TWI396617B - Method for manufacturing a sheet having transferred minute shape and apparatus for manufacturing the same - Google Patents

Description

Preparation method and manufacturing device of fine shape transfer sheet

The present invention relates to a method and apparatus for producing a sheet having a fine three-dimensional shape on a surface thereof by transferring a fine shape.

In a method of forming a three-dimensional shape such as fine unevenness on a surface of a resin sheet or the like, there is known a method (Patent Document 1-2), in which a resin sheet or the like is heated by a heated mold having fine irregularities. A method of transferring a three-dimensional shape to the resin sheet.

However, in this method, when the fine shape is transferred and formed into a large-area resin sheet, since the air is bitten between the mold on the transfer surface and the sheet to be processed, the fine three-dimensional shape cannot be completely transferred, resulting in poor transfer. The problem.

This problem of biting air is generated when the thickness of the processed sheet-like substrate is uneven or the planarity of the pressure plate is uneven.

In order to solve such a problem, the above-mentioned Patent Document 2 proposes a method and apparatus for bending a transfer sheet so as to protrude toward a resin sheet when the pressure plate starts to abut, and then pressurizing in this state. The fine shape is transferred by removing air from the vicinity of the center of the shaping surface and continuing to contact the film with the pressure plate. Specifically, the bending is performed by spring members having different elasticity.

However, since the method bends the pressure plate by springs of different elasticity, even if it is flattened by pressurization by a press machine, a surface pressure distribution occurs on the shaping surface due to a high pressure of the protrusions. The transfer accuracy of the fine shape in the shaped surface is different, and as a result, uniform transfer accuracy is still not obtained. This situation is particularly remarkable when the surface shape is finer, and because the surface pressure distribution is different, it also affects the thickness of the obtained processed film, which is not preferable. Moreover, it is not practical to change the position of the spring member or its support each time, in order to change the amount of deformation.

[Patent Document 1] JP-A-H05-60920 [Patent Document 2] JP-A-2006-35573

In view of the above problems, an object of the present invention is to provide a method and a manufacturing apparatus for a fine-shaped transfer sheet which are produced by heating a sheet-like substrate and a mold having a fine uneven shape, and When the fine concavo-convex shape is formed on the surface of the sheet-like substrate by contact and pressurization, the transfer surface does not cause transfer failure due to air being bitten between the mold and the sheet-like substrate. On the other hand, it is possible to form a desired fine uneven shape on the surface.

In order to achieve the above object, the method for producing a fine-shaped transfer sheet of the present invention is constituted by the following (1).

(1) A method for producing a fine-shaped transfer sheet which heats a mold having a sheet-like base material and a fine uneven shape, and causes the fine uneven shape to be formed on the sheet-like base by contact and pressurization A method for producing a fine-shaped transfer sheet of a material surface, characterized in that the shaping surface is changed (by at least one of a pressure plate or a mold, or a combination thereof, by arranging the sheet-like substrate and the mold by pressing the sheet-like substrate and the mold The shape is formed by the planarity.

Moreover, the method for producing the fine-shaped transfer sheet of the present invention is more specifically preferably constituted by the following constitutions (2) or (3).

(2) The method for producing a fine-shaped transfer sheet according to (1) above, wherein when the shaping is changed by changing the planarity of the shaped surface, the pressing is started from a point in the shaping surface of the sheet-like substrate. And changing the planarity of the shaping surface to gradually reduce the pressing force to the peripheral portion of the sheet-like base material.

(3) The method for producing a fine-shaped transfer sheet according to the above (1) or (2), wherein, when the shape is changed by changing the planarity of the shaped surface, the planarity of the shaped surface is changed after the shaping starts. To make the pressing force in the shaping surface uniform.

Moreover, in order to achieve the above object, the method for producing another fine-shaped transfer sheet of the present invention is constituted by the following constitution (4).

(4) A method for producing a fine-shaped transfer sheet, which is obtained by heating a mold having a sheet-like base material and a fine uneven shape, and bringing the sheet-like base material into contact with both of the molds to pressurize the fine unevenness A method for producing a fine-shaped transfer sheet having a shape formed on a surface of a sheet-like substrate, characterized in that the temperature is adjusted so that the self-forming surface (pressurized by one of the sheets arranged by pressing the sheet-like substrate and the mold) At a point in at least one of the plate or the mold or a combination thereof, the temperature is gradually lowered toward the peripheral portion of the sheet-like substrate to form a shape.

Moreover, the method for producing the fine-shaped transfer sheet of the present invention is more preferably constituted by the following constitutions (5) or (6).

(5) The method for producing a fine-shaped transfer sheet according to the above (4), wherein the temperature is adjusted so that the planarity of the shaped surface is larger than a maximum value of a thickness distribution of the shaped surface of the sheet-like base material.

(6) The method for producing a fine-shaped transfer sheet according to the above (4) or (5), wherein, when the mold is in contact with the sheet-like substrate at the time of forming, a temperature of a point of the shaping surface is higher than The temperature of other parts of the shaped surface is higher, and the temperature difference becomes smaller after the start of shaping.

Moreover, in order to achieve the above object, the apparatus for a fine-shaped transfer sheet of the present invention has the following configuration (7).

(7) A manufacturing apparatus for a fine-shaped transfer sheet comprising a sheet-like base material, a mold having a fine uneven shape, and a fine shape transfer for heating and pressing the sheet-like base material and the mold The manufacturing apparatus of the sheet is characterized in that a temperature gradient of the mold and/or a pair of pressure plates is applied to the self-forming surface (by pressing one of the sheet-like substrate and the mold to pressurize the plate or the mold) At one point in at least one of them or a combination thereof, the temperature is gradually lowered toward the peripheral portion of the sheet-like substrate.

Moreover, it is preferable that the apparatus for producing a fine-shaped transfer sheet of the present invention is constituted by any one of the following (8) to (14).

(8) The apparatus for manufacturing a fine-shaped transfer sheet according to (7), wherein the mold is provided with a temperature adjustment means for providing a temperature gradient to the mold so as to extend from a point in the shaping surface of the mold to the periphery of the sheet-like substrate. Slowly lower the temperature.

(9) The apparatus for manufacturing a fine-shaped transfer sheet according to (7) or (8), wherein the power density of the heating source for heating the pressurizing plate or the mold is higher in the shaping surface than at other positions Structure.

(10) The apparatus for manufacturing a fine-grained transfer sheet according to any one of (7) to (9), wherein the electric heating heater is used as a heating means for heating the pressure plate or the mold, and is provided The density of the heater wiring in the pressurizing plate or the mold is higher at a point in the shaping surface than at other positions.

(11) The apparatus for manufacturing a fine-grained transfer sheet according to any one of (7) to (10), wherein the heat medium is used as a heating means for heating the pressure plate or the mold, and is provided in a pressurization The density of the heat medium flow path of the plate or mold is higher at a point in the shaping surface than at other positions.

(12) The apparatus for producing a fine-grained transfer sheet according to any one of (7) to (11), wherein the pressure plate or the mold is heated in a wide range of temperature in the shaping surface thereof. Two systems of means and independent heating means for raising the temperature at any point.

(13) The apparatus for manufacturing a fine-grained transfer sheet according to any one of (7) to (12), wherein the pressure plate or the mold is heated in a wide range of temperature in the shaping surface thereof. There are two types of means for the means and the independent cooling means for lowering the temperature of the peripheral portion of the shaped surface.

(14) The apparatus for producing a fine-shaped transfer sheet according to any one of (7) to (13), wherein a thickness measuring means for the sheet-like base material is provided, and a signal for transmitting the thickness measuring means is provided. The heating means and the means for transmitting the cooling means are controlled.

According to the method and device of the present invention, the mold and/or the pressure plate itself have the function of controlling the planarity (the flatness of the shaping surface), and the bending amount and the position characteristic can be operated according to the state of the mold, and the pressure is applied. After that, the air can be removed while moving to a uniform surface state.

Therefore, the pressure in the shaping surface is made uniform after the pressurization, and since the air can be removed, the air is not bitten, and a uniform and highly accurate transfer forming state can be obtained.

According to the method and apparatus for producing a fine-shaped transfer sheet of the present invention, a sheet having a fine shape transferred onto the surface can be favorably produced.

Hereinafter, the manufacturing method and manufacturing apparatus of the fine-shaped transfer sheet of the present invention will be described in more detail with reference to the drawings and the like.

In the method for producing a fine-shaped transfer sheet of the present invention, a mold having a sheet-like base material and a fine uneven shape is heated, and the fine uneven shape is formed on the surface of the sheet-like substrate by contact and pressurization. The method for producing a fine-shaped transfer sheet is characterized in that the shaping surface is changed (consisting of at least one of a pressure plate or a mold or a combination thereof by pressurizing the sheet-like substrate and the mold) Shaped and shaped.

Here, the "planarity of the shaped surface" means "the degree of planarity of the flat-shaped space formed by the gap between the pressure plate and the mold", and "changing the planarity" means changing the degree of planarity. Here, the planarity of the shaped surface is not limited to the combination of the pressure plate and the mold, and the same applies when the mold is used up and down, and in this case, when the pressure plate is used.

In the method of the present invention, when the planarity of the shaped surface is changed, the pressure is initially applied from a point in the shaping surface of the sheet-like substrate, and the planarity is changed to apply pressure to the peripheral portion of the sheet-like substrate. Slowly getting smaller. That is, the air is removed from the vicinity of the center of the shaping surface, and the pressing is continued. In particular, the initial pressing point does not have to be the central center portion of the shaping surface, or may be located at a point near the peripheral end of the shaping surface. . When the pressure is applied from a point near the peripheral end portion, the planarity is changed, and the pressing force is gradually reduced toward the peripheral end portion on the opposite side.

Here, "changing the planarity to gradually increase the pressing force" means that the pressure applied to each unit area of the shaped surface is gradually reduced.

When the planarity of the shaped surface is changed, the planarity of the shaped surface is changed after the shaping starts to make the pressing force in the shaped surface uniform. Here, "after the start of shaping" means that a point in the shaping surface of the sheet-like base material comes into contact with the mold and/or the pressure plate, and is pressurized from the first state, and then after the state is reached, Control makes the applied pressure uniform and effective.

The above-mentioned series of pressure control is performed by partially heating the pressure plate or the mold to cause partial thermal expansion deformation, and abutting against the mold of the sheet-like substrate, which can be initially tied at a certain point. The partial contact is performed in such a manner that the abutting portion expands toward the peripheral portion as the pressure is pressurized, and specifically, the specific method of the present invention described below is carried out.

In other words, the method for producing a fine-shaped transfer sheet of the present invention is specifically performed by heating a mold having a sheet-like base material and a fine uneven shape, and bringing the sheet-like base material into contact with both of the molds to pressurize the sheet. The method for producing the fine-shaped transfer sheet having the fine uneven shape formed on the surface of the sheet-like substrate, wherein the temperature is adjusted to a self-forming surface (by one of the methods of pressing the sheet-like substrate and the mold) A method in which the temperature is gradually lowered to the peripheral portion of the sheet-like base material at a point in at least one of the pressure plate or the mold or a combination thereof to form a shape.

In such a method, it is preferable to adjust the temperature so that the planarity of the shaping surface is larger than the maximum value of the thickness distribution of the shaping surface of the sheet-like substrate, and the "planarity ratio of the shaping surface" The maximum value of the thickness distribution of the shaping surface of the sheet-like base material is larger, which means that the numerical value of the degree of planarity is greater than the maximum value of the sheet thickness distribution.

Further, it is preferable that the temperature at one point of the shaping surface is higher than the temperature of the other portion at the time of contact between the mold and the sheet-like substrate at the time of forming, and the temperature difference is changed after the shaping starts.

The above specific method of the present invention can be carried out by the apparatus for producing a fine-shaped transfer sheet of the present invention described below.

That is, a manufacturing apparatus for a fine-shaped transfer sheet is provided with a sheet-like base material, a mold having a fine uneven shape, and a fine shape transfer for heating and pressing the sheet-like base material and the mold. The manufacturing apparatus of the sheet is characterized in that a temperature gradient of the mold and/or a pair of pressure plates is applied to the self-forming surface (by pressing one of the sheet-like substrate and the mold to pressurize the plate or the mold) A point in at least one of them or a combination thereof gradually decreases the temperature toward the peripheral portion of the sheet-like substrate.

Fig. 1 is a schematic front view showing an embodiment of a manufacturing apparatus for a fine-shaped transfer sheet of the present invention which is suitable for carrying out the method for producing a fine-shaped transfer sheet of the present invention. Fig. 2 is a schematic front view showing another embodiment of the apparatus for producing a fine-shaped transfer sheet of the present invention which is suitable for carrying out the method for producing a fine-shaped transfer sheet of the present invention.

In the first and second figures, a 1 type fine-shaped transfer sheet manufacturing apparatus, a 2-series press apparatus, a 3-series mold, a 4-series sheet-like base material, a 5-series temperature adjustment plate, and a 6-series lower temperature adjustment plate 7 series central heating heating medium flow path, 8 series heat medium circulation device, 9 series cooling water heat cycle device, and 10 series central heating heater, giving the mold and/or a pair of pressure plate temperature gradients A point in the shape of the surface gradually decreases the temperature in the peripheral portion of the sheet-like base material, and the pattern in the first embodiment is borrowed from the central heating heating medium passage 7 and the second embodiment. This is achieved by a specially provided central heating heater 10. Therefore, in the first and second aspects, the upper temperature adjustment plate 5 and the lower temperature adjustment plate 6 constitute the object of the pressure plate referred to in the first aspect of the patent application.

FIG. 3 is a schematic front view showing a state in which the manufacturing apparatus of the fine-shaped transfer sheet of the present invention is used as shown in FIG. 1 and the heating state of the central portion of the shaping surface is turned ON. The temperature adjustment plates 5 and 6 are in a state in which the central portion of the shaping surface is inflated and bulged.

Fig. 4 is a view schematically showing the use of the apparatus for manufacturing the fine-shaped transfer sheet of the present invention shown in Fig. 3, wherein the heating state of the central portion of the shaping surface is turned ON and pressurized (i.e., after the start of shaping) This is a schematic front view showing the state in which the shaping surface is uniformly heated and flattened.

Fig. 5 is a schematic front view showing an example of the relationship between the temperature distribution of the temperature adjustment plate and the amount of thermal expansion of the temperature adjustment plate, which is used in the apparatus for manufacturing the fine shape transfer sheet of the present invention, as exemplified in Fig. 1 . The state of the first embodiment to be described later is shown. As shown in the figure, by generating a temperature difference of 10 ° C (100 ° C ~ 10 ° C) at the end and the center of the temperature adjustment plate, the amount of expansion will produce a height difference of 15 μm in the vertical direction (175 to 190). Micrometer) gradient. By using this gradient difference, the entire shaping surface can be pressurized in such a manner that the air is not bitten, and when the whole is in a pressurized state, the central portion is additionally heated and turned off to eliminate the gradient difference.

Fig. 6 is a schematic plan view showing four examples of the state of the heating medium attached to the central portion of the temperature adjustment plate of the apparatus for manufacturing a fine-shaped transfer sheet of the present invention. In the same figure, (a) is the central heat medium piping (parallel) method, (b) is the central heat medium piping (straight line), (c) is the central heater buried and the heat medium piping method, and (d) is the heater. The embedding method, in each of (a) to (d), is a plan view on the left side and a side view on the right side.

The piping flow path or the heater for heating the heat medium is not necessarily required to be provided in the temperature adjustment plate, and the usual temperature adjustment plate may be used as it is, in particular, the piping flow path of the heat medium may be partially disposed inside the mold or The heater is also available. Fig. 7 is a schematic front view showing another example of the apparatus for manufacturing a fine-shaped transfer sheet of the present invention, which is a schematic view showing an example of a device in which a temperature adjustment system is incorporated in a mold. Fig. 8 is a schematic front view showing a state in which the manufacturing apparatus of the fine-shaped transfer sheet shown in Fig. 7 is used and the heating state of the central portion of the shaping surface is turned ON.

In the aspect of the apparatus shown in Fig. 9, a means for measuring the thickness of the sheet-like base material and a means for transmitting a signal from the thickness measuring means to control the heating means and the cooling means are provided, and the thickness of the 21-seed sheet is measured. The sensor, the 22-series sheet conveying roller, and the 23-series signal calculator are configured to measure the thickness of the sheet-like base material before the start of the shaping press by the sheet thickness measuring sensor, and the processing is performed based on the measurement result. The batch performs temperature control, planar control, and the like.

That is, in the apparatus of the present invention, a preferred configuration is to provide a temperature adjustment means in the mold and to impart a temperature gradient to the mold to gradually lower the temperature from a point in the shaping surface of the mold to the peripheral portion. When it is placed in the mold, it is much more convenient because the temperature adjustment plate can use the usual things.

An example of the configuration is a mold in which a heat medium flow path is formed or a pressure plate is connected to a plurality of temperature adjustment systems (circulation of a heat medium or a refrigerant). When the temperature of the heat medium flowing through the end portion is lower than the center portion, the temperature rises slowly at the end portion of the mold at a low temperature of the heat medium, and a temperature gradient can be imparted at the time of press molding to bring the vicinity of the center of the mold to the periphery. Slowly lower the temperature. Further, the temperature difference between the center and the end portion varies depending on the pressed sheet substrate or the shape of the pattern, and is usually preferably 1 to 20 ° C, more preferably 5 to 10 ° C. When the temperature is less than 1 ° C or less, the mold temperature gradient cannot be imparted, and when the temperature is more than 20 ° C or more, the mold temperature at the end portion is too low, and the moldability of the sheet substrate is likely to be lowered.

Further, it is preferable that the power density of the heating source of the heating plate or the mold is higher than the other positions in the shaping surface, and particularly referred to herein as the "heating source" means the heating source. When it is provided in any of the pressure plate or/and the mold, the structure is such that the entire heating source is used, and the power density is higher in the shaping surface than at other positions. In order to remarkably obtain the effect of the present invention, the power density at this point is preferably higher than 5kW/m ² (0.5 W/cm ² ) or more of the other portions, and the upper limit is 50 kW/m ² (5.0 W/cm ² ). about. Therefore, depending on the heat transfer property of the mold or the like, it is preferably about 10 to 30 kW/m ² (1.0 to 3.0 W/cm ² ).

As described above, in the apparatus of the present invention, it is preferable that the structure uses a resistance heating heater as a means for heating the pressure plate or the mold, and the density of the heater wiring provided on the pressure plate or the mold is on the shaping surface. The inside is higher than the other positions.

Further, the structure may be a means for heating the pressure plate or the mold using a heat medium, and the density of the heat medium flow path provided in the pressure plate or the mold is higher in the shaping surface than at other positions.

Further, the heating means is preferably provided with two types of systems, and includes heating means for increasing the temperature of the pressure plate or the mold in a wide range in the shaping surface thereof, and independent heating means for raising the temperature at an arbitrary point.

Further, it is preferable to provide two types of systems including a heating means and a cooling means, and includes a heating means for raising the temperature of the pressure plate or the mold in a wide range in the shaping surface thereof, and a temperature for lowering the peripheral portion of the shaping surface. Independent cooling means.

The pressurizing machine is connected to a hydraulic pump and an oil groove (not shown), and the upper temperature adjusting plate 5 is moved up and down by a hydraulic pump to control the pressing force. Further, in the present embodiment, a hydraulic cylinder of a hydraulic pressure type is applied. However, any means for controlling the pressure may be used.

The pressure range is preferably in the range of 0.1 MPa to 20 MPa, and more preferably in the range of 1 MPa to 10 MPa.

The pressurization speed of the press machine is preferably controlled in the range of 0.01 MPa/s to 1 MPa/s, and more preferably in the range of 0.05 MPa/s to 0.5 MPa/s.

The mold 3 used in the present invention will be described. The transfer surface of the mold has a fine pattern, and the method of forming the pattern in the mold includes machining, laser processing, photolithography, electron beam drawing, and the like. Here, the "fine concavo-convex shape" formed in the mold is formed in a convex shape with a height of 10 nm to 1 mm and a period of 10 nm to 1 mm. The height of the convex shape is preferably from 1 μm to 100 μm, and the period is preferably from 1 μm to 100 μm. Examples of the convex shape include a protrusion having an arbitrary shape represented by a triangular pyramid, a cone, a quadrangular pyramid, and a dome shape, which are arranged in a discrete shape or a dot shape, or a cross section of a triangle, a square, a trapezoid, a semicircle, and An ellipse or the like is a member in which irregular protrusions of any shape are arranged in a stripe shape.

When the material of the mold is capable of obtaining the strength required for pressurization, the accuracy of pattern processing, and the release property of the film, for example, a metal material such as stainless steel, nickel, or copper, bismuth, glass, ceramic, resin, or the like is used. A material obtained by coating an organic film with the release property of the surface is suitable for use. The fine pattern of the mold corresponds to a fine concavo-convex pattern to be applied to the surface of the sheet.

The temperature adjustment plate is preferably made of an aluminum alloy, and can be controlled by an electric heater which is cast into a plate. Further, the heating control may be performed by flowing a temperature-controlled heat transfer medium to a copper or stainless steel pipe cast in a temperature adjustment plate or flowing inside a hole machined by machining. Furthermore, it may be constituted by a combination of both devices.

The thickness measuring sensor of the sheet is preferably a radiation type, an infrared type, a light interference type or the like. In addition, a plurality of sets of thickness measurement and width measurement may be provided in a plurality of sheets in the conveyance direction of the sheet, and the thickness measurement in the width direction may be performed by moving the sensor head horizontally. Further, the above-described heating means and the control of the cooling means may be a thickness measurement result obtained by measuring the thickness of the sheet in another place in advance.

For the heat medium, BARRELTHREM (Songcun Oil Co., Ltd.), NeoSK-OIL (Chemical Co., Ltd.) can be used, and water which has been heated to 100 ° C or higher can be circulated. Further, in order to efficiently transfer heat, the Reynold's number inside the pipe is preferably in the range of 1.0 × 10 ⁴ to 12 × 10 ⁴ .

The sheet-like base material to be used in the method and apparatus of the present invention preferably has a glass transition temperature Tg of 40 to 180 ° C, preferably 50 to 160 ° C, and a film of a thermoplastic resin of 50 to 120 ° C as a main component. When the glass transition temperature is less than this range, the heat resistance of the molded article is lowered, and the shape is changed over time, which is not preferable. Further, when the temperature is higher than this range, the molding temperature is increased, the energy is not efficient, and the volume fluctuation during heating/cooling of the film is increased, and the film is not allowed to be released from the mold, and even It is not preferable to be able to demold, based on the disadvantage that the pattern accuracy is low or the pattern is partially missing.

The sheet-like substrate which is suitable for application to the thermoplastic resin as the main component of the present invention is specifically preferably polyethylene terephthalate, polyethylene-2,6-naphthalate or polyethylene terephthalate. Polyester resin such as ester or polybutylene terephthalate, polyolefin resin such as polyethylene, styrene, polypropylene, polyisobutylene, polybutene or polymethylpentene, polyamine resin, polyfluorene Imine resin, polyether resin, polyester phthalamide resin, polyether ester resin, acrylic resin, polyurethane resin, polycarbonate resin, or polyvinyl chloride resin Etc. In particular, the number of monomers to be copolymerized is large, and therefore, it is easy to adjust the physical properties of the material, and the like, in particular, a mixture selected from a polyester resin, a polyolefin resin, a polyamide resin, an acrylic resin, or the like. It is preferred that the thermoplastic resin is mainly formed. More preferably, it is 50% by weight or more of the above thermoplastic resin.

The film to be used in the present invention may be a film composed of the above resin monomers, or may be a laminate composed of a plurality of resin layers. In this case, surface characteristics such as slipperiness and abrasion resistance, mechanical strength, heat resistance, and the like can be imparted as compared with the monomer film. In the case of the laminated body composed of the plurality of resin layers, it is preferable that the entire sheet satisfies the above-described requirements, and even if the entire sheet cannot satisfy the above-described requirements, the surface layer can be formed at least to satisfy the above-described requirements, and the surface layer can be easily formed. surface.

Further, the preferred thickness (thickness, film thickness) of the film suitable for use in the present invention is preferably in the range of 0.01 to 1 mm. When the thickness is less than 0.01 mm, the thickness for forming is insufficient, and when it is more than 1 mm, the rigidity of the film is generally difficult to handle. However, in the case of a sheet processed by a single sheet, it is preferable to have a plate-like body having a thickness of 0.3 mm or more, more preferably 1 mm or more, in order to suppress conveyance and the like.

A method for forming a film of the present invention, for example, a monomer sheet, which is obtained by heating and melting a sheet forming material in an extruder and extruding it from a nozzle onto a cooled casting drum to form a sheet. Method (melt casting method). In another method, a sheet forming material may be dissolved in a solvent, and the solution may be extruded from a nozzle onto a support such as a casting drum or an endless belt to form a film, and then dried from such a film layer. A method (solution casting method) or the like which is processed into a sheet form by removing the solvent.

Further, the method for producing a laminate may be a method in which two different thermoplastic resins are put into two extruders, melted, and co-extruded from a nozzle onto a cooled casting drum to be processed into a sheet shape ( Co-extrusion method; a method in which a coating material is introduced into an extruder and melt-extruded and laminated on a sheet made of a single film while being extruded from a nozzle (melt lamination method); Each of the sheet and the easy-to-surface shaped sheet are respectively produced by a single film, and are subjected to a thermocompression bonding method by a heated roll group or the like (thermal lamination method); in addition, a sheet forming material is dissolved in a solvent, A method (coating method) or the like in which the solution is applied to a sheet. Moreover, in the case of a surface-formable sheet laminate, the above-described melt lamination method, hot lamination method, or coating method can also be used. Such a substrate may also be a treated article such as a substrate conditioner or a primer. Further, it may be a composite of a substrate having another function.

Further, various additives may be added to the film of the present invention at the time of polymerization or after polymerization. The additive which can be added to the formulation may, for example, be an organic fine particle, an inorganic fine particle, a dispersant, a dye, a fluorescent whitening agent, an antioxidant, a weathering agent, an antistatic agent, a mold release agent, a tackifier, a plasticizer, a pH adjuster. And salt. In particular, a small surface-added carboxylic acid or a derivative thereof having a low surface tension such as a long-chain carboxylic acid or a long-chain carboxylate, a long-chain alcohol or a derivative thereof, or a low surface tension alcohol such as a modified eucalyptus oil may be added during the polymerization. A compound or the like is preferred as the release agent.

Further, the sheet (film) to which the present invention is applied is preferably a structure in which a release layer is further laminated on the surface of the formed layer. The outermost surface of the film, that is, by providing a release layer in advance on the contact surface with the mold, can improve the durability (reuse times) of the release coating formed on the surface of the mold, even when the mold release effect is partially lost. Release the mold evenly without problems. Further, even if the mold is not subjected to the release treatment at all, the mold release layer can be released in advance on the film side, and the mold release treatment cost can be reduced, which is preferable. Further, when the formed sheet is released from the mold, it is possible to prevent the formation pattern from being collapsed due to resin adhesion, or to release the film at a higher temperature and to shorten the cycle time, and in terms of molding precision and productivity, Preferably. Further, by further improving the smoothness of the surface of the formed sheet, it is preferable because the scratch resistance can be improved and the disadvantages caused by the process and the like can be reduced.

When the forming layer is laminated on the outermost layer with the support layer as the center, the release layer may be provided on the surface of the forming layer on either side, or the release layer may be provided on both outermost layers.

The resin constituting the release layer is not particularly limited, and is preferably composed of a lanthanoid resin, a fluorine resin, a fatty acid resin, a polyester resin, an olefin resin, or a melamine resin as a main component. A lanthanoid resin, a fluorine resin, or a fatty acid resin is more preferable. Further, in the release layer, in addition to the above-mentioned resin, for example, an acrylic resin, a urethane resin, an epoxy resin, a urea resin, a phenol resin, or the like can be blended, and various additives such as an antistatic agent can be formulated. Surfactants, antioxidants, heat stabilizers, weather stabilizers, UV absorbers, pigments, dyes, microparticles with or with inorganic particles, fillers, nucleating agents, crosslinkers, and the like. Further, the thickness of the release layer is not particularly limited, and is preferably 0.01 to 5 μm. When the thickness of the release layer is less than 0.01 μm, it is necessary to pay attention to the fact that the effect of improving the mold release property may be lowered.

The method of forming the release layer is not particularly limited, and for example, a reverse roll coating method, a gravure coating method, a rod coating method, a bar coating method, a die coating method, or a spray coating method can be used. Further, in terms of productivity and uniformity of coating, it is preferred to carry out the above-described coating and film-forming on-line coating.

[Examples]

Hereinafter, specific configurations and effects of the method and apparatus of the present invention will be described based on examples.

In each of the following examples, the fine-shaped transfer sheet was produced by imparting a fine shape to each of the molds, pressurizing devices, and processing conditions of the specifications shown in (1) to (10).

Example 1

(1) Mold size: 500 mm (film thickness direction) × 800 mm (film traveling direction) × 20 mm (thickness).

(2) Mold material: copper.

(3) Fine shape: a shape having a rectangular shape with a pitch of 50 μm, a convex portion width of 25 μm, a convex portion height of 50 μm, and a cross section when viewed from the film traveling direction.

(4) Pressurizing device: It can be pressurized up to 3000 kN at the maximum and pressurized by a hydraulic pump.

(5) Two temperature-adjusting plates made of aluminum alloy and having a size of 700 mm (film thickness direction) × 1000 mm (film traveling direction) were attached to the pressurizing device, and each was connected to a heating device and a cooling device. Further, the mold is attached to the lower temperature adjustment plate. The heating device was a heat medium circulation device, and the heat medium was BARRELTHERM #400 (manufactured by Matsumura Oil Co., Ltd.), and the material heated to 150 ° C was flowed at a flow rate of 100 liter / minute. Further, the cooling device was a cooling water circulation device, and water cooled to 20 ° C was flowed at a flow rate of 150 liter / minute.

(6) Further, a 7 kW electric heater is embedded in the vicinity of the center of the vertical temperature adjustment plate, and the temperature can be adjusted separately from the heat medium heating device.

(7) Sheet: It consists of a polyethylene terephthalate resin having a thickness of 100 μm (uneven thickness: ± 7 μm) and a width of 520 mm.

(8) Method of operation: Using the above apparatus, molding was carried out as follows. The resin sheet was placed on the mold in advance, and then the temperature adjustment plate was heated up and down to 110 ° C in the center portion and 100 ° C in the peripheral portion, and then the upper side plate was lowered to start film pressing. The surface of the pressurizing mold was 5 MPa and was carried out for 30 seconds. Further, only the electrothermal heater of the temperature adjustment plate is turned OFF during the pressurization. Subsequently, the upper and lower temperature adjustment plates are cooled while the pressurization is continued. The cooling was stopped when each temperature adjustment plate became 60 °C. When the cooling is completed, the pressure is released. The sheet is then released from the mold.

The above operation was repeated to produce 10 formed films. The molding surface was visually evaluated, and as a result, a molded sheet having no air biting or poor transfer, and uniformly transferred over the entire surface was obtained.

(9) The results of the deformation of the temperature adjustment plate before pressurization were measured using the above conditions, and it was confirmed that the vicinity of the center was 190 μm, the vicinity of the peripheral portion was 175 μm, and it was pressurized to have a central convexity of 15 μm. status.

The above-described pressurization deformation was measured using a laser focus displacement meter LT8100 manufactured by KEYENCE. Place the sensor head over the temperature adjustment plate and measure the 20-point displacement on the entire surface of the plate. Further, the deformation of the measuring plate can be measured using a dial gauge of the insulated front end.

The temperature control of the surface of the board is performed by the temperature of the thermocouple inserted inside the board. The thermocouple is attached to the surface of the board in advance, and the relationship between the surface temperature of the board and the internal temperature of the board is grasped, and the mutual relationship is controlled by the temperature inside the board.

Further, in the following examples and comparative examples, the deformation of the sheet and the temperature of the surface of the control panel were measured in the same manner.

Example 2

(1) Mold size: 500 mm (film thickness direction) × 800 mm (film traveling direction) × 20 mm (thickness).

(2) Mold material: copper.

(3) Fine shape: a shape having a rectangular shape with a pitch of 50 μm, a convex portion width of 25 μm, a convex portion height of 50 μm, and a cross section when viewed from the film traveling direction.

(4) Pressurizing device: It can be pressurized up to 3000 kN at the maximum and pressurized by a hydraulic pump.

(5) Two temperature-adjusting plates made of aluminum alloy and having a size of 700 mm (film thickness direction) × 1000 mm (film traveling direction) were attached to the pressurizing device, and each was connected to a heating device and a cooling device. Further, the mold is attached to the lower temperature adjustment plate. The heating device was a heat medium circulation device, and the heat medium was BARRELTHERM #400 (manufactured by Matsumura Oil Co., Ltd.), and the material heated to 150 ° C was flowed at a flow rate of 100 liter / minute. Further, the cooling device was a cooling water circulation device, and water cooled to 20 ° C was flowed at a flow rate of 150 liter / minute.

(6) Further, in the vicinity of the center of the vertical temperature adjustment plate, the heating medium flow path is provided with a separate heat medium flow path, and the heat medium (BARRELTHERM #400) is flowed at a flow rate of 150 ° C and 20 liters / minute. .

(7) Sheet: It consists of a polyethylene terephthalate resin having a thickness of 100 μm (uneven thickness: ± 10 μm) and a width of 520 mm.

(8) Method of operation: Using the above apparatus, molding was carried out as follows. The resin sheet was placed on the mold in advance, and then the temperature adjustment plate was heated up and down to 110 ° C in the center portion and 100 ° C in the peripheral portion, and then the upper side plate was lowered to start film pressing. The surface of the pressurizing mold was 5 MPa and was carried out for 30 seconds. Further, only the electrothermal heater of the temperature adjustment plate is turned OFF during the pressurization. Subsequently, the upper and lower temperature adjustment plates are cooled while the pressurization is continued. The cooling was stopped when each temperature adjustment plate became 60 °C. When the cooling is completed, the pressure is released. The sheet is then released from the mold.

The above operation was repeated to produce 10 formed films. The molding surface was visually evaluated, and as a result, a molded sheet having no air biting or poor transfer, and uniformly transferred over the entire surface was obtained.

(9) The results of the deformation of the temperature adjustment plate before pressurization were measured using the above conditions, and it was confirmed that the vicinity of the center was 200 μm, the vicinity of the peripheral portion was 170 μm, and it was pressurized to have a central convexity of 30 μm. status.

Example 3

(1) Mold size: 500 mm (film thickness direction) × 800 mm (film traveling direction) × 40 mm (thickness).

(2) Mold material: copper.

(3) Fine shape: a shape having a rectangular shape with a pitch of 50 μm, a convex portion width of 25 μm, a convex portion height of 50 μm, and a cross section when viewed from the film traveling direction.

(4) Pressurizing device: It can be pressurized up to 3000 kN at the maximum and pressurized by a hydraulic pump.

(5) Two temperature-adjusting plates made of aluminum alloy and having a size of 700 mm (film thickness direction) × 1000 mm (film traveling direction) were attached to the pressurizing device, and each was connected to a heating device and a cooling device. Further, the mold is attached to the lower temperature adjustment plate. The heating device was a heat medium circulation device, and the heat medium was BARRELTHERM #400 (manufactured by Matsumura Oil Co., Ltd.), and the material heated to 150 ° C was flowed at a flow rate of 100 liter / minute. Further, the cooling device was a cooling water circulation device, and water cooled to 20 ° C was flowed at a flow rate of 150 liter / minute.

(6) Further, a heat medium pipe was provided inside the mold to heat the vicinity of the center of the mold, and the heat medium heated to 120 ° C was flowed at a flow rate of 10 liter / minute.

(7) Sheet: It consists of a polyethylene terephthalate resin having a thickness of 80 μm (thickness unevenness: ± 4 μm) and a width of 520 mm.

(8) Method of operation: Using the above apparatus, molding was carried out as follows. The resin sheet was placed on the mold in advance, and then the temperature adjustment plate was set at 110 ° C to adjust the temperature, and the temperature was raised to 112 ° C in the center of the mold by flowing the heat medium in the center of the mold, and the peripheral portion was After 105 ° C, the upper side plate was lowered to start film pressurization. The surface of the pressurizing mold was 5 MPa and was carried out for 30 seconds. Further, the heat medium circulation of the mold is stopped during heating. Subsequently, the upper and lower temperature adjustment plates are cooled while the pressurization is continued. The cooling was stopped when each temperature adjustment plate became 60 °C. When the cooling is completed, the pressure is released. The sheet is then released from the mold.

The above operation was repeated to produce 10 formed films. The molding surface was visually evaluated, and as a result, a molded sheet having no air biting or poor transfer, and uniformly transferred over the entire surface was obtained.

(9) The results of the deformation of the temperature adjustment plate before pressurization were measured using the above conditions, and it was confirmed that the vicinity of the center was 80 μm, the vicinity of the peripheral portion was 71 μm, and it was pressurized to have a central projection of 9 μm. status.

Example 4

(1) Mold size: 500 mm (film thickness direction) × 800 mm (film traveling direction) × 20 mm (thickness).

(2) Mold material: copper.

(3) Fine shape: a shape having a rectangular shape with a pitch of 50 μm, a convex portion width of 25 μm, a convex portion height of 50 μm, and a cross section when viewed from the film traveling direction.

(4) Pressurizing device: It can be pressurized up to 3000 kN at the maximum and pressurized by a hydraulic pump.

(5) Two temperature-adjusting plates made of aluminum alloy and having a size of 700 mm (film thickness direction) × 1000 mm (film traveling direction) were attached to the pressurizing device, and each was connected to a heating device and a cooling device. Further, the mold is attached to the lower temperature adjustment plate. The heating device was a heat medium circulation device, and the heat medium was BARRELTHERM #400 (manufactured by Matsumura Oil Co., Ltd.), and the material heated to 150 ° C was flowed at a flow rate of 100 liter / minute. Further, the cooling device was a cooling water circulation device, and water cooled to 20 ° C was flowed at a flow rate of 150 liter / minute.

(6) Further, a 7 kW electric heater is embedded in the vicinity of the center of the vertical temperature adjustment plate, and the temperature can be adjusted separately from the heat medium heating device.

(7) Sheet: It consists of a polyethylene terephthalate resin having a thickness of 100 μm (uneven thickness: ± 7 μm) and a width of 520 mm.

(8) Thickness gauge: An X-ray type sheet thickness measuring sensor is fixedly attached to the pressing side to measure the thickness of the sheet conveying direction. The thickness distribution is 14 microns.

(9) Method of operation: Using the above apparatus, molding was carried out as follows. The thickness of the sheet was measured using a thickness sensor and mounted on a mold. Next, the temperature adjustment plate was heated up and down to a central portion of 110 ° C, and the peripheral portion was 100 ° C, and then the upper side plate was lowered to start film pressurization. The surface of the pressurizing mold was 5 MPa and was carried out for 30 seconds. Further, only the electrothermal heater of the temperature adjustment plate is turned OFF during the pressurization. Subsequently, the upper and lower temperature adjustment plates are cooled while the pressurization is continued. The cooling was stopped when each temperature adjustment plate became 60 °C. When the cooling is completed, the pressure is released. The sheet is then released from the mold.

The above operation was repeated to produce 10 formed films. The molding surface was visually evaluated, and as a result, a molded sheet having no air biting or poor transfer, and uniformly transferred over the entire surface was obtained.

(10) The results of the deformation of the temperature adjustment plate before pressurization were measured using the above conditions, and it was confirmed that the vicinity of the center was 190 μm, the vicinity of the peripheral portion was 175 μm, and the pressure was raised to 15 μm. status.

Comparative example 1

The same apparatus as that of the apparatus of Example 1 was used, but the central heating heater was not used, and the same conditions were applied under the same conditions as in Example 1, and as a result, a non-transfer portion was generated at the center of the film due to air seizure. Ten molded films were produced under the same conditions, but a non-transfer portion was produced on all the sheets.

1. . . Manufacturing device for fine shape transfer sheet

2. . . Pressurizing device

3. . . Mold

4. . . Flaky substrate

5. . . Upper temperature adjustment plate

6. . . Lower temperature adjustment plate

7. . . Central heating temperature adjustment plate

8. . . Heat medium circulation device

9. . . Cooling water thermal cycle device

10. . . Central heating temperature adjustment plate

twenty one. . . Sheet thickness measuring sensor

twenty two. . . Sheet conveying roller

twenty three. . . Signal calculator

Fig. 1 is a schematic front view showing an embodiment of a manufacturing apparatus for a fine-shaped transfer sheet of the present invention which is suitable for carrying out the method for producing a fine-shaped transfer sheet of the present invention.

Fig. 2 is a schematic front view showing another embodiment of the apparatus for producing a fine-shaped transfer sheet of the present invention which is suitable for carrying out the method for producing a fine-shaped transfer sheet of the present invention.

FIG. 3 is a schematic front view showing a state in which the manufacturing apparatus of the fine-shaped transfer sheet of the present invention is used as shown in FIG. 1 and the heating state of the central portion of the shaping surface is turned ON.

Fig. 4 is a view schematically showing a manufacturing apparatus for implementing the fine-shaped transfer sheet of the present invention shown in Fig. 3, wherein the heating state of the central portion of the shaping surface is turned ON, and the pressure is turned off to make the shaping surface uniform. A schematic front view of the pressurized state after being flattened by temperature.

Fig. 5 is a schematic front view showing an example of the relationship between the temperature distribution of the temperature adjustment plate and the amount of thermal expansion of the temperature adjustment plate, which is used in the apparatus for manufacturing the fine shape transfer sheet of the present invention.

Fig. 6 is a schematic plan view showing various aspects of a heating medium attached to a central portion of a temperature adjustment plate of a manufacturing apparatus for a fine-shaped transfer sheet of the present invention, and is a central heat medium pipe (a) in the same drawing ( Parallel), (b) central heat medium piping (straight), (c) central heater burying and heat medium piping, (d) heater burying, and (a) to (d) The figure is a plan view on the left side and a side view on the right side.

Fig. 7 is a view schematically showing another embodiment of a manufacturing apparatus for a fine-shaped transfer sheet of the present invention which is suitable for carrying out the method for producing a fine-shaped transfer sheet of the present invention, which is a mode display for temperature adjustment in a mold. A schematic front view of a system example of a system.

FIG. 8 is a schematic front view showing a state in which the manufacturing apparatus of the fine-shaped transfer sheet of the present invention is used to form a device in which the heating state of the central portion of the shaping surface is turned on and pressurized.

Fig. 9 is a view schematically showing the manufacture of the fine-shaped transfer sheet of the present invention in which the apparatus for manufacturing a fine-shaped transfer sheet of the present invention is carried out as shown in Fig. 1 and the heating means and the cooling means are controlled in accordance with the thickness of the sheet. A schematic front view of another embodiment of the device.

1. . . Manufacturing device for fine shape transfer sheet

2. . . Pressurizing device

3. . . Mold

4. . . Flaky substrate

5. . . Upper temperature adjustment plate

6. . . Lower temperature adjustment plate

7. . . Central heating temperature adjustment plate

8. . . Heat medium circulation device

9. . . Cooling water thermal cycle device

Claims (11)

A method for producing a fine-shaped transfer sheet, which is obtained by heating a mold having a sheet-like base material and a fine uneven shape, and pressing the sheet-like base material and the mold to pressurize the fine uneven shape The method for producing a fine-shaped transfer sheet formed on the surface of a sheet-like substrate is characterized in that the temperature is adjusted so that a point in the self-forming surface is gradually lowered in temperature toward the peripheral portion of the sheet-like substrate to form a shape, wherein The shaping surface is formed by at least one of a pressure plate or a mold, or a combination thereof, which is disposed by pressing the sheet-like base material and the mold. The method for producing a fine-shaped transfer sheet according to claim 1, wherein the temperature is adjusted so that the planarity of the shaped surface is larger than a maximum value of a thickness distribution of the shaped surface of the sheet-like substrate. The method for producing a fine-shaped transfer sheet according to claim 1 or 2, wherein a point at which the mold is in contact with the sheet-like substrate at the time of forming, a temperature of a point of the shaped surface is higher than the shaped surface The temperature of other parts is higher, and the temperature difference becomes smaller after the start of shaping. A manufacturing apparatus for a fine-shaped transfer sheet comprising a sheet-like base material, a mold having a fine uneven shape, and a fine-shaped transfer sheet for heating and pressing the sheet-like base material and the mold a manufacturing apparatus characterized in that a temperature gradient is applied to a mold and/or a pair of pressure plates to gradually lower the temperature in a portion of the self-forming surface toward a peripheral portion of the sheet-like substrate, wherein the shaping surface is Pressurizing the sheet-like substrate and the mold One of the configurations is configured for at least one of a pressure plate, or a mold, or a combination thereof. The apparatus for manufacturing a fine-shaped transfer sheet according to claim 4, wherein a temperature adjustment means is provided in the mold to set a temperature gradient to the mold so as to extend from a point in the shaping surface of the mold to the periphery of the sheet-like substrate. Slowly lower the temperature. A manufacturing apparatus for a fine-shaped transfer sheet according to item 4 of the patent application, which has a structure in which a power density of a heating source for heating the pressure plate or the mold is higher in a forming surface than at other positions. A manufacturing apparatus for a fine-shaped transfer sheet according to claim 4, which has a resistance heating heater as a heating means for heating the pressure plate or the mold, and is heated in the pressure plate or the mold. The density of the wiring is higher at a point in the shaping surface than at other locations. The apparatus for manufacturing a fine-shaped transfer sheet according to claim 4, which has a heat medium flow path which is used as a heating means for heating the pressure plate or the mold, and which is provided on the pressure plate or the mold. The density is a little higher in the shaping plane than in other locations. The apparatus for manufacturing a fine-grained transfer sheet of claim 4, wherein a heating means for setting the pressure plate or the mold to a wide range of temperature in the shaping surface thereof is provided, and Two systems of independent heating means for rising temperature. The apparatus for manufacturing a fine-shaped transfer sheet according to claim 4, wherein a heating means for setting the pressure plate or the mold to a wide range of temperature in the shaping surface thereof, and a shaping means are provided. Under the perimeter Two systems for cooling down independent cooling means. The apparatus for manufacturing a fine-shaped transfer sheet according to claim 4, wherein the thickness measuring means for the sheet-like base material is provided, and the heating means and the cooling means are controlled by a signal for transmitting the thickness measuring means. The means of sending letters.