WO2008038789A1

WO2008038789A1 - Process for producing microconfiguration transfer sheet and apparatus therefor

Info

Publication number: WO2008038789A1
Application number: PCT/JP2007/069049
Authority: WO
Inventors: Nobutsugu Chigira; Kiyoshi Minoura; Fumiyasu Nomura
Original assignee: Toray Industries, Inc.
Priority date: 2006-09-29
Filing date: 2007-09-28
Publication date: 2008-04-03
Also published as: KR20090074721A; CN101522396B; TW200824882A; TWI396617B; KR101400820B1; CN101522396A; JPWO2008038789A1; JP4946871B2

Abstract

A process for producing a sheet and apparatus therefor that in the operation of heating a sheet substratum and a metal mold with fine uneven configuration, bringing them into mutual contact and pressurizing the same so as to form the fine uneven configuration on a surface of the sheet substratum, avoid transfer failure attributed to air trapping at the transfer face between the metal mold and the sheet substratum to thereby obtain a sheet having the desired fine uneven configuration formed on its surface. There are provided a process for producing a microconfiguration transfer sheet, and apparatus therefor, comprising, in the microconfiguration transfer sheet producing operation including heating a sheet substratum and a metal mold with fine uneven configuration, bringing them into mutual contact and pressurizing the same so as to form the fine uneven configuration on a surface of the sheet substratum, carrying out the configuration formation while changing the planarity of a configuration forming face consisting of at least one, or a combination, of a pair of pressurization plates or metal molds arranged so as to apply pressure to the sheet substratum and the metal mold.

Description

Specification

Manufacturing method and manufacturing apparatus for fine shape transfer sheet

Technical field

TECHNICAL FIELD [0001] The present invention relates to a manufacturing method and a manufacturing apparatus for a sheet having a fine three-dimensional shape on a surface onto which a fine shape is transferred.

Background art

[0002] As a method of forming a three-dimensional shape such as fine irregularities on the surface of a resin sheet or the like, the concave and convex three-dimensional solids are pressed by pressing a mold having heated fine irregularities against a resin sheet or the like. A method of transferring the shape onto the resin sheet is known (Patent Document 12).

However, when trying to transfer and mold a fine shape on a large-area resin sheet with this method, air is squeezed between the mold and the processed sheet on the transfer surface, and the fine three-dimensional shape is completely There was a problem that the image was not transferred to the image and the transfer was poor.

[0004] This problem of entrapping air occurs when the sheet-like substrate to be processed has uneven thickness, or when the flatness of the pressure plate has unevenness.

[0005] In order to solve such a problem, in Patent Document 2, the transfer plate is bent so as to protrude with respect to the resin sheet at the start of contact of the pressure plate, and the pressure is applied in this state. Thus, there is proposed a method and an apparatus in which the pressure plate comes into contact with the film while air is excluded from the vicinity of the center of the shaping surface, and the fine shape is transferred. Specifically, the bending has different elasticity. It is carried out with panel members.

[0006] In this method, since the pressure plate is bent by springs having different elasticity, even if the pressure plate is flattened by pressurization, the pressure on the protruding portion is high. As a result, the fine shape transfer accuracy differs within the shaping surface, and as a result, uniform transfer accuracy cannot still be obtained. This is particularly notable as the surface shape becomes finer, and since the surface pressure distribution is different, it may affect the thickness of the processed sheet to be obtained. Furthermore, it was not practical to change the amount of deformation each time there was a need to change the position of the panel member and its support holder. Patent Document 1: JP-A-5-60920

Patent Document 2: JP 2006-35573 A

Disclosure of the invention

Problems to be solved by the invention

[0007] In view of the above-described points, the object of the present invention is to heat a mold having a sheet-like base material and a fine concavo-convex shape, and to contact and pressurize both to form a fine surface on the surface of the sheet-like base material. When shaping the concave / convex shape, the surface is formed with the desired fine concave / convex shape that does not cause poor transfer due to air trapped between the mold and the sheet-like substrate on the transfer surface. Another object of the present invention is to provide a manufacturing method and a manufacturing apparatus.

Means for solving the problem

[0008] The method for producing a fine shape transfer sheet of the present invention that achieves the above-mentioned object comprises the following configuration (1).

(1) A fine shape transfer sheet that heats a mold having a sheet-like base material and a fine concavo-convex shape, and contacts and presses both to form the fine concavo-convex shape on the surface of the sheet-like substrate. The surface of the shaping surface composed of at least one of a pair of pressure plates or molds arranged to pressurize the sheet-like substrate and the mold or a combination thereof. A method for producing a fine shape transfer sheet, characterized by forming by changing properties.

[0009] Further, the method for producing the fine shape transfer sheet of the present invention, more specifically, preferably comprises the following constitution (2) or (3).

(2) When shaping by changing the flatness of the shaping surface, pressurization starts first from one point in the shaping surface of the sheet-like substrate, and gradually toward the peripheral edge of the sheet-like substrate. The method for producing a fine shape transfer sheet according to the above (1), wherein the flatness is changed so as to reduce the pressure force S.

(3) When shaping by changing the flatness of the shaping surface, after the start of shaping, the flatness of the shaping surface is changed so that the applied pressure in the shaping surface is uniform. The method for producing a fine shape transfer sheet according to the above (1) or (2).

[0010] Further, another method for producing a fine shape transfer sheet of the present invention that achieves the above-described object, It has the following configuration (4).

(4) Heating a mold having a sheet-like base material and a fine concavo-convex shape, and bringing the sheet-like base material and the mold into contact with each other to pressurize the fine concavo-convex shape on the surface of the sheet-like substrate. In the manufacturing method of the fine shape transfer sheet to be shaped! /, At least one of a pair of pressure plates or molds arranged to pressurize the sheet-like substrate and the mold, or a combination thereof A method for producing a fine-shaped transfer sheet, wherein the forming is performed by adjusting the temperature so that the temperature gradually decreases from one point in the shaping surface constituted by the sheet toward the peripheral edge of the sheet-like substrate.

[0011] Further, the method for producing the fine shape transfer sheet of the present invention, more specifically, preferably comprises the following constitution (5) or (6).

(5) The fine shape transfer sheet according to the above (4), wherein the temperature is adjusted so that the flatness of the shaping surface is larger than the maximum value of the thickness distribution on the shaping surface of the sheet-like substrate. Manufacturing method.

(6) At the time when the mold and the sheet-like base material come into contact with each other during shaping, the temperature at one point of the shaping surface is higher than the other part of the shaping surface The method for producing a fine shape transfer sheet according to the above (4) or (5), wherein the temperature differential force S is changed to be small after the shaping starts.

[0012] The fine shape transfer sheet manufacturing apparatus of the present invention that achieves the above-described object has the following configuration (7).

(7) In a fine shape transfer sheet manufacturing apparatus comprising a sheet-like base material and a mold having a fine uneven shape, and means for heating and pressurizing the sheet-like base material and the mold, the sheet-like base material The temperature gradually increases from one point in the shaping surface composed of at least one of a pair of pressure plates or molds arranged to press the material and the mold or a combination thereof toward the peripheral edge of the sheet-like substrate. An apparatus for producing a fine shape transfer sheet, wherein the temperature of the mold and / or the pair of pressure plates is graded so as to descend.

[0013] In addition, the apparatus for producing a fine shape transfer sheet according to the present invention preferably has the following configurations (8) to (14)! /.

(8) A temperature adjusting means is provided in the mold, and from one point in the shaping surface of the mold to the peripheral part. The apparatus for producing a fine shape transfer sheet according to (7), wherein the temperature of the mold is given a gradient so that the temperature gradually decreases.

(9) The watt density of the heating source for heating the pressure plate or the mold is higher at one point in the shaping surface than the other places! The apparatus for producing a fine shape transfer sheet as described in (7) or (8) above,

(10) A resistance heating type heater is used as a means for heating the pressure plate or the mold, and the density force of the heater wiring provided on the pressure plate or the mold is higher than the other places at one point in the shaping surface. The manufacturing apparatus for a fine shape transfer sheet according to any one of the above (7) to (9), characterized in that the structure is! /.

(11) A heating medium is used as a means for heating the pressure plate or the mold, and the density force of the heat medium flow path provided in the pressure plate or the mold is higher than the other places at one point in the shaping surface. The apparatus for producing a fine shape transfer sheet according to any one of the above (7) to (; 10), characterized in that the structure is! /.

(12) The heating plate for raising the temperature of the pressure plate or the mold in a wide range within the shaping surface and the independent heating means for raising the temperature of an arbitrary point are provided. The apparatus for producing a fine shape transfer sheet according to any one of the above (7) to (11).

(13) Two systems were provided: a heating means for raising the temperature of the pressure plate or the mold over a wide range within the shaping surface, and an independent cooling means for lowering the temperature of the periphery of the shaping surface. The apparatus for producing a fine shape transfer sheet according to any of (7) to (; 12) above, characterized in that:

(14) The above-mentioned (7) to (7), characterized in that there are provided thickness measuring means for the sheet-like substrate and means for transmitting a signal for controlling the heating means and cooling means from the thickness measuring means. The apparatus for producing a fine shape transfer sheet according to any one of 13).

The invention's effect

According to the method and apparatus of the present invention, the mold and / or the pressure plate itself has a function of controlling flatness (flatness of the shaping surface), and according to the state of the sheet and the mold at that time, It is characterized by manipulating the amount and position of bending, and it can be moved by applying a uniform surface pressure while excluding air after pressurization. [0015] Therefore, the pressure in the shaping surface after pressurization can be made uniform and air can be eliminated, so that air entrapment is eliminated and a uniform and highly accurate transfer molding state can be obtained.

[0016] According to the method and apparatus for producing a fine shape transfer sheet of the present invention, it is possible to satisfactorily produce a sheet having a fine shape transferred to the surface.

Brief Description of Drawings

[0017] FIG. 1 shows a model example of an embodiment of a production apparatus for a fine shape transfer sheet of the present invention suitably used for carrying out the method for producing a fine shape transfer sheet of the present invention. FIG.

[FIG. 2] FIG. 2 schematically shows another embodiment of the apparatus for producing a fine shape transfer sheet of the present invention, which is preferably used for carrying out the method for producing a fine shape transfer sheet of the present invention. FIG.

[FIG. 3] FIG. 3 is a schematic diagram schematically showing a state where pressing is performed with the heating state at the center of the shaping surface turned on using the apparatus for producing a fine shape transfer sheet of the present invention shown in FIG. It is a front view.

[FIG. 4] FIG. 4 shows the shaping surface after the pressing is performed with the heating state at the center of the shaping surface turned on using the manufacturing apparatus for the fine shape transfer sheet of the present invention shown in FIG. It is the schematic front view which showed the press state which flattened by making temperature uniform.

[FIG. 5] FIG. 5 is a model of an example of the relationship between the temperature distribution of the temperature control plate and the amount of thermal expansion of the temperature control plate in the manufacturing apparatus of the fine shape transfer sheet as shown in FIG. FIG.

[Fig. 6] Fig. 6 is a schematic plan view schematically showing various embodiments in which a heating medium is attached to the central portion of the temperature control plate in the apparatus for manufacturing a fine shape transfer sheet, which is effective in the present invention. In this figure, (a) is the central heating medium piping (parallel) system, (b) is the central heating medium piping (direct) system, (c) is the central heater and heating medium piping system, and (d) is the heater embedded. In each of the diagrams (a) to (d), the left side is a plan view and the right side is a side view.

[FIG. 7] FIG. 7 is a schematic view of a plate suitable for carrying out the method for producing a fine shape transfer sheet of the present invention. 1 is a schematic front view showing an example of an apparatus in which a temperature control system is incorporated in a mold. FIG.

[FIG. 8] FIG. 8 schematically shows a state where pressing is performed with the heating state of the center portion of the shaping surface turned on using the apparatus for producing a fine shape transfer sheet of the present invention shown in FIG. FIG.

[FIG. 9] FIG. 9 shows the fine shape of the present invention in which the structure for controlling the heating means and the cooling means in accordance with the thickness of the sheet is added to the apparatus for producing a fine shape transfer sheet, which is the power of the present invention shown in FIG. It is the schematic front view which showed other example of 1 embodiment of the manufacturing apparatus of the transcription | transfer sheet | seat as a model. Explanation of symbols

[0018] 1 Fine shape transfer sheet manufacturing apparatus

2 Press equipment

3 Mold

4 Sheet substrate

5 Upper temperature control plate

6 Lower temperature control plate

7 Heating medium flow path for central heating

8 Heat medium circulation device

9 Cooling water circulation device

10 Heater for central heating

21 Sheet thickness measurement sensor

22 Sheet transport roll

23 Signal calculator

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the method and apparatus for producing a fine shape transfer sheet of the present invention will be described in more detail with reference to the drawings.

[0020] The method for producing a fine shape transfer sheet of the present invention comprises heating a sheet-shaped substrate and a mold having a fine uneven shape, and contacting and pressurizing both the sheet-shaped substrate and the mold. Yotsu In a method for producing a fine shape transfer sheet for shaping the fine uneven shape on the surface of the sheet-like substrate! /, A pair of pressure plates arranged to pressurize the sheet-like substrate and the mold or It is characterized in that it is shaped by changing the flatness of the shaping surface composed of at least one of the molds or a combination thereof.

Here, “flatness of the shaping surface” means “the degree of flatness of the flat space formed as a gap between the pressure plate and the mold”, and “changes the flatness”. Means changing the degree of flatness. In addition, the flatness of the shaping surface is determined when the pressure plate is used in the case where the die is used up and down only by the combination of the pressure plate and the die. Is the same.

In the method of the present invention, when changing the flatness of the shaping surface, preferably, pressure starts first from one point in the shaping surface of the sheet-like substrate, and the peripheral portion of the sheet-like substrate In other words, the flatness is changed so that the applied pressure gradually decreases toward the surface. In other words, pressurizing while excluding air without squeezing is particularly effective in the vicinity of the peripheral edge of the shaping surface where the first pressurization point does not need to be in the center and center of the shaping surface. It can be a single point. When pressurization is started from one point in the vicinity of the peripheral edge, the planarity is changed so that the applied pressure gradually decreases toward the peripheral edge on the opposite side.

[0023] Here, "change the flatness so that the applied pressure gradually decreases" means that the pressure applied to each unit area on the shaping surface gradually decreases. .

[0024] When changing the flatness of the shaping surface, it is preferable to change the flatness of the shaping surface so that the applied pressure in the shaping surface becomes uniform after the start of shaping. The term "after shaping starts" here refers to the point after the first pressurization starts when one point in the shaping surface of the sheet-shaped substrate comes into contact with the mold and / or the pressure plate (pressure plate). After reaching this state, it is effective to control it to be uniform.

[0025] A series of control of the pressurizing force as described above generates partial thermal expansion deformation by partially heating the shaping surface of the pressure plate (pressure plate) or the mold, Thus, the mold force that abuts against the sheet-like base material can be achieved by first abutting at a certain point portion and expanding the abutting portion toward the peripheral edge as pressurization proceeds. The method is carried out by the specific method of the present invention as described below. [0026] That is, in the method for producing a fine shape transfer sheet of the present invention, specifically, a sheet-like base material and a mold having fine irregularities are heated, and both the sheet-like base material and the die are heated. In a method for producing a fine shape transfer sheet that forms the fine irregularities on the surface of the sheet-like substrate by contacting and pressurizing, the sheet-like substrate and the mold are arranged to be pressurized. The temperature is adjusted so that the temperature gradually decreases from one point in the shaping surface formed by at least one of the pair of pressure plates or molds or a combination thereof to the peripheral edge of the sheet-like substrate. How to shape.

[0027] In the force, the method, preferably, the temperature is adjusted so that the flatness of the shaping surface is larger than the maximum value of the thickness distribution on the shaping surface of the sheet-like substrate, , "The flatness of the shaping surface is greater than the maximum value of the thickness distribution on the shaping surface of the sheet-shaped substrate! /," Means that the flatness degree! / Is the maximum value of the sheet thickness distribution. It is bigger than! /, It means being in a state.

[0028] Further, preferably, at the time when the mold at the time of shaping and the sheet-like substrate are in contact, the temperature at which one point of the shaping surface is higher than the other part of the shaping surface It is to change so that the temperature difference becomes smaller after the start.

[0029] The above-described specific method of the present invention can be performed by the apparatus for producing a fine shape transfer sheet of the present invention described below.

[0030] That is, in the fine shape transfer sheet manufacturing apparatus comprising a sheet-like base material and a mold having a fine uneven shape, and means for heating and pressurizing the sheet-like base material and the die, the sheet shape Gradually from one point in the shaping surface composed of at least one of a pair of pressure plates or molds arranged to pressurize the substrate and the mold or a combination thereof toward the periphery of the sheet-like substrate The apparatus for producing a fine shape transfer sheet is characterized in that the temperature of the mold and / or the pair of pressing plates is graded so that the temperature drops.

[0031] FIG. 1 is a schematic diagram schematically showing an embodiment of an apparatus for producing a fine shape transfer sheet of the present invention that is preferably used for carrying out the method of producing a fine shape transfer sheet of the present invention. FIG. 2 is a front view, and FIG. 2 shows another embodiment of the fine shape transfer sheet manufacturing apparatus of the present invention suitably used for carrying out the fine shape transfer sheet manufacturing method of the present invention. It is the schematic front view shown in model.

In FIGS. 1 and 2, 1 is a fine shape transfer sheet manufacturing apparatus, 2 is a press apparatus, 3 is a mold, 4 is a sheet-like substrate, 5 is an upper temperature control plate, 6 is a lower temperature control plate, 7 is a heat medium flow path for central heating, 8 is a heat medium circulation device, 9 is a cooling water circulation device, and 10 is a central heating heater. Gradually from one point on the shaping surface toward the peripheral edge of the sheet-like substrate The temperature gradient of the mold and / or the pair of pressure plates attached so as to drop in temperature is particularly provided with the central heating medium 7 in the embodiment of FIG. 1 and the central heater 10 in the embodiment of FIG. This is realized. Therefore, in the embodiment shown in FIGS. 1 and 2, the upper temperature control plate 5 and the lower temperature control plate 6 constitute the pressure plate referred to in claim 1.

FIG. 3 is a schematic front view schematically showing a state where pressing is performed with the heating state at the center of the shaping surface turned on using the apparatus for manufacturing a fine shape transfer sheet of the present invention shown in FIG. It is a figure. The temperature control plates 5 and 6 are expanded and swelled at the center of the shaping surface.

[0034] FIG. 4 shows a state after pressing with the heating state at the center of the shaping surface turned on using the apparatus for producing a fine shape transfer sheet of the present invention shown in FIG. 3 (that is, after the start of shaping). FIG. 6 is a schematic front view schematically showing a state in which the shaping surface is flattened with a uniform temperature by turning it off.

Yes

[0035] FIG. 5 is a model of an example of the relationship between the temperature distribution of the temperature control plate and the thermal expansion amount of the temperature control plate in the apparatus for manufacturing a fine shape transfer sheet, which is the power of the present invention shown in FIG. It is a schematic front view to explain, and shows a state in Example 1 to be described later. As shown here, by causing a temperature difference of 10 ° C (100 ° C to 10 ° C) at the center of the end of the temperature control plate, the expansion amount of the plate can be adjusted in the vertical plane direction. The difference in height is 15 m (175 to 190 m). Using this gradient difference, do not squeeze the air! / The entire shaping surface can be in a pressurized state, and when the entire pressurized state is reached, the gradient difference disappears. In this way, the partial additional heating at the center is turned off.

FIG. 6 is a schematic plan view schematically showing four examples of a state in which a heating medium is attached to the central portion of the temperature control plate in the apparatus for manufacturing a fine shape transfer sheet that is effective in the present invention. The In the figure, (a) is the central heating medium piping (parallel) system, (b) is the central heating medium piping (straight) (C) is the central heater embedment and heating medium piping system, (d) is the heater embedment system, and in each figure of (a) to (d), the left side shows the plan view and the right side shows This is a side view.

[0037] The heating medium piping passage heater used for heating does not necessarily need to be provided on the temperature control plate. The normal temperature control plate is used as it is, and in particular, the heat medium pipe flow partially inside the mold. A road heater may be attached. FIG. 7 shows a model of another embodiment of the fine shape transfer sheet manufacturing apparatus of the present invention in that case, and shows an example of an apparatus in which a temperature control system is incorporated in a mold. It is the schematic front view shown in model. FIG. 8 is a schematic front view schematically showing a state where pressing is performed with the heating state at the center of the shaping surface turned on using the apparatus for manufacturing a fine shape transfer sheet shown in FIG.

In the embodiment of the apparatus shown in FIG. 9, there are provided sheet thickness measuring means and means for transmitting a signal for controlling the heating means and the cooling means from the thickness measuring means. 21 is a sheet thickness measurement sensor, 22 is a sheet transport roll, 23 is a signal calculator, and the thickness of the sheet-like substrate before the start of shaping pressurization is measured in-line by the sheet thickness measurement sensor 21. Measurements are made sequentially, and based on the measurement results, temperature control, flatness control, etc. are performed on the processing batch.

That is, in the apparatus of the present invention, as one structure, preferably, a temperature adjusting means is provided in the mold, and the temperature gradually decreases from one point in the shaping surface of the mold toward the peripheral portion. The temperature of the mold is given a gradient. This is because, if it is provided in the mold, it is often convenient because a normal temperature control plate can be used.

[0040] As an example of a configuration for realizing this, a plurality of temperature control systems for circulating the heat medium and the refrigerant are connected to a mold or a pressure plate (pressure plate) in which the heat medium flow path is formed. Things. If the temperature of the heat transfer medium flowing at the end is set lower than the center, the temperature rise is slow at the end of the mold where the heat transfer temperature is low.Therefore, when press molding, the temperature gradually increases from the center of the mold toward the periphery. A moderate temperature gradient that lowers the temperature can be provided. The temperature difference between the center and the edge varies depending on the pattern of the sheet base material to be pressed. Generally, it is in the range of !!-20 ° C, more preferably 5-10 ° C. If the temperature is 1 ° C or less, a temperature gradient cannot be given to the mold, and if it is 20 ° C or more, the mold temperature at the end Is too low, there is a high possibility that the formability of the sheet substrate will be lowered.

[0041] Preferably, the watt density of the pressure plate (pressure plate) or heating source for heating the mold

1S It is a structure that is higher than other places at one point on the shaping surface. In particular, “in the shaping surface” here means that the heating source is a pressure plate (pressure plate) or / and Regardless of which mold is installed, the watt density is one point on the shaping surface, and higher than other places! That is. The upper limit that is desirable in order to obtain the effects of the present invention remarkably, and that the watt density at one point is desirably 5 kW / m ² (0.5 W / cm ² ) or more higher than the other parts, Up to about 50kW / m ² (5. OW / cm ² ). Accordingly, it is preferable that the force due to the heat transfer property of the mold or the like is about 10 to 30 kW / m ² (1.0 to 3.0 OW / cm ² ).

As described above, in the apparatus of the present invention, preferably, a resistance heating heater is used 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 increased. It has a structure that is higher than other places at one point in the shape.

[0043] In addition, a heat medium is used as a means for heating the pressure plate or the mold, and the density force of the heat medium flow path provided in the pressure plate or the mold is larger than the other places at one point in the shaping surface. It has a high structure.

[0044] In addition, the heating means is provided with two systems of a heating means for raising the temperature of the pressure plate or the die over a wide range within the shaping surface and an independent heating means for raising the temperature of an arbitrary point. Preferably there is.

[0045] In addition, there are provided two systems: a heating means for raising the temperature of the pressure plate or mold over a wide range within the shaping surface, and an independent cooling means for lowering the temperature of the peripheral portion of the shaping surface. It is preferable that

[0046] The press is connected to a hydraulic pump (not shown) and an oil tank, and the hydraulic pump controls the raising / lowering operation of the upper temperature control plate 5 and the applied pressure. Further, in the present embodiment, any mechanism may be used as long as it is capable of controlling the force and pressure applied with a hydraulic press cylinder.

[0047] It is preferable and more preferable that the pressure range can be controlled in the range of 0.1 lMPa to 20MPa. Is preferably controlled in the range of ~ lOMPa by IMPa.

[0048] The pressurization speed of the press is preferably controllable in the range of 0.01 MPa / s to lMPa / s, more preferably in the range of 0.05 MPa / s to 0.5 MPa / s.

[0049] The mold 3 used in the present invention will be described. The transfer surface of the mold has a fine pattern, and methods for forming the pattern on the mold include machining, laser processing, photolithography, and electron beam drawing. Here, the “fine concavo-convex shape” formed on the mold is a convex shape that is periodically repeated in the range of height from lOnm to; lmm, period from 10 nm to; 1 mm. The height of the convex shape is more preferably 1 m to 100 m, and the period is more preferably 1 m to 100 m. As examples of convex shapes, protrusions of any shape typified by triangular pyramids, cones, quadrangular prisms, dome shapes, etc. are arranged in a discrete or dot shape, and the cross section is triangular, square or trapezoidal. In addition, there are projections having arbitrary shapes represented by semicircles, ellipses, etc. arranged in a stripe shape.

[0050] The material of the mold is not particularly limited as long as the desired press strength, patterning accuracy, and film releasability can be obtained. For example, metal materials including stainless steel, nickel, copper, etc., Silicone, glass, ceramics, resin, or those whose surfaces are coated with an organic film for improving releasability are preferably used. The fine pattern of the mold is formed corresponding to the fine uneven pattern to be applied to the sheet surface.

[0051] The temperature control plate is preferably made of an aluminum alloy, and is preferably controlled by an electric heat heater inserted into the plate. Alternatively, the heat control may be performed by flowing a temperature-controlled heat medium into copper or stainless steel pipes inserted into the temperature control plate, or inside a hole processed by machining. Furthermore, a device configuration combining both of them may be used.

[0052] As the sheet thickness measurement sensor, it is preferable to use a radiation type, an infrared type, a light interference type, or the like. In addition, multiple units, such as two for measuring the thickness in the conveyance direction of the sheet and two for measuring the thickness in the width direction, may be provided, and the thickness measurement in the width direction may be performed by moving the sensor head horizontally. . Note that the control of the heating means and cooling means described above is measured in advance at another location. You can use the thickness measurement result of the sheet! /

[0053] Barreltherm (Matsumura Oil Co., Ltd.), NeoSK—OIL (Soken Techniques)

In addition, water heated to 100 ° C or higher may be circulated. As it can be efficiently heat transfer, the Reynolds number of the internal pipe 1. 0 X 10 ⁴ ~; Rukoto Preferably such a range of 12 X 10 ^4.

[0054] The sheet-like base material applied to the method of the present invention preferably has a glass transition temperature Tg (from about 40 to 180 ° C, more preferably from about 50 to 160 ° C). Yes, most preferably (Also a film mainly composed of a thermoplastic resin of 50 to 120 ° C. If the glass transition temperature Tg is below this range, the heat resistance of the molded product is lowered and the shape changes over time. If the temperature exceeds this range, the molding temperature must be increased, resulting in inefficiency in energy, and the volume fluctuation during heating / cooling of the film increases, causing the film to die. It is not preferable because it can not be released due to stagnation, or even if it can be released, the transfer accuracy of the pattern is reduced, or the pattern may be partially defective, resulting in a defect.

[0055] The sheet-like base material mainly composed of the thermoplastic resin applied to the present invention is preferably, specifically, polyethylene terephthalate, polyethylene 2, 6-naphthalate, polypropylene terephthalate, polybutylene terephthalate, or the like. Polyester resins, polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene and other polyolefin resins, polyamide resins, polyimide resins, polyether resins, polyesteramide resins, polyetherester resins Resin, acrylic resin, polyurethane resin, polycarbonate resin, or polychlorinated bur resin. Among these, there are various types of monomers to be copolymerized, and it is easy to adjust the physical properties of the materials, which makes polyester resin, polyolefin resin, polyamide resin, acrylic resin, etc. More preferably, the above-mentioned thermoplastic resin, which is preferably formed mainly from a thermoplastic resin selected from a series resin or a mixture thereof, comprises 50% by weight or more.

[0056] The film applied to the present invention may be a film composed of the above-mentioned resin alone or a laminate composed of a plurality of resin layers. In this case, compared to a single sheet Thus, it is possible to impart surface properties such as easy slipping and friction resistance, mechanical strength and heat resistance. In the case of a laminate composed of a plurality of resin layers as described above, it is preferable that the entire sheet satisfies the above-mentioned requirements. However, even if the entire film does not satisfy the above-mentioned requirements, a layer satisfying at least the above-mentioned requirements is present. If it is formed on the surface layer, the surface can be easily molded with force S.

[0057] Further, the preferred thickness (thickness, film thickness) of the film applied to the present invention is preferably in the range of 0.01 to lmm. If it is less than 0.01 mm, the thickness is not sufficient for molding. If it is more than 1 mm, it is generally difficult to convey due to the rigidity of the film. However, in the case of a sheet to be processed into a sheet form, a plate-like body having a thickness of 0.3 mm or more, more preferably 1 mm or more is preferable in order to suppress conveyance deflection and the like.

[0058] As a method for forming a film applied to the present invention, for example, in the case of a single sheet, a method for processing a sheet-forming material by heating and melting in an extruder and extruding it from a die onto a cast drum cooled to form a sheet (Melt cast method). As another method, the sheet forming material is dissolved in a solvent, and the solution is extruded from a die onto a support such as a cast drum or an endless benolet to form a film, and then the solvent is removed from the film layer by drying. A method of processing into a sheet form (solution casting method) and the like can also be mentioned.

[0059] In addition, as a method for producing a laminate, two different thermoplastic resins are put into two extruders, melted and coextruded on a cast drum cooled from a die, and processed into a sheet ( (Co-extrusion method), coating layer raw material is put into an extruder into a sheet made of a single film, melt extruded and laminated while extruding from a die (melt laminating method), sheet made with a single film and easy surface shaping A single film is made separately for each of the adhesive sheets and thermocompression bonded with a heated group of rolls (thermal laminating method). Other methods include dissolving the sheet-forming material in a solvent and applying the solution onto the sheet. (Coating method). Also in the case of an easily surface-shaped sheet laminate, the above-mentioned melt lamination method, heat lamination method, coating method, and the like can be used. Such a base material may be subjected to a treatment such as a base preparation material or an undercoat material. Further, a structure as a composite with a base material having other functions is also preferable.

[0060] Various additives are added to the film applied to the present invention during or after the polymerization. The ability to get S Examples of additives that can be added and blended include, for example, organic fine particles, inorganic fine particles, dispersants, dyes, fluorescent brighteners, antioxidants, weathering agents, antistatic agents, mold release agents, thickeners. , Plasticizers, pH adjusters and salts. In particular, as the release agent, low surface tension carboxylic acids such as long chain carboxylic acids or long chain carboxylates and their derivatives, and low surface tensions such as long chain alcohols and their derivatives, modified silicone oils, etc. It is preferable to add a small amount of an alcohol compound or the like during polymerization.

[0061] The sheet (film) applied to the present invention preferably has a structure in which a release layer is further laminated on the surface of the molding layer. By preliminarily providing a release layer on the outermost surface of the film, that is, the surface in contact with the mold, the durability (number of repeated use) of the release coat formed on the mold surface can be improved. Even when a mold that has lost its mold release effect is used, it is possible to release the mold uniformly without any problem. Further, even if the mold is not subjected to any mold release treatment, it is possible to release the mold by forming a mold release layer in advance on the film side, which is preferable because the mold mold release processing cost can be reduced. . In addition, it is possible to prevent deformation of the molding pattern due to resin adhesion when the molded sheet is released from the mold, and it is possible to release at a higher temperature, thereby shortening the cycle time. It is also preferable in terms of points. Further, it is preferable because the slip resistance on the surface of the molded sheet is further improved to improve the scratch resistance and to reduce defects caused in the production process.

[0062] When the molding layer is laminated on both outermost layers centering on the support layer, a release layer may be provided on the surface of one of the molding layers! /, And a release layer is provided on both outermost layers. May be provided!

[0063] The resin constituting the release layer is not particularly limited, and may be composed mainly of a silicone resin, a fluorine resin, a fatty acid resin, a polyester resin, an olefin resin, or a melamine resin. Of these, silicone resins, fluorine resins, or fatty acid resins are more preferable. In addition to the above-described resins, the release layer may contain, for example, an acrylic resin, a urethane resin, an epoxy resin, a urea resin, or a phenol resin, and various additives such as an antistatic agent. Agents, surfactants, antioxidants, heat stabilizers, weathering stabilizers, ultraviolet absorbers, pigments, dyes, organic or inorganic fine particles, fillers, nucleating agents, crosslinking agents, and the like may be blended. The thickness of the release layer is not particularly limited, but is preferably 0.01 to 5111. The thickness of the release layer is 0.01 If it is less than m, the above-mentioned releasability improvement effect may be reduced, so care must be taken.

[0064] The method for forming the release layer is not particularly limited, but various coating methods such as reverse coating, gravure coating, rod coating, bar coating, die coating, or spray coating may be used. Can do. And inline coating which performs said application | coating simultaneously with film forming is preferable from a viewpoint of productivity and application | coating uniformity.

[0065] Examples

The specific configuration and effects of the method and apparatus of the present invention will be described below based on examples.

[0066] In each of the following examples, a fine shape transfer sheet is manufactured by applying a fine shape with a die, a pressing device, and processing conditions having the specifications shown in (1) to (; 10). It is a thing.

Example 1

[0067] (1) Mold size: 500mm (film width direction) X 800mm (film running direction) X

20mm (thickness).

(2) Mold material: Copper.

(3) Fine shape: a pitch 50 m, a convex width 25 111, a convex height 50 m, and a rectangular cross section when viewed from the film running direction was used.

(4) Press machine: The press machine can pressurize up to 3000kN, and pressurization is done by a hydraulic pump.

(5) Two temperature control plates made of aluminum alloy with a size of 700mm (film width direction) x 1000mm (film running direction) are installed in the press machine, and connected to the heating and cooling devices, respectively. Has been. The mold is attached to the lower temperature control plate. The heating device is a heat medium circulation device, and the heat medium is Barrel Therm # 400 (manufactured by Matsumura Oil Co., Ltd.), which is heated to 150 ° C and flows at a flow rate of 100 L / min. In addition, the cooling device is a cooling water circulation device that allows water cooled to 20 ° C to flow at a flow rate of 150 L / min.

(6) Furthermore, a 7kW electric heater is embedded near the center of the top and bottom temperature control plate, and the temperature can be controlled separately from the heating medium heating device. (7) Sheet: Made of polyethylene terephthalate resin, thickness is 100 μm (thickness unevenness: soil 7 μm), and width is 520 mm.

(8) Operation method: Using the above apparatus, molding was performed as follows. Place the resin sheet on the mold in advance. Next, heating is performed until the central portion is 110 ° C. and the peripheral portion is 100 ° C. on both the upper and lower sides of the temperature control plate, and then the upper plate is lowered to start film pressing. The press was performed at 5 MPa on the mold surface for 30 seconds. In addition, only the electric heater of the temperature control plate was turned off during pressing. After that, cool down the temperature control plate while keeping pressing. Stop cooling when each temperature control plate reaches 60 ° C. When both the top and bottom are cooled, the press is released. Thereafter, the sheet is released from the mold.

The above operation was repeated to create 10 molded films. As a result of visual evaluation of the molding surface, a molding sheet was obtained that was evenly transferred over the entire surface without air stagnation or transfer failure.

(9) As a result of individually measuring the deformation of the temperature control plate before pressurization under the above conditions, it was 1 90 μm near the center and 175 μm near the peripheral edge, and it was pressed with a convexity of about 15 m in the center. It was confirmed that

The plate deformation was measured using a Keyence Laser Focus Displacement Meter LT8100. The sensor head was placed above the temperature control plate, and 20 points of displacement were measured across the plate. The plate deformation may be measured using a dial gauge with a thermally insulated tip.

The temperature of the plate surface is controlled by the temperature of the thermocouple inserted in the plate. A thermocouple was attached to the plate surface in advance, and the correlation between the plate surface temperature and the plate internal temperature was ascertained. Based on this correlation, the temperature inside the plate was controlled.

In the following examples and comparative examples, plate deformation measurement and plate surface temperature control were performed in the same manner.

Example 2

[0069] (1) Mold size: 500mm (film width direction) X 800mm (film running direction) X 20mm

(Thickness).

(2) Mold material: Copper. (3) Fine shape: pitch 50 m, convex width 25 111, convex height 50 m, and rectangular cross section when viewed from the film running direction.

(4) Press device: The press can pressurize up to 3000kN, and pressurization is done by a hydraulic pump.

(5) Two temperature control plates made of aluminum alloy with a size of 700mm (film width direction) x 1000mm (film running direction) are installed in the press machine, and connected to the heating and cooling devices, respectively. Has been. The mold is attached to the lower temperature control plate. The heating device is a heat medium circulation device, and the heat medium is Barrel Therm # 400 (manufactured by Matsumura Oil Co., Ltd.), which is heated to 150 ° C and flows at a flow rate of 100 L / min. In addition, the cooling device is a cooling water circulation device that allows water cooled to 20 ° C to flow at a flow rate of 150 L / min. ½) In addition, a heating medium flow path separate from the heating medium flow path is provided near the center of the upper and lower temperature control plates, and the heating medium (barrel therm # 400) is flowed at a flow rate of 150 ° C and 20 L / min.

(7) Sheet: made of polyethylene terephthalate, with a thickness of 100 Hm (thickness variation: ± 10 m) and a width of 520 mm.

(8) Operation method: Using the above apparatus, molding was performed as follows. Place the sheet on the mold in advance. Next, after heating the top and bottom of the temperature control plate to 110 ° C at the center and 100 ° C at the periphery, lower the upper plate and start pressing the film. The press was performed at 5 MPa on the mold surface for 30 seconds. Also, only one electric heater on the temperature control plate was turned off during pressing. After that, cool down the temperature control plate both top and bottom with pressing. Stop cooling when each temperature control plate reaches 60 ° C. When cooling is completed on both the top and bottom, the press is released. Thereafter, the sheet is released from the mold.

Yes

(9) As a result of individually measuring the deformation of the temperature control plate before pressurization under the above conditions, it was 200 μm near the center and 170 μm near the peripheral edge, which was pressed with a center convex of about 30 μm. It was confirmed that

Example 3 (1) Mold size: 500mm (film width direction) X 800mm (film running direction) X 40mm (thickness).

(2) Mold material: Copper.

(5) Two temperature control plates made of aluminum alloy with a size of 700mm (film width direction) x 1000mm (film running direction) are installed in the press machine, and connected to the heating and cooling devices, respectively. Has been. The mold is attached to the lower temperature control plate. The heating device is a heat medium circulation device, and the heat medium is Barrel Therm # 400 (manufactured by Matsumura Oil Co., Ltd.), which is heated to 150 ° C and flows at a flow rate of 100 L / min. The cooling device is a cooling water circulation device that allows water cooled to 20 ° C to flow at a flow rate of 150 L / min.

(6) A heating medium pipe for heating the vicinity of the center of the mold was provided inside the mold, and the heating medium heated to 120 ° C was flowed at a flow rate of 10 L / min.

(7) Sheet: Polyethylene terephthalate, thickness is 80 μm (thickness variation: ± 4 m), and width is 520 mm.

(8) Operation method: Using the above apparatus, molding was performed as follows. Place the sheet on the mold in advance. Next, the temperature is adjusted at 110 ° C on both the top and bottom of the temperature control plate, and heated to a temperature of 112 ° C at the center of the mold and 105 ° C at the periphery by flowing a heat medium in the center of the mold. Lower the upper plate and start pressing the film. The press was performed at 5 MPa on the mold surface for 30 seconds. Also, the heat medium circulation of the mold was stopped during the pressing. After that, cool down both the top and bottom of the temperature control plate while continuing the press. Stop cooling when each temperature control plate reaches 60 ° C. When the cooling is completed for both the upper and lower sides, the press is released. Then, the sheet is released from the mold.

The above operation was repeated to create 10 molded films. As a result of visual evaluation of the molding surface, a molding sheet was obtained that was evenly transferred over the entire surface without air stagnation or transfer failure. (9) As a result of individually measuring the deformation of the mold before pressurization under the above conditions, it is 80 [I m near the center and 71,1 m near the peripheral edge, and is pressed with a central convex of about 9 m. It was confirmed that

Example 4

(1) Mold size: 500mm (film width direction) X 800mm (film running direction) X 20mm (thickness).

(2) Mold material: Copper.

(3) Fine shape: pitch 50 m, convex width 25 111, convex height 50 m, and the cross section when viewed from the film running direction is rectangular.

(6) Furthermore, a 7kW electric heater is embedded near the center of the top and bottom temperature control plate, and the temperature can be controlled separately from the heating medium heating device.

(7) Sheet: made of polyethylene terephthalate, with a thickness of 100 μm (thickness variation: ± 7 m) and a width of 520 mm.

(8) Thickness meter: An X-ray sheet thickness measurement sensor was fixedly installed on the press side, and the thickness in the sheet conveyance direction was measured. The thickness distribution was 14 Hm.

(9) Operation method: Using the above apparatus, molding was performed as follows. Set the sheet thickness on the mold while measuring with the thickness sensor. Next, after heating until the central force S is 110 ° C on both the top and bottom of the temperature control plate and the peripheral edge is 100 ° C, the upper plate is lowered and the film press is started. The press was performed at 5 MPa on the mold surface for 30 seconds. In addition, only the electric heater of the temperature control plate was turned off during pressing. After that, keep the press Cool the adjustment plate both top and bottom. Stop cooling when each temperature control plate reaches 60 ° C. When the cooling is completed for both the upper and lower sides, the press is released. Then release the sheet from the mold.

(10) As a result of individually measuring the deformation of the temperature control plate before pressurization under the above conditions, it is 190 m near the center and 175 μm near the peripheral edge, and it is pressed with a center convex of about 15 m. Was confirmed.

Comparative Example 1

Using the same device as in Example 1, but without using the central heating heater, the result of pressing under the same conditions as in Example 1 resulted in a non-transfer area due to air stagnation in the center of the film. There has occurred. 10 sheets of cast film were created under the same conditions, and non-transfer areas occurred in all films.

Claims

The scope of the claims

[1] A sheet-shaped substrate and a mold having a fine uneven shape are heated, and both the sheet-shaped substrate and the mold are brought into contact with and pressed to form the fine uneven shape on the surface of the sheet-shaped substrate. In the manufacturing method of the fine shape transfer sheet to be shaped, it is composed of at least one of a pair of pressure plates or molds arranged to pressurize the sheet-like substrate and the mold or a combination thereof. A method for producing a finely shaped transfer sheet, comprising shaping by changing the flatness of the shaping surface.

[2] When shaping by changing the flatness of the shaping surface, the pressure starts first from one point in the shaping surface of the sheet-like substrate, and the directing force is applied to the peripheral edge of the sheet-like substrate. 2. The method for producing a fine shape transfer sheet according to claim 1, wherein the flatness is changed so that the pressure is gradually reduced.

[3] When forming by changing the flatness of the shaping surface, after the start of shaping, the flatness of the shaping surface is changed so that the applied pressure in the shaping surface is uniform. The method for producing a fine shape transfer sheet according to claim 1 or 2.

[4] A sheet-shaped substrate and a mold having a fine uneven shape are heated, and both the sheet-shaped substrate and the mold are brought into contact with each other and pressed to form the fine uneven shape on the surface of the sheet-shaped substrate. And / or a method for producing a fine shape transfer sheet for shaping the sheet-like substrate, and / or at least one of a pair of pressure plates or molds arranged to pressurize the sheet-like substrate and the mold. A method for producing a fine shape transfer sheet, characterized by forming by adjusting the temperature so that the temperature decreases gradually from one point in the shaping surface constituted by the combination to the peripheral edge of the sheet-like substrate .

[5] The fine shape transfer according to claim 4, wherein the temperature is adjusted so that the flatness of the shaping surface is larger than the maximum thickness distribution on the shaping surface of the sheet-like substrate. Sheet manufacturing method.

[6] After the start of shaping, the temperature at one point of the shaping surface is higher than the other parts of the shaping surface at the time when the mold and the sheet-like base material come into contact at the time of shaping. 6. The method for producing a fine shape transfer sheet according to claim 4, wherein the temperature difference is changed to be small.

[7] In the apparatus for producing a fine shape transfer sheet, comprising the sheet-like substrate and a mold having a fine uneven shape, and means for heating and pressurizing the sheet-like substrate and the mold, the sheet-like substrate And a gradual drop in temperature from one point in the shaping surface consisting of at least one of a pair of pressure plates or molds arranged to pressurize the mold or a combination thereof toward the periphery of the sheet-like substrate An apparatus for producing a fine shape transfer sheet, wherein the temperature of the mold and / or the pair of pressure plates is inclined.

[8] The mold is provided with a temperature adjusting means, and the temperature of the mold is graded so that the temperature is gradually lowered from one point on the shaping surface of the mold toward the peripheral portion. The apparatus for producing a fine shape transfer sheet according to claim 7.

[9] The watt density of the heating plate for heating the pressure plate or the mold is higher at one point in the shaping surface than the other places! The apparatus for manufacturing a fine transfer sheet according to claim 7,

[10] A resistance heating type heater is used as a means for heating the pressure plate or the mold, and the density force of the heater wiring provided on the pressure plate or the mold is made higher than the other places at one point in the shaping surface. 8. The apparatus for producing a fine shape transfer sheet according to claim 7, wherein

[11] A heating medium is used as a means for heating the pressure plate or the mold, and the density force S of the heat medium flow path provided in the pressure plate or the mold is larger than the other places at one point in the shaping surface. 8. The apparatus for producing a fine shape transfer sheet according to claim 7, wherein the apparatus has a high structure.

[12] It is characterized in that two systems are provided: a heating means for raising the temperature of the pressure plate or the mold over a wide range within the shaping surface and an independent heating means for raising the temperature of an arbitrary point. The apparatus for producing a fine shape transfer sheet according to claim 7.

[13] Two systems are provided: a heating means for raising the temperature of the pressure plate or the mold over a wide range within the shaping surface, and an independent cooling means for lowering the temperature of the periphery of the shaping surface. 8. The apparatus for producing a fine shape transfer sheet according to claim 7, wherein:

[14] The thickness measurement means of the sheet-like substrate and means for transmitting a signal for controlling the heating means and the cooling means from the thickness measurement means are provided. Manufacturing equipment for fine shape transfer sheet.