are used. Resins, polyethylene terephthalate resins, ethylene glycol modified polyethylene terephthalate resins, and other resins having low melt viscosity are preferred, and polyethylene terephthalate resins are more preferred.
From the standpoint of transparency and heat resistance, polyethylene terephthalate resin, ethylene glycol modified polyethylene terephthalate resin, or cycloolefin resin is preferred, and polyethylene terephthalate resin For the better.
The support is preferably a stretched resin substrate from the viewpoints of smoothness and thickness uniformity, and more preferably a uniaxially or biaxially stretched resin substrate.
The thickness of the support is not particularly limited, but a range of 50 μm or more and 300 μm or less is preferable, and a range of 50 μm or more and 200 μm or less is more preferable from the viewpoint of uniform molding (forming) at a high temperature. If it is in the said range, a resin base material will not crack easily, it will not crack easily during the processing at the time of a shaping process (for example, during conveyance), and it will not crack easily at the time of three-dimensional molding.

In addition, a lens shape is formed as the concave-convex shape, and from the viewpoint of using the obtained shaped sheet as a microlens array, it is preferable that the support has transmittance to visible light, and the support transmits light at a wavelength of 400 nm to 700 nm. The ratio is preferably 85% or more. The upper limit of the light transmittance is not particularly limited, but may be 100% or less.
The light transmittance is measured by the method described in the examples.

As the resin substrate, commercially available products can be used. For example, an acrylic resin film (Akuripuren HBS010P, thickness: 125 μm) made by MITSUBISHI RAYON CO., LTD., And polyethylene terephthalate made by TORAY INDUSTRIES, INC. Can be used. A resin film (Lumirror S10, thickness: 100 μm), a cycloolefin polymer film (product name ARTON) manufactured by JSR Corporation, a polycarbonate resin film (Iupilon H-3000, thickness 125 μm) manufactured by Teijin Chemicals Ltd., and the like.

-Resin layer-
The resin layer is not particularly limited as long as it is a resin-containing layer. A curable resin layer is preferred, and a photo-curable (eg, UV-curable) or thermosetting resin layer is more preferred. From the viewpoint of performance, a photocurable resin layer is more preferable.
As a resin for forming such a curable resin layer, a polyurethane resin, a polyester acrylate resin, an epoxy acrylate resin, a polyether acrylate resin, an acrylic acrylate resin, and a polythiol resin can be used. , UV curing resins such as butadiene acrylate resins.
Examples of the thermosetting resin include ethylene glycol modified polyethylene terephthalate resin (PETG).
As a sheet-like material having a non-curable resin, a sheet-like material described in International Publication No. 2016/114367 and the like can be used.

The resin layer may further include known other components such as a release agent, a polymerization inhibitor, a hardening accelerator, and a stabilizer in the method for producing a shaped sheet.

The thickness of the resin layer may be appropriately changed depending on the formed uneven shape, and 2 μm to 130 μm is more preferable, and 2 μm to 100 μm is more preferable.

＜ Cutting process ＞
The manufacturing method of the shaped sheet of this disclosure has a process (cutting process) which detects the said position information, and performs cutting.
The cutting in the cutting process is also called "punching processing".
Hereinafter, the details of the cutting process will be described using FIG. 1.

[A sheet-like material given a lens shape]
FIG. 1 is a schematic view of a sheet-like material provided with a lens shape as a concave-convex shape used in the method for manufacturing a shaped sheet of the present disclosure.
In FIG. 1, in the forming process described above, a sheet-like material 10 is provided with a concave-convex shape (a lens shape arranged in a honeycomb structure) 12, a convex circular positioning mark 22, and a convex cross-shaped positioning mark 24.
In FIG. 1, an arrow A indicates a conveying direction of the sheet-like material 10. In the sheet-like material 10, a plurality of uneven shapes 12 and positioning marks 22 and 24 are formed along the conveying direction.
In FIG. 1, the conveyance direction A and the arrangement direction in the uneven shape 12 are described as different angles.

In FIG. 1, an area 16 indicated by a dotted line indicates a product effective area, and an area 14 indicated by a solid line indicates a product size. In the cutting process in the present disclosure, it is necessary to punch a sheet-like material 10 representing the size of the area 14 of the product size in the concave-convex shape 12 inside the product effective area, that is, the area 16.
The region 14 representing the product size in FIG. 1 is described as the center of the region 14 and the center of the product effective region 16 overlap. The one-dot chain line in FIG. 1 indicates the centers of the regions 14 and 16. The position of the area 14 described in FIG. 1 is the position of the optimal punching area for punching the product sheet.
If the punched area includes the product effective area, that is, the area not included in the area 16, it will become a defective product. Therefore, in the manufacturing of the shaped sheet, it is very important to determine the position during cutting.
In the cutting process in the present disclosure, when the sheet-like material shown in FIG. 1 is used in the cutting process, the positioning marks 22 and 24 are detected as position information, and the cutting position is determined.
In the forming process in the present disclosure, the positioning marks 22 and 24 are formed by the same mold as the uneven shape 12, so the positional deviation between the uneven shape 12 and the positioning marks 22 and 24 is suppressed. Therefore, if the positioning information is determined by using the positioning marks 22 and 24 in the cutting process, it is easy to punch out a size equivalent to the area 14 in a manner included in the area 16. That is, it is considered that the punching accuracy of the manufacturing method of the shaped sheet of the present disclosure is high and the displacement of the punching position on the obtained shaped sheet is suppressed.

The positional relationship between the above-mentioned uneven shape 12, the positioning marks 22 and 24, the region 14, and the region 16 will be further described with reference to FIG. 2.
FIG. 2 is an enlarged view of a region in which the uneven shape 12 in the sheet-like material 10 described in FIG. 1 is formed.
In FIG. 2, the position of the region 14 indicating the product size is described at a position where the center of the region 14 coincides with the center of the product effective region 16.
In FIG. 2, the positioning marks 22 of the convex circle shape and the positioning marks 24 of the convex cross shape are respectively from the corner of the above-mentioned region 14 in FIG. 2 to the short-side direction L1 = 7.5 mm and to the long-side direction L2 = 10mm position.

In the cutting process, the CCD (Charge Coupled Device) camera and other detection methods are used to detect the position information such as the positioning marks, and the punching position is determined after the punching position is determined.
In addition, a mat material is used for cutting. As the above-mentioned mat material, a component whose L ^* in the CIE (International Illumination Commission) -Lab color system is less than 28 is used to improve the detection sensitivity at the time of detection. The punching accuracy of the material is high, and it is easy to suppress the displacement of the punching position in the obtained shaped sheet.

〔Padding material〕
The cushion material is a component in the CIE-Lab color system where L ^{* is} less than 28, L ^* is preferably less than 24, and less than 20 is more preferable. In addition, the lower limit of L ^* in the CIE-Lab color measurement system is 0.
The L ^* was measured using SM-T-H1 manufactured by Suga Test Instruments Co., Ltd.
Examples of the mat member include a black member and a dark blue member. A black member is preferred.
The material of the mat is not particularly limited, and members having a certain degree of elasticity are used, and examples include PET, PETG, acrylic resin, silicone resin, polycarbonate resin, polystyrene resin, MS resin, AS Resin, polyolefin resin, PVC, etc.
As the mat material, for example, in a punching process, a person who colors a known mat material can be used.

[Another aspect of the shaped sheet material]
FIG. 3 is a schematic view showing another aspect of a sheet-like material shaped into a lens shape as a concave-convex shape used in the manufacturing method of the shaped sheet of the present disclosure.
FIG. 3 shows a case where a concave-convex shape 12 is formed in the sheet-like material 10 and is punched out in a region 14 indicating a product size.
In FIG. 3, the description of the positioning marks 22 and 24 and the product effective area 16 is omitted.
In FIG. 3, the arrangement direction of the microlens array in the concave-convex shape 12 is orthogonal to the conveyance direction A, and it is described that the area 14 that is punched out, that is, the area 14 has an angle with respect to the conveyance direction A.

[Cut method]
The cutting method in the forming process is not particularly limited, and a known method can be used.
The punching machine equipped with a CCD camera with punching posture correction function can use a universal machine sold by several punching machine manufacturers. For example, an image positioning press "IPA series" (manufactured by Fujishoko Machinery Co ,. Ltd.) with a CCD camera, a coil positioning die cutting machine "SCP250E-APS series" (manufactured by SAKAMOTO ZOKI CO., LTD), a roll Material die cutting machine "T261 Series" (manufactured by Yamaha Fine Technologies Co., Ltd.), etc.

In the cutting process in the present disclosure, from the viewpoints of suppressing the displacement of the punching position in the obtained shaped sheet and the viewpoint of productivity, after detecting the position information, the position information is used for the sheet. It is preferable to correct at least one of the posture of the shaped material or the rotation angle of the area to be cut in the cutting process.
The correction is performed by a punching posture correction function or the like of the punching machine.
The detection of the position information is performed by, for example, a CCD camera mounted on a punching machine.
The posture of the sheet-like material indicates a conveying direction and / or an orthogonal direction of the sheet-like material.
For example, in the cutting process of the sheet-like material described in FIG. 1 described above, the angle of the area to be cut is fixed, the posture of the sheet-like material being conveyed is corrected, and the angle of the area 14 indicating the product size can be made (The rotation angle of the punched area) matches the angle of the product effective area 16 on the sheet-like material.
In the cutting process of cutting the sheet-like material described in FIG. 3 described above, the conveying direction of the sheet is fixed, and the rotation angle of the area to be cut is corrected, so that the angle of the area to be cut and the sheet can be adjusted. The angle of the product's active area on the material is matched.
Furthermore, in the cutting process for cutting the sheet-like material described in FIG. 1 or FIG. 3 described above, both the posture of the sheet and the rotation angle of the area to be cut can be corrected.

＜ Roll-up process, roll-out process ＞
When the manufacturing method of the shaped sheet of the present disclosure is implemented by the roll-to-roll method, it is preferable to include a winding process for winding the sheet-like material or a rolling-out process for unwinding the sheet-like material.
The winding process and the unwinding process can be arbitrarily included before or after each process, for example, they can be performed in the order described in Method A below.
(Method A)
(1) a process of rolling out the sheet-like material using a roll-like sheet-like material (2) a process of providing a concave-convex shape to the rolled-up sheet-like material (the forming process described above)
(3) the process of winding the sheet-like material to which the uneven shape is given (4) the process of rolling out the rolled-up sheet material (5) the process of cutting the rolled-up sheet-like material (the above Cutting process)
In the above method A, the winding process and the unwinding process described in (3) and (4) may be omitted, and the forming process and the cutting process may be continuously performed while being conveyed.

＜ Other processes ＞
The manufacturing method of the shaped sheet of the present disclosure may further include other processes.
Other processes include, for example, a process for forming a protective film on a shaped sheet, and when a shaped sheet is used as a grating sheet, it is formed on a surface opposite to the lens forming surface of the shaped sheet. Process of printing ink receiving layer, etc.
[Example]

Hereinafter, the present disclosure will be described in detail through examples, but the present disclosure is not limited to these. In addition, in this embodiment, unless otherwise stated, "%" and "part" represent "mass%" and "mass part", respectively.

(Example 1)
＜ Production of forming sheet (forming process) ＞
A 2P method was used to form a shaped sheet on a roll-to-roll basis.
A roll mold having a pattern in which a microlens array (MLA) having a lens pitch of 20 μm arranged in a honeycomb structure (lens pitch of 20 μm) and a positioning mark having a concave circle shape was prepared on the surface.
The positioning marks exist in the area where the microlens array pattern is not formed, and are set to be 7.5 mm from the short side and 10 mm from the long side of the corner of the area to be punched as a product sheet (see Fig. 2). A total of four positioning marks 22 and 24 are shown).
A PET film (COSMOSHINE A4300, manufactured by TOYOBO CO., LTD., With a light transmittance of 95%) having a thickness of 50 μm, a width of 350 mm, and a length of 300 m was used as a support, and an ultraviolet curable resin (Aica Kogyo Co. ., Ltd., Z-977-7L, UV-curable resin A), press the roll mold to transfer the reversed pattern of the pattern, and after curing by irradiating ultraviolet rays, the cured sheet is peeled from the roll mold状 材料。 Like material. In addition, the sheet-like material provided with the positioning mark and the microlens array pattern on the PET film is wound in a roll shape by a winding device.
The shape of the positioning mark formed on the roll die is the above-mentioned concave ○ type. Therefore, the shape of the positioning mark formed on the sheet-like material is a cylindrical shape (convex ○) with a diameter of 3 mm on the bottom surface.
Table 1 shows the light transmittance of the support, that is, the PET film at a wavelength of 400 nm to 700 nm.
The light transmittance was measured by a device in which an integrating sphere assist device ARV-474 was mounted on a spectrophotometer V-560 (manufactured by JASCO Corporation).

＜ Punching of cutting sheet (cutting process) ＞
In the sheet continuous punching machine, the mat is set to a black polyethylene terephthalate (PET) substrate, and the position is detected by the CCD camera through the position information, that is, the positioning mark. The sheet-like material obtained in the manufacturing process is punched.
The PET substrate used for the mat of the punching machine was Lumirror (manufactured by TORAY INDUSTRIES, INC., H10 # 500, haze (milky white with high turbidity, L ^* = 55)). The position information, that is, the positioning mark detection, is detected by a CCD camera assembled into the punching machine, and it is distinguished. Therefore, it is important to ensure the visibility. However, the shaped part of the shaped sheet is low in haze (close to white), so it is not easy. Identify the shaped positioning marks.
Therefore, in order to improve the visibility of the CCD camera, black Lumirror (manufactured by TORAY INDUSTRIES, INC., X30 # 250, L ^* = 12) is used as a mat, thereby making it possible to make the substrate portion (transparent) and The shading difference of the shaped part (low haze) becomes larger, and detection stability is improved.
The CCD camera equipped with a punching posture correction function uses a coil positioning die cutter "SCP250E-APS Series" (manufactured by SAKAMOTO ZOKI CO., LTD).

(Example 2)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the positioning mark in the roll die was set to a concave ten. The shape of the positioning mark formed on the sheet-like material is a 2.5 mm square convex cross shape (convex +).

(Example 3)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the positioning mark in the roll mold was set to a concave shape. The shape of the positioning mark formed on the sheet-like material is a cylindrical shape (convex) having a diameter of 3.0 mm.

(Example 4)
A shaped sheet was produced in the same manner as in Example 1 except that the positioning mark in the roll die was a concave Δ shape, and punched out. The shape of the positioning mark formed on the sheet-like material is a triangular column shape (convex Δ) with 3.0 mm on one side.

(Example 5)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the position information was a boundary portion (a fine-shaped pattern of MLA) of the formation range and the non-formation range of the microlens array pattern. As the boundary portion, four corners of the pattern are used (four places indicated by the arrow L in FIG. 2).

(Example 6)
Except for using the function of correcting the posture of the sheet-like material during punching and the rotation angle of the area to be cut during the cutting process, a shaped sheet was produced and punched in the same manner as in Example 1. Cut.

(Example 7)
A shaped sheet was produced in the same manner as in Example 1 except that the thickness of the PET film (COSMOSHINE A4300 manufactured by TOYOBO CO., LTD.) Of the support was 100 μm, and punching was performed.

(Example 8)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the material of the support was a COP film (ARTON manufactured by JSR Corporation).

(Example 9)
A shaped sheet was produced in the same manner as in Example 1 except that the ultraviolet curable resin was changed to a resin having a high hardness (manufactured by Aica Kogyo Co., Ltd., Z-977-8L, UV curable resin B), and Punching.

(Example 10)
A shaped sheet was produced in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was 2 μm, and punched out.

(Example 11)
A shaped sheet was produced in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was 5 μm, and punched out.

(Example 12)
A shaped sheet was produced in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was 8 μm, and punched out.

(Example 13)
A shaped sheet was produced in the same manner as in Example 1 except that the lens pitch of the microlens array was set to 40 μm, and punched out.

(Example 14)
A shaped sheet was produced in the same manner as in Example 1 except that the lens pitch of the microlens array was 100 μm, and punched out.

(Example 15)
A shaped sheet was produced in the same manner as in Example 1 except that the lens pitch of the microlens array was 200 μm, and punched out.

(Example 16)
Set the pattern as a lenticular lens with a pitch of 127 μm (200 LPI, LPI is the number of cylindrical lenses per inch, and 2.54 cm per inch), and transmit and transfer the axial direction of a semi-cylinder of each cylindrical lens. Except that the directions were formed in parallel directions, a shaped sheet was produced in the same manner as in Example 1 and punched out.

(Example 17)
Except that the ultraviolet curable resin forming the resin layer was changed to a thermosetting resin (ethylene glycol modified polyethylene terephthalate PETG, thermosetting resin C), a shaped sheet was produced in the same manner as in Example 1. Material and punched.

(Example 18)
In the sheet continuous punching machine, a shaped sheet was produced in the same manner as in Example 1 except that the mat was changed to a dark blue polyethylene terephthalate (PET) substrate (L ^* = 22). And punched out.

(Comparative Example 1)
The forming sheet is punched out in a sheet continuous punching machine without providing position information such as the boundary between the formation range and the unformed range of the positioning mark and pattern. The mat material was a milky white PET substrate (L ^* = 55).

(Comparative Example 2)
A mold having a pattern in which a microlens array having a lens pitch of 20 μm arranged in a honeycomb structure was prepared on the surface was prepared. A 50 μm-thick PET film (COSMOSHINE A4300, manufactured by TOYOBO CO., LTD.) Was used as a support, and an ultraviolet curable resin (Aica Kogyo Co., Ltd., Z-977- 7L) After pressing the mold, it is irradiated with ultraviolet rays to harden it.
The hardened resin was peeled from the mold, and the microlens array pattern was shaped on the PET film. An inkjet printer was used to print a positioning mark at a position of 7.5 mm from the corner of the product sheet in the short side direction and 10 mm from the long side direction.
In the sheet continuous punching machine, the mat was set to a milky white PET substrate (L ^* = 55), and the shaped sheet was punched while detecting the position with a CCD camera.

(Comparative Example 3)
In the sheet continuous punching machine, the shaped sheet produced in the same manner as in Example 1 was used, and the mat was set as a milky white PET substrate (L ^* = 55), and the position information, that is, the positioning mark was detected using a CCD camera One side punched the shaped sheet.

(Evaluation)
<Evaluation of shift of punching position>
According to the arrangement direction of the pattern, that is, the angle difference between the center line of each lens and the long side of the punched sheet, the punched position in the method for manufacturing the shaped sheet of each embodiment or comparative example The offset was evaluated. About the center line of each lens, the micro lens array indicates the smaller one of the two straight lines drawn so as to pass through the center of the lens, and the smaller angle with the long side.
Details of the evaluation method are shown in FIG. 4.
The figure on the left in FIG. 4 shows the sheet-like material before punching, and θ1 represents the angle between the long side of the punching position as the target and the center line of each lens.
The figure on the right in FIG. 4 shows the shaped sheet after punching, and θ2 represents the angle between the long side of the punched sheet and the center line of each lens.
The absolute value (| θ1-θ2 |) of the difference between the θ1 and the θ2 was set as an evaluation index, and the evaluation results are described in Table 1 according to the following evaluation criteria. As a result of the evaluation, AA, A, B or C is preferred, AA, A or B is more preferred, and AA or A is further preferred.
For the evaluation, a digital microscope VHX-500F (manufactured by Keyence Corporation) was used.

[Evaluation Criteria]
AA: | θ1-θ2 | is 0 ° or more and less than 0.2 °.
A: | θ1-θ2 | is 0.2 ° or more and less than 0.4 °.
B: | θ1-θ2 | is 0.4 ° or more and less than 0.6 °.
C: | θ1-θ2 | is 0.6 ° or more and less than 1.0 °.
D: | θ1-θ2 | is 1.0 ° or more and less than 1.2 °.
E: | θ1-θ2 | is 1.2 ° or more.

＜ Evaluation of abrasion resistance ＞
Regarding the surface of the punched shaped sheet in each example or comparative example, the surface hardness measuring machine "HEIDON TYPE14FW" (Shinto) was used in accordance with the pencil hardness evaluation method specified in JIS K 5600-5-4 (1999). Scientific Co., Ltd.) and pencil "Uni" (manufactured by Mitsubishi Pencil Co., Ltd.) were repeatedly scratched 10 times with a pencil of each hardness at a weight of 500 g, and the hardest one without scratches was found. Pencil level.
If the pencil hardness is evaluated as A or B, it is preferable to prevent scratches in the positioning marks due to friction with the mat material at the time of punching, and it is excellent in detection accuracy of the positioning marks.

[Evaluation Criteria]
A: The pencil hardness is F or more.
B: The pencil hardness is 2B or more and HB or less.
C: The pencil hardness is 3B or less.

[Table 1]

As shown in Table 1, the manufacturing method of the formed sheet of the present disclosure is excellent in suppressing the displacement of the punched position in the obtained formed sheet. Moreover, the manufacturing method of the shaped sheet of the said Example is also excellent in abrasion resistance and productivity.

Regarding the disclosure of Japanese Patent Application No. 2018-046461 filed on March 14, 2018, the entirety is incorporated herein by reference.
All the documents, patent applications, and technical specifications described in this specification are incorporated into this specification by reference to the same extent as the cases where each document, patent application, and technical specification is incorporated by reference, and each case is specifically entered.

10‧‧‧ Sheet material

12‧‧‧ Bump shape

14, 16‧‧‧ area

22, 24‧‧‧ positioning mark

A‧‧‧Transfer direction

L‧‧‧ Arrow

L1‧‧‧ Positioning marks 22, 24 from the corner of area 14 to the short side

L2‧‧‧ Positioning marks 22, 24 from the corner of the area 14 to the long side

θ1, θ2‧‧‧ angle

FIG. 1 is a schematic view of a sheet-like material that is given a lens shape as an uneven shape.

FIG. 2 is an enlarged view of a region where uneven shapes are formed in the sheet material shown in FIG. 1.

FIG. 3 is a schematic view showing another aspect of a sheet-like material that is given a lens shape as a concave-convex shape.

FIG. 4 is a schematic diagram showing a method for evaluating a displacement of a punching position in an example.

Claims (8)

A manufacturing method of a shaped sheet, comprising: using a sheet-like material having a support and a resin layer, using the same mold to form a concave-convex shape of the resin layer and a forming process of cutting position information; And the process of cutting by detecting the position information, and in the detection of the position information, as a cushion material when cutting the sheet-like material shaped by the forming process, the CIE-Lab color is used Parts with L ^* less than 28 in the system. The method for manufacturing a shaped sheet according to item 1 of the scope of patent application, wherein The location information is an anchor. The manufacturing method of the shaped sheet according to item 1 or 2 of the scope of patent application, wherein The position information is a boundary portion between the formation range and the non-formation range of the uneven shape on the resin layer. The manufacturing method of the shaped sheet as described in the first or second scope of the patent application, wherein The mat is a black part. The manufacturing method of the shaped sheet as described in the first or second scope of the patent application, wherein This uneven shape is a lens shape. The method for manufacturing a shaped sheet according to item 5 of the scope of patent application, wherein The maximum lens pitch of this lens shape is 200 μm or less. The manufacturing method of the shaped sheet as described in the first or second scope of the patent application, wherein The light transmittance of the support at a wavelength of 400 nm to 700 nm is 85% or more. The manufacturing method of the shaped sheet as described in the first or second scope of the patent application, wherein After detecting the position information, use the position information to correct at least one of a posture of the sheet-like material or a rotation angle of a region to be cut in the cutting process.