WO2009113453A1 - 表面に微細な凹凸パターンを有するフィルムの製造方法および製造装置 - Google Patents
表面に微細な凹凸パターンを有するフィルムの製造方法および製造装置 Download PDFInfo
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- WO2009113453A1 WO2009113453A1 PCT/JP2009/054270 JP2009054270W WO2009113453A1 WO 2009113453 A1 WO2009113453 A1 WO 2009113453A1 JP 2009054270 W JP2009054270 W JP 2009054270W WO 2009113453 A1 WO2009113453 A1 WO 2009113453A1
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- film
- roll
- processed
- main roll
- mold
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
- B29C31/004—Arrangements for converting the motion of a material which is continuously fed to a working station in a stepwise motion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
- B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
- B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
- B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
- B29C2043/3405—Feeding the material to the mould or the compression means using carrying means
- B29C2043/3422—Feeding the material to the mould or the compression means using carrying means rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C2043/3602—Moulds for making articles of definite length, i.e. discrete articles with means for positioning, fastening or clamping the material to be formed or preforms inside the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/256—Sheets, plates, blanks or films
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2883/00—Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material
- B29K2883/005—LSR, i.e. liquid silicone rubbers, or derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
Definitions
- the present invention relates to a method and apparatus for producing a film having a fine uneven pattern on the surface.
- a film having a fine uneven pattern on the surface is used as a material for forming an optical medium or an optical product.
- an optical film used for an optical medium such as a light guide plate, a light diffusing plate, and a lens
- the film is pressed against the surface of the original plate on which a fine concavo-convex pattern is formed.
- a method of transferring a fine uneven pattern on an original plate is known.
- a long resin film is used as the film, and the surface of the transfer plate (die) having a fine uneven pattern on the surface intermittently with a predetermined length portion of the long film as a film to be processed
- the film to be processed is pressed against the surface of the transfer plate, the pattern is transferred to the surface of the film to be processed, and after the transfer is completed, the film to be processed on which the pattern has been formed is processed.
- Patent Document 1 or Patent Document 2 proposes a manufacturing method of an optical product in which a film to be processed having a predetermined length is supplied to the surface of the transfer plate.
- This known method has a peeling step of peeling the processed film from the surface of the transfer plate and a supplying step of supplying the new film to be processed having a predetermined length to the surface of the transfer plate. Since the peeling step is a step of releasing the film on which the pattern is formed from the surface on which the pattern is formed, that is, the mold, it may be called a release step. In this known method, the following problem may occur.
- the film sticks to the mold surface due to the characteristics of the film to be applied and the mold release agent is consumed on the mold surface, and the mold surface is damaged, or the film transfer surface. There is a problem of leaving a release mark like a scratch on the surface.
- the present invention has been obtained in the course of studying a technique for solving the above problems.
- a processed film in which a fine concavo-convex pattern is formed on a predetermined length portion of a long film is peeled off from the mold surface, and a new film to be processed at a predetermined length portion next to the long film.
- One of the objectives is to suppress pattern formation defects by supplying the new film to be processed without wrinkles along the mold surface.
- Another object of the present invention is to suppress the undulation generated by the local heat load of the film before pressing the film to be processed on the mold surface.
- the method for producing a film having a fine uneven pattern on the surface of the present invention is as follows.
- the pattern on the surface of the mold is transferred to the surface of the film to be processed by pressing the film to be processed supplied to the surface of the mold in the film supplying step against the surface of the mold.
- a pattern forming step for forming a fine uneven pattern on the surface of the film to be processed, (1-c) a film peeling step for peeling the treated film having the pattern formed on the surface thereof in the pattern forming step from the mold surface; and (1-d) a film sending step for feeding the treated film peeled from the mold surface in the film peeling step to a long film storage source located downstream;
- the processed film formed in the pattern forming step is peeled off from the mold surface in the film peeling step, and then the next processed film is intermittent for a predetermined length in the film supplying step.
- the processed film is fed to the film storage source in the film delivery step so that the processed film has a predetermined length.
- a method for producing a film having a fine concavo-convex pattern on a surface produced by being sequentially repeated, (1-e) peeling of the processed film in the film peeling step is performed by moving the film gripping means that grips the processed film from the downstream side to the upstream side in the longitudinal direction of the processed film; and , (1-f)
- the supply of the film to be processed in the film supply step is upstream of the film to be processed in the longitudinal direction of the wrinkle generation preventing means for preventing wrinkle generation in the film to be processed supplied to the mold surface.
- the manufacturing method of the film which has a fine uneven
- the film production method of the present invention is any one of the following three embodiments.
- First embodiment of the method for producing a film (2-a) A combination of a main roll that makes contact with the surface of the film opposite to the surface on which the pattern is formed and an auxiliary roll that makes contact with the surface on which the pattern of the film is formed.
- each roll axis of the main roll and the auxiliary roll faces the width direction of the film, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- each of the main roll and the auxiliary roll is a rotatable roll
- (2-b) When the processed film is suspended in an S shape on the main roll and the auxiliary roll, a gripping state of the processed film by the main roll and the auxiliary roll is formed, and the gripping state Is formed, the film gripping means moves from the downstream side to the upstream side along the mold surface, whereby the processed film is peeled from the mold surface, (2-c) While the film gripping means is stopped at the position moved upstream, the main roll and the auxiliary roll rotate, whereby the film to be processed having the new predetermined length.
- the main roll is used as the wrinkle generation preventing means, (2-e) While the film gripping means moves from the upstream side to the downstream side along the mold surface, the main roll moves while rotating, thereby generating wrinkles of the film to be processed.
- the film production method of the present invention wherein the new film to be processed having a predetermined length is supplied to the mold surface while preventing the above.
- Second embodiment of film production method (3-a) A combination of a main roll contacting the surface of the film opposite to the surface on which the pattern is formed and an auxiliary roll contacting the surface of the film on which the pattern is formed.
- each roll axis of the main roll and the auxiliary roll faces the width direction of the film, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- each of the main roll and the auxiliary roll is a rotatable roll
- (3-b) When the processed film is suspended in an S shape on the main roll and the auxiliary roll, a gripping state of the processed film by the main roll and the auxiliary roll is formed, and the gripping state Is formed, the film gripping means moves from the downstream side to the upstream side along the mold surface, whereby the processed film is peeled from the mold surface, (3-c)
- the main roll and the auxiliary roll rotate while the film gripping means is stopped at the position moved to the upstream side, whereby the film to be processed having the new predetermined length.
- the wrinkle generation preventing means on the upstream side of the main roll, it is positioned parallel to the main roll at a distance from the surface opposite to the surface on which the pattern of the film is formed.
- a rotatable wrinkle-stretching roll that contacts the surface is used, (3-e) While the film gripping means moves from the upstream side to the downstream side along the mold surface, the wrinkle stretching roll rotates following the movement of the film gripping means.
- Third embodiment of the method for producing a film (4-a) A combination of a main roll that contacts the surface of the film opposite to the surface on which the pattern is formed and an auxiliary roll that contacts the surface on which the pattern of the film is formed.
- the roll axis of each of the main roll and the auxiliary roll faces the width direction of the film, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- each of the main roll and the auxiliary roll is a rotatable roll
- (4-b) When the processed film is suspended in an S shape on the main roll and the auxiliary roll, a gripping state of the processed film by the main roll and the auxiliary roll is formed, and the gripping state Is formed, the film gripping means moves from the downstream side to the upstream side along the mold surface, whereby the processed film is peeled from the mold surface, (4-c)
- the film gripping means is moved from the upstream side to the downstream side in a state where the rotation of the main roll is prevented after the film gripping means stops at the position moved to the upstream side.
- the wrinkle generation preventing means By moving, the supply of the film to be processed of the new predetermined length is performed, (4-d)
- the upstream side of the main roll is located in parallel with the main roll at a distance from the surface opposite to the surface on which the pattern of the film is formed.
- a rotatable wrinkle-stretching roll that contacts the surface is used, (4-e)
- the wrinkle-stretching roll moves the film gripping means while the film gripping means moves from the upstream side to the downstream side along the mold surface.
- the film to be processed having a new predetermined length is supplied to the mold surface while preventing wrinkling of the film to be processed by moving while rotating following the movement of the film. Film manufacturing method.
- the apparatus for producing a film having a fine uneven pattern on the surface of the present invention is as follows.
- a mold having a fine uneven pattern on the surface having a fine uneven pattern on the surface
- a film take-out device for taking out a film to be processed from a long film supply source located upstream
- a film pressing device for pressing the film to be processed against the surface of the mold
- the film to be processed which is taken out by the film take-out device and intermittently supplied to the surface of the mold is pressed against the surface of the mold by the film pressing device.
- a film peeling apparatus for peeling the treated film having a fine concavo-convex pattern formed by transferring the fine concavo-convex pattern on the surface of the mold onto the surface of the treatment film;
- a film take-up device that pulls the processed film peeled off from the surface of the mold by the film peeling device and sent to the downstream side to the long film storage source located on the downstream side , The processed film processed by the film pressing device is peeled from the mold surface by the film peeling device, and the film to be processed taken out by the film removing device is removed by the film peeling device.
- the processed film is sent out to the film take-up device, whereby the processed film of the predetermined length is sequentially repeated to produce fine irregularities on the surface.
- An apparatus for producing a film having a pattern includes a film gripping device that moves from the downstream side to the upstream side along the longitudinal direction of the processed film in a state of gripping the processed film; and (5-g) The film gripping device includes a wrinkle generation preventing device for preventing wrinkle generation in the processed film supplied to the surface of the mold, and the supply of the processed film includes the wrinkle generation preventing device.
- the film manufacturing apparatus which has a fine uneven
- the film production apparatus of the present invention is preferably one of the following three embodiments.
- the film gripping device includes a main roll that can contact a surface of the film opposite to a surface on which the pattern is formed, and an auxiliary roll that can contact the surface of the film on which the pattern is formed.
- a combination of (6-b) The roll axis of the main roll and the roll axis of the auxiliary roll face the width direction of the film, respectively, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- the main roll is supported by the main roll support arm so as to be rotatable about its roll axis
- the auxiliary roll is supported by an auxiliary roll support arm so as to be rotatable about its roll axis
- the main roll support arm and the auxiliary roll support arm are fixed to a base
- the pedestal is supported by a pedestal movement guide provided along the longitudinal direction of the film so as to be movable in the longitudinal direction of the film
- the film gripping device is equipped with film gripping device moving means for moving the film gripping device along the pedestal moving guide
- the film gripping device is moved from the downstream side to the upstream side by the film gripping device moving means, so that the processed film is peeled from the surface of the mold.
- (6-i) Supplying the film to be processed having a new predetermined length by the rotation of the main roll and the auxiliary roll while the film gripping device is stopped at the position moved upstream. Is performed to the downstream side through the main roll and the auxiliary roll, (6-j) The main roll is used as the wrinkle generation preventing device, (6-k) The main roll moves while rotating while the film holding device is moved from the upstream side to the downstream side along the surface of the mold by the film holding device moving means.
- the new predetermined length of covering is applied to the surface of the mold.
- the film gripping device moving means includes a combination of the main roll and main roll rotation driving means for actively rotating the main roll, and the pedestal along the pedestal and the pedestal moving guide. It is preferable to consist of either one of the combination with the pedestal driving means for positively moving the two or both.
- Second aspect of film production apparatus (8-a) a main roll capable of contacting the surface of the film opposite to the surface on which the pattern is formed, and an auxiliary roll capable of contacting the surface of the film on which the pattern is formed; A combination of (8-b) The roll axis of the main roll and the roll axis of the auxiliary roll face each other in the width direction of the film, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- Position to, (8-c) The main roll is supported by the main roll support arm so as to be rotatable about its roll axis.
- the auxiliary roll is supported by an auxiliary roll support arm so as to be rotatable about its roll axis.
- the main roll support arm and the auxiliary roll support arm are fixed to a base
- the pedestal is supported by a pedestal movement guide provided along the longitudinal direction of the film so as to be movable in the longitudinal direction of the film
- the film gripping device is equipped with a film gripping device moving means for moving the film gripping device along the pedestal moving guide
- the processed film is suspended in an S shape by the main roll and the auxiliary roll, whereby the processed film is gripped by the main roll and the auxiliary roll. With the state formed, the film gripping device is moved from the downstream side to the upstream side by the film gripping device moving means, so that the processed film is peeled from the surface of the mold.
- the wrinkle generation preventing device While the film gripping device is stopped at the position moved upstream, the supply of the film to be processed having a new predetermined length is performed by the rotation of the main roll and the auxiliary roll. Is performed to the downstream side through the main roll and the auxiliary roll, (8-j) As the wrinkle generation preventing device, on the upstream side of the main roll, the wrinkle generation preventing device is located in parallel with the main roll at a distance from the surface opposite to the surface on which the pattern of the film is formed.
- Wrinkle-stretching roll that contacts the surface is used, (8-k)
- the wrinkle-stretching roll is supported on a wrinkle-stretching roll support arm so as to be rotatable about its roll axis, and the wrinkle-stretching roll support arm is fixed to the pedestal, (8-1) While the film gripping device is moved from the upstream side to the downstream side along the surface of the mold by the film gripping device moving means, the wrinkle stretching roll is By following the movement of the apparatus and moving while rotating, the mold is prevented from generating wrinkles in the film to be processed already supplied to the downstream side through the main roll and the auxiliary roll.
- the film production apparatus of the present invention wherein the new film to be processed having a predetermined length is supplied to the surface of the film.
- the film gripping device moving means includes a combination of the main roll and main roll rotation driving means for actively rotating the main roll, and the pedestal along the pedestal and the pedestal moving guide. It is preferable to consist of either one of the combination with the pedestal driving means for positively moving the two or both.
- the film gripping device includes a main roll that can contact a surface of the film opposite to a surface on which the pattern is formed, and an auxiliary roll that can contact the surface of the film on which the pattern is formed.
- a combination of (10-b) The roll axis of the main roll and the roll axis of the auxiliary roll are each directed in the width direction of the film, and the main roll and the auxiliary roll are parallel to each other with an interval through which the film can pass.
- the main roll is supported by the main roll support arm so as to be rotatable about its roll axis
- the auxiliary roll is supported by the auxiliary roll support arm so as to be rotatable about the roll axis;
- the main roll support arm and the auxiliary roll support arm are fixed to a base,
- the pedestal is supported by a pedestal movement guide provided along the longitudinal direction of the film so as to be movable in the longitudinal direction of the film, and
- the film gripping device is equipped with a film gripping device moving means for moving the film gripping device along the pedestal moving guide, (10-h)
- the processed film is suspended in an S shape by the main roll and the auxiliary roll, so that the processed film is gripped by the main roll and the auxiliary roll.
- the film gripping device is moved from the downstream side to the upstream side by the film gripping device moving means, so that the processed film is peeled from the surface of the mold.
- the film gripping device is moved by the film gripping device moving means while the rotation of the main roll is blocked.
- the film to be treated having a new predetermined length is supplied to the surface of the mold.
- the wrinkle generation preventing device As the wrinkle generation preventing device, on the upstream side of the main roll, the wrinkle generation preventing device is located in parallel with the main roll at a distance from the surface opposite to the surface on which the pattern of the film is formed.
- Wrinkle-stretching roll that contacts the surface is used, (10-k)
- the wrinkle-stretching roll is supported on a wrinkle-stretching roll support arm so as to be rotatable about its roll axis, and the wrinkle-stretching roll support arm is fixed to the pedestal, (10-l)
- a wrinkle stretching roll follows the movement of the film gripping device and moves while rotating, thereby preventing wrinkles from occurring on the film to be processed and preventing the generation of wrinkles on the surface of the mold.
- the film production apparatus of the present invention in which the film to be treated is supplied.
- the film gripping device moving means includes a combination of the main roll and main roll rotation driving means for actively rotating the main roll, and the pedestal along the pedestal and the pedestal moving guide. It is preferable to consist of either one of the combination with the pedestal driving means for positively moving the two or both.
- the outer surface of the main roll is preferably formed of a foamed sponge mainly composed of a silicone resin or a fluorine resin.
- the outer surface of the wrinkle-stretching roll is preferably formed of a foamed sponge mainly composed of a silicone resin or a fluorine resin.
- a film having a good pattern forming surface can be produced.
- the film on which the pattern is formed is moved by the film gripping means that moves along the longitudinal direction of the mold surface. Since it is continuously peeled along the longitudinal direction of the mold surface, the occurrence of peeling traces on the film surface, that is, mold release traces is suppressed. Further, generation of local wrinkles and wrinkles from the mold surface of a new predetermined length of the film to be supplied next along the mold surface prevents wrinkles from moving along with the supply of the film to be processed. Suppressed by means. Therefore, even if the film to be used is a thin film or a film having low rigidity, a film having a good pattern forming surface with little forming wrinkles and waviness can be produced.
- the film is rotated over the entire length in the longitudinal direction of the mold surface.
- the film is supplied along the mold surface, so that the film can be fed and wrinkled without rubbing the film on the mold surface. Damage can be suppressed, and generation of molding wrinkles and waviness can be suppressed.
- the film is drawn from the film supply source by moving the film gripping means.
- the film is supplied along the mold surface, and the wrinkle-stretching roller moves while following the movement of the gripping means of the film.
- the cycle time of pattern formation on a film having a predetermined length can be shortened, and generation of forming wrinkles and waviness can be suppressed.
- FIG. 1 is a schematic side view of an example of the film production apparatus of the present invention.
- 2 is a cross-sectional view taken along the line XX in FIG.
- FIG. 3 is a diagram for explaining the operating state of main operating elements when the first embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (h) are diagrams for explaining a time-series change in the operating state.
- FIG. 4 is a partial schematic side view of another example of the film production apparatus of the present invention.
- FIG. 5 is a diagram for explaining the operating state of the main operating elements when the second embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (h) are diagrams for explaining a time-series change in the operating state.
- FIG. 1 is a schematic side view of an example of the film production apparatus of the present invention.
- 2 is a cross-sectional view taken along the line XX in FIG.
- FIG. 3 is a
- FIG. 6 is a diagram for explaining the operating state of the main operating elements when the third embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (g) are diagrams for explaining a time-series change in the operating state.
- FIG. 7 is a schematic side view of still another example of the film production apparatus of the present invention. 8 is a cross-sectional view taken along the line YY in FIG.
- FIG. 9 is a diagram for explaining the operating state of main operating elements when the third embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (h) are diagrams for explaining a time-series change in the operating state.
- FIG. 1 is a schematic side view of an example of the first embodiment of the film production apparatus of the present invention.
- 2 is a cross-sectional view taken along the line XX in FIG.
- FIG. 3 is a diagram for explaining the operating states of main operating elements when the first embodiment of the film manufacturing method of the present invention is carried out using the film manufacturing apparatus shown in FIG. (A) thru
- FIG. 1 shows a film manufacturing apparatus 1 according to the present invention.
- the film manufacturing apparatus 1 is equipped with a mold 3 having a fine uneven pattern on a surface (mold surface) 3a.
- a film take-out device 50 for taking out the film (processed film) 2 from a long film supply source (processed film roll) 2 ⁇ / b> S is equipped.
- the film manufacturing apparatus 1 is equipped with a film pressing device 10 that presses the film 2 supplied to the mold surface 3a against the mold surface 3a.
- the film 2 taken out from the film take-out apparatus 50 is intermittently supplied to the surface of the mold, and the film pressing apparatus 10 presses the film 2 against the mold surface 3a.
- the film (processed film) having a fine concavo-convex pattern formed by transferring the fine concavo-convex pattern of the mold surface 3a onto the surface (molding surface) 2a of the film 2 is peeled off from the mold surface 3a.
- a peeling device 20A is provided.
- a film (processed film) peeled from the mold surface 3a by the film peeling apparatus 20A and sent downstream is treated as a long film storage source (processed) located downstream.
- Film take-up device 60 to take up to 2F.
- a film transport path 2 ⁇ / b> A is formed between the film take-out device 50 and the film take-out device 60.
- the film take-out device 50 and the film take-out device 60 form a film transport device that transports a predetermined length of the film 2 along the film transport path 2A.
- the film peeling device 20A is equipped with a film gripping device 20.
- the film gripping device 20 moves along the longitudinal direction of the film 2 while gripping the film 2.
- the film gripping device 20 moves from the downstream side to the upstream side, the processed film on which the pattern has been formed is peeled off from the mold surface 3a.
- the film gripping device 20 is equipped with a wrinkle generation preventing device 20B.
- the wrinkle generation preventing device 20 ⁇ / b> B moves along the longitudinal direction of the mold 3.
- the wrinkle generation preventing device 20B moves from the upstream side to the downstream side along with the supply of the film to be processed along the mold surface 3a, the generation of wrinkles in the film to be processed along the mold surface 3a is prevented.
- the film pressing apparatus 10 has a lower fixed base 16b.
- the lower fixed base 16b is provided with four support columns 11 extending upward, and an upper fixed base 16a is provided at the upper end of the four support columns 11. It is attached.
- the movable base 16S is attached to the support column 11 so as to be movable up and down.
- An upper pressure plate 14a is attached to the lower surface of the moving base 16S, and an upper temperature adjustment plate 15a is attached to the lower surface of the upper pressure plate 14a.
- a lower pressure plate 14b is attached to the upper surface of the lower base 16b, and a lower temperature adjustment plate 15b is attached to the upper surface of the lower pressure plate 14b.
- a mold 3 is attached to the upper surface of the lower temperature control plate 15b. A fine uneven pattern is formed on the mold surface 3a.
- the upper fixed base 16a is equipped with a pressing cylinder 12, and a piston rod extending from the pressing cylinder 12 is coupled to the moving base 16S.
- the moving base 16S moves downward, and presses the film 2 against the mold surface 3a. Further, the operation of the pressing cylinder 12 moves the moving base 16S upward, and the pressing of the film 2 on the mold surface 3a is released.
- the upper temperature control plate 15a is used for heating or cooling the film 2 when the film 2 is pressed against the mold surface 3a, and the temperature control is performed by the heating unit 30 or the cooling unit 40.
- the lower temperature control plate 15b is used for heating or cooling the mold 3 when the film 2 is pressed against the mold surface 3a, and the temperature control is performed by the heating unit 30 or the cooling unit 40.
- the mold 3 may be attached to the lower surface of the upper temperature control plate 15a.
- the flatness on the film pressing surface side of the upper temperature control plate 15a and the lower temperature control plate 15b is preferably 10 ⁇ m or less, and more preferably 5 ⁇ m or less.
- the pattern forming process is not limited to the heat forming method, and can be performed by, for example, a light forming method. When not using the heat molding method, the upper and lower temperature control plates, and the heating unit and the cooling unit connected to them are unnecessary.
- the eaves pressing cylinder 12 is connected to a hydraulic pump (not shown).
- the hydraulic pump controls the raising and lowering operation of the upper pressurizing plate 14a and the pressurizing force.
- the pressing mechanism may be a pressurizing mechanism that can control the pressing force other than the hydraulic pressing cylinder.
- the pressure for forming the ridge pattern is preferably 0.1 MPa to 20 MPa. More preferably, it is 1 MPa to 10 MPa. When the pressure exceeds 20 MPa, the mold may be damaged or deformed. When the pressure is less than 0.1 MPa, the resin forming the film may not flow sufficiently during molding, and a pattern according to the pattern on the mold surface may not be molded on the film surface.
- the pressurization speed of the pressing cylinder is preferably 0.01 MPa / second to 10 MPa / second. More preferably, it is 0.05 MPa / second to 5 MPa / second.
- the pressurization speed exceeds 10 MPa / second, the deformation of the resin forming the film at the time of pressurization cannot follow the pressurization speed, and the pattern on the mold surface may not be formed on the film surface.
- the pressure increase rate is less than 0.01 MPa / second, it takes time to form a pattern and the productivity is lowered.
- the fine concavo-convex pattern on the plating mold surface 3a is formed by machining, laser processing, photolithography, an electron beam drawing method, or the like.
- the height of the unevenness in the fine unevenness pattern is usually in the range of 10 nm to 1 mm, and the period of the unevenness is usually in the range of 10 nm to 1 mm.
- the height of the unevenness is preferably 1 ⁇ m to 100 ⁇ m.
- the period of the irregularities is preferably 1 ⁇ m to 100 ⁇ m.
- Various protrusions are used as the projections in the projections and depressions depending on the desired optical product.
- the protrusions are usually arranged in a discrete shape or a dot shape on the mold surface 3a.
- protrusions examples include a triangular pyramid, a cone, a quadrangular prism, and a lens shape.
- protrusions having a cross section of a triangle, a square, a trapezoid, a semicircle, an ellipse and the like are arranged in a stripe shape.
- the material for forming the mold is selected in consideration of the strength during pressing, the pattern processing accuracy, and the film releasability.
- the material include metal materials including stainless steel, nickel, and copper, silicone, glass, ceramics, and resin. If necessary, an organic film is coated on the surface of the mold for the purpose of improving the releasability.
- an elastic plate 17 having a heat resistant temperature of 130 ° C. or higher is attached to the lower surface of the upper temperature control plate 15a. Even if the film 2 has a certain degree of thickness unevenness, the film 2 is pressed against the mold surface 3a uniformly over the entire surface by the elastic plate 17 being interposed.
- the elastic plate 17 is formed of, for example, ethylene / propylene / diene rubber (EPDM) having a thickness of 0.3 mm to 1.0 mm, silicone rubber, or fluorine rubber.
- EPDM ethylene / propylene / diene rubber
- the surface of the elastic plate 17 is preferably subjected to a treatment for making the surface of the film 2 slippery.
- the heat resistant temperature of a certain material refers to a temperature at which the rate of change in tensile strength of the material exceeds 10% when the material is left for 24 hours.
- the film gripping device 20 in the film peeling device 20A has a pattern of the main roll 21 and the film 2 that can contact the surface 2b opposite to the surface (molding surface) 2a on which the pattern of the film 2 is molded. It consists of the combination of the auxiliary roll 22 which can contact the surface 2a to be performed.
- the roll axis of the main roll 21 and the roll axis of the auxiliary roll 22 face the width direction of the film 2 respectively, and the main roll 21 and the auxiliary roll 22 are positioned in parallel with an interval through which the film 2 can pass.
- Both ends of the main roll 21 are rotatably supported by a pair of main roll support arms 21Aa and 21Ab.
- Both ends of the auxiliary roll 22 are rotatably supported by a pair of auxiliary roll revolution support arms 22Aa and 22Ab, and the pair of auxiliary roll revolution support arms 22Aa and 22Ab are fixed to the pair of auxiliary roll revolution drive shafts 22Ba and 22Bb.
- the pair of auxiliary roll revolving drive shafts 22Ba and 22Bb are rotatably supported by the pair of auxiliary roll support arms 22Ca and 22Cb.
- the auxiliary roll revolving drive shaft 22Ba is connected to the auxiliary roll 22 by the main roll 21.
- Auxiliary roll revolving drive means 24 for revolving in the positive and negative directions is coupled along the peripheral surface.
- the auxiliary roll revolution driving means 24 for example, an electromagnetic motor or an actuator using pneumatic pressure is used.
- the above aspect of supporting the auxiliary roll so as to revolve with respect to the main roll is an example in which the operation of suspending the film in an S shape between the main roll and the auxiliary roll and the operation of releasing the suspended state are repeated. is there.
- the relationship between the main roll and the auxiliary roll is not limited to the above embodiment.
- the means for moving the auxiliary roll in the vicinity of the peripheral surface of the main roll is not particularly limited as long as the film can be suspended in an S shape between the two rolls. It is sufficient if the film can be suspended in an S shape between the main roll and the auxiliary roll, and the suspended state may be maintained, that is, the suspended state may not be released.
- the lower ends of the pair of main roll support arms 21Aa and 21Ab are fixed to a pair of bases 26a and 26b provided on both sides along the longitudinal direction of the mold 3, and the lower ends of the pair of auxiliary roll support arms 22Ca and 22Cb The part is also fixed to the pair of pedestals 26a and 26b.
- the pair of pedestals 26a and 26b is supported by a pair of pedestal movement guides 25a and 25b provided on both sides along the longitudinal direction of the mold 3 so as to be movable in the longitudinal direction of the mold 3, and is a film gripping device.
- 20 is provided with a film gripping device movement drive means 29 for moving the film gripping device 20 along a pair of pedestal movement guides 25a and 25b.
- a linear drive motor (servo motor) is suitable as the film gripping device movement drive means 29, but an electromagnetic actuator or a pneumatic actuator may be used.
- the auxiliary roll 22 is revolved with respect to the main roll 21 by the auxiliary roll revolution driving means 24, and the processed film is suspended in the S-shape on the main roll 21 and the auxiliary roll 22.
- the film gripping device 20 is moved from the downstream side to the upstream side by the film gripping device moving means 29. As a result, the treated film is peeled off from the mold surface 3a.
- the main roll 21 and the auxiliary roll 22 rotate to supply a new predetermined length of film to be processed. And the auxiliary roll 22 to the downstream side.
- the main roll 21 is used as the wrinkle prevention device 20B, and the film gripping device 20 is moved from the upstream side to the downstream side along the mold surface 3a by the film gripping device moving means 29.
- the main roll 21 moves while rotating, thereby preventing the generation of wrinkles in the film to be processed that has already been supplied to the downstream side via the main roll 21 and the auxiliary roll 22, and the mold surface 3 a. Then, a new film to be processed having a predetermined length is supplied.
- the main roll rotation driving means 23 coupled to the roll shaft of the main roll 21 and the main roll rotation driving means 23 are coupled to each other, and the rotation direction and the rotational speed (peripheral speed of the roll) of the main roll 21 are determined.
- a main roll rotation controller 28 to control is equipped.
- a servo motor is preferably used as the main roll rotation driving means 23 and a servo amplifier is used as the main roll rotation controller 28.
- the main roll 21 is rotationally driven by the main roll rotation driving means 23, the rotational movement speed (circumferential speed) of the main roll 21 by the main roll rotation driving means 23 and the film gripping means 20 by the film gripping apparatus movement driving means 29. It is preferable that each is driven so that the moving speed of moving along the pair of pedestal movement guides 25a and 25b is synchronized.
- the film gripping means 20 is reciprocated by the film gripping device moving drive means 29, so that the film 2 is peeled from the mold surface 3a without forcibly pulling the film 2 from the downstream side, and the film to be processed Can be supplied along the mold surface 3a.
- the film gripping device moving drive means 29 is reciprocated by the film gripping device moving drive means 29, so that the film 2 is peeled from the mold surface 3a without forcibly pulling the film 2 from the downstream side, and the film to be processed Can be supplied along the mold surface 3a.
- the pair of pedestal movement guides 25a of the film gripping means 20 can be obtained only by the frictional force and the tension acting on the film 2. , 25b is obtained. In this case, the positive movement of the pair of pedestals 26a and 26b by the film gripping device movement driving means 29 is not necessary.
- At least the peripheral surface of the peripheral surface of the main roll 21 in contact with the film 2 is supplied while the film 2 is in contact with or pressed against the mold surface 3a so that the fine uneven pattern on the mold surface 3a is not damaged.
- the foaming sponge which has a silicone type resin or a fluorine resin as a main component so that the surface of the main roll 21 may not deteriorate with the high temperature metal mold
- the peripheral surface of the main roll 21 may be formed of rubber having a certain elasticity and adhesiveness.
- the rubber hardness (JIS K6253) of the rubber is preferably 40 to 70, and more preferably 50 to 60.
- the center line average roughness (JIS B0601) of the peripheral surface of the main roll 21 is preferably 0.01 ⁇ m to 1.0 ⁇ m. More preferably, the thickness is 0.01 ⁇ m to 0.5 ⁇ m.
- Suitable rubbers include ethylene / propylene / diene rubber (EPDM), silicone rubber, and fluorine rubber.
- the adhesion between the film 2 and the main roll 21 may not be sufficient.
- slippage may occur between the film 2 and the main roll 21, and the peeling force may be reduced due to a reduction in the tension of the film 2.
- the rubber hardness is less than 40, the deformation of the rubber during the peeling operation increases, and the peeling operation may become unstable. In this case, a peeling trace may occur on the film surface.
- a main roll having a center line average roughness of less than 0.01 ⁇ m may be difficult to manufacture.
- main roll When the film is peeled off from the mold surface or supplied to the mold surface, the main roll is the surface opposite to the surface in contact with the mold surface of the film located on the mold surface. You may touch. In this way, when peeling operation or supply operation is performed in a state where the main roll is in contact with the surface of the film located on the mold surface, it is possible to control the pressing force of the main roll to the mold surface. It is preferable to do.
- main roll pressure adjusting means made of an elastic member such as an air cylinder or a spring is attached to both ends of the roll axis of the main roll so that the pressing force of the main roll toward the mold surface can be controlled. It is preferable.
- main roll pressure adjusting means made of an elastic member such as an air cylinder or a spring is attached to both ends of the roll axis of the main roll so that the pressing force of the main roll toward the mold surface can be controlled. It is preferable.
- the mold surface When the film is extremely thin or easily deformed in the thickness direction, and the fine uneven pattern on the mold surface is extremely fine, the mold surface may be damaged when the main roll comes into contact with the mold surface. If there is, the distance (clearance) H between the peripheral surface of the main roll and the mold surface is preferably selected within the range of 0.1 mm to 5 mm, as shown in FIG. A range of 0.1 mm to 1 mm is more preferable.
- the clearance H is 5 mm or less from the viewpoint of the film peeling operation and the feeding operation. That is, in the film peeling operation, when the clearance H is 5 mm or less, the peeling point of the film from the mold surface is almost immediately below the main roll, which is preferable because the peeling point moves continuously with the movement of the main roll. In the film supply operation, when the clearance H is 5 mm or less, the film can be supplied with high flatness along the mold surface, which is preferable from the viewpoint of preventing the generation of wrinkles.
- the movement of the peeling point stops or the peeling point moves to the upstream side at a speed higher than the peripheral speed of the main roll. It may become.
- a linear peeling trace may appear in the width direction of the film at the place where the movement of the peeling point stops.
- the flatness of the film on the mold surface may be in a poor state.
- the parallelism between the main roll and the mold surface is preferably 0.5 mm or less, and more preferably 0.1 mm or less.
- the parallelism between the main roll and the mold surface can be measured by displacement sensors attached to both end faces in the film width direction with the mold surface as a reference plane. That is, the difference between both ends of the distance between the mold surface and the roll outer surface measured when the main roll is positioned directly above the displacement sensor is measured, and the value is defined as parallelism.
- a cooling water may be circulated through either or both of the main roll and the auxiliary roll to adjust the temperature of the roll to a constant temperature. Since the temperature is high when the film is peeled off from the mold surface, the roll is provided with temperature control means so that the temperature of the main roll and auxiliary roll contacting the film is kept as constant as possible. It is preferable. By doing in this way, it becomes possible to lower the temperature of the film at the time of peeling and immediately after peeling. It also helps to stabilize the film transport and winding after molding.
- a vibration applying means may be attached to the roll shaft of the main roll so that the main roll vibrates finely in the axial direction when the heel film is peeled off.
- a vibration drive element in the vibration applying means for example, an electromagnetic actuator, a linear actuator, or an ultrasonic vibrator can be used.
- Vibration imparting means for vibrating only the outer surface of the main roll may be provided. When the entire main roll or the outer surface of the main roll vibrates, the vibration is transmitted to the peeling point via the film wound around the main roll, and the film has a smooth peeling effect.
- the contact length in the film longitudinal direction between the film and the main roll can be set in a range of 30 mm to 300 mm.
- the diameter of the main roll is preferably in the range of 50 mm to 200 mm.
- the main roll is idle. If the diameter of the main roll is less than 50 mm, when the film immediately after the release is placed along the peripheral surface of the main roll, the curvature of the film becomes too large, and the film may be deformed such as curl. When the diameter of the main roll is larger than 200 mm, a wider space is required to perform the peeling operation. It may be difficult in terms of device design to secure such a wide space in the film pressing device.
- the peeling speed depends on the material of the film, the shape of the pattern to be molded, and the like, but is generally preferably 10 m / min to 100 m / min. More preferably, it is 20 m / min to 60 m / min. If the peeling speed is less than 10 m / min, the productivity is extremely low, and if the peeling speed exceeds 100 m / min, air can easily be caught between the surface of the main roll and the film. Slip easily occurs.
- the peripheral surface with which at least the film 2 contacts the peripheral surface of the auxiliary roll 22 may be formed of the same material as the peripheral surface of the main roll 21 described above.
- wrinkles may be induced in the film on the surface of the auxiliary roll.
- the tension applied to the film during the peeling operation depends on the material of the film and the temperature of the film, it is generally preferably in the range of 1 to 100N. More preferably, it is 5 to 50N.
- the heat resistant temperature of the material forming the peripheral surfaces of the main roll and the auxiliary roll is preferably 100 ° C. or higher, and more preferably 130 ° C. or higher. Since each roll comes into contact with a high-temperature film, it may cause dimensional changes and strength reduction over time due to the high temperature. Therefore, the material forming the peripheral surface should have the above heat-resistant temperature value. Is preferred. Thereby, peeling operation failure can be prevented.
- the definition of the heat-resistant temperature here is as described above.
- the upper temperature control plate 15a and the lower temperature control plate 15b are formed of an aluminum alloy, and an electric heater is cast in each plate.
- the temperature of each electric heater is controlled by the heating unit 30.
- the temperature control of each plate may be performed by providing a heat medium flow passage in each temperature control plate and circulating the heat medium.
- the heat medium for example, Barrel Therm (Matsumura Oil Co., Ltd.), NeoSK-OIL (Soken Techniques Co., Ltd.) or water heated to 100 ° C. or higher is used.
- the number of lay nozzles inside the heat medium flow path is preferably in the range of 1.0 ⁇ 10 4 to 12 ⁇ 10 4 so that heat can be transferred efficiently.
- the temperature of a plurality of portions of the temperature control plate can be divided and controlled.
- the temperature difference at a plurality of positions of the plate is preferably within 10 ° C., more preferably within 5 ° C., in the temperature rising, temperature lowering, and constant temperature maintaining stages.
- a heat medium flow passage may be provided in the mold together with the temperature control plate, and the temperature of the mold may be directly controlled by the heat medium.
- a refrigerant flow passage is provided in the upper temperature adjustment plate 15a and the lower temperature adjustment plate 15b, and the temperature of each plate is controlled by circulating the refrigerant.
- the temperature of each plate by the refrigerant is controlled by the cooling unit 40.
- the refrigerant water is optimal, but an ethylene glycol solution or the like may be used.
- the temperature of the refrigerant is preferably in the range of 10 ° C to 50 ° C.
- the number of lay nozzles in the refrigerant flow passage is preferably in the range of 1.0 ⁇ 10 4 to 12 ⁇ 10 4 so that heat can be transferred efficiently.
- the film take-out device 50 includes a film supply source 2S.
- the film supply source 2S is usually composed of a film roll 2Sa on which a film (film to be processed) is wound up.
- the film roll 2Sa is rotatably supported by a roll rotation shaft attached to a pair of support arms extending from the base.
- Unwinding roll rotation drive means 51 is provided at one end of the roll rotation shaft.
- the film take-out device 50 further includes transport rolls 52a, 52b, 52c and 52d, an unwind buffer unit 53, and a film fixing unit 54.
- the film take-up device 60 includes a film storage source 2F.
- the film storage source 2F is usually composed of a film roll 2Fa on which a film (processed film) is wound up.
- the film roll 2Fa is rotatably supported by a roll rotation shaft attached to a pair of support arms extending from the base.
- a winding roll rotation driving means 61 is provided at one end of the roll rotation shaft.
- the film take-up device 60 further includes transport rolls 62a, 62b and 62c, a take-up buffer unit 63, a transport drive roll 64, and a film fixing unit 65.
- the soot unwinding buffer unit 53 includes a box 55 and suction / exhaust means 56 connected thereto.
- the winding buffer unit 63 includes a box 66 and suction / exhaust means 67 connected thereto.
- Each suction / exhaust means 56, 67 may be any one that can suck and exhaust air, such as a vacuum pump.
- the length of the film to be present in the box is appropriately the length of the film that is intermittently conveyed before and after forming the film.
- Sensors 57 a and 57 b are attached in the box 55.
- Sensors 68 a and 68 b are mounted in the box 66. These sensors detect the position of the film present in the box.
- the film is conveyed. Done.
- the unwinding roll rotation driving means 51 or the winding roll rotation driving means 61 is driven.
- the unwinding roll rotation driving means 51 the film to be processed is supplied to the box 55, and a state in which the film to be processed having a predetermined length is located in the box 55 is formed.
- the processed film is supplied to the box 66 by driving of the take-up roll rotation driving means 61, and a state in which the processed film having a predetermined length is located in the box 66 is formed.
- the film fixing part 54 is located facing the film transport path 2A, and stops and allows the movement of the film in the longitudinal direction.
- the film fixing unit 65 faces the film transport path 2A between the mold 3 and the transport roll 62a, and stops and allows the movement of the film in the longitudinal direction.
- Each of the film fixing portions 54 and 65 is typically an air suction box whose upper surface is formed of a flat plate having a number of suction holes. Instead of this air suction method, a mechanical clip method may be used to stop and allow the movement of the film.
- both the film fixing portions 54 and 65 operate so as to restrain the movement of the film.
- the film fixing unit 54 operates to fix the film, and the film fixing unit 65 is opened.
- both the film fixing portions 54 and 65 are opened.
- the scissors transport drive roll 64 is connected to rotation drive means (not shown) such as a motor. At the time of film conveyance, the nip roll 64a approaches the conveyance drive roll 64, sandwiches the film, and the film is conveyed under a constant tension while torque control is performed by the conveyance drive roll 64.
- a series of film manufacturing steps includes the following steps (A) to (K).
- the mold 3 is attached to the upper surface of the lower temperature control plate 15b.
- a film roll (film roll to be processed) 2Sa is set in the film take-out device 50.
- initial film passing is performed along the film transport path 2A from the film take-out device 50 to the film take-out device 60. That is, the film 2 unwound from the film roll 2Sa in the film take-out device 50 includes the transport roll 52a, the box 55 of the unwind buffer unit 53, the transport rolls 52b, 52c, 52d, the film fixing unit 54, and the mold surface 3a.
- the film gripping device 20, the film fixing unit 65, the transport driving roll 64, the transport rolls 62a and 62b, the box 66 of the take-up buffer unit 63, and the transport roll 62c are sequentially passed.
- the film is wound as 2Fa, and the film passing to the film transport path 2A is completed.
- the film pressing device 10 is operated, the upper temperature control plate 15a is lowered, and the film 2 is pressed between the mold surface 3a and the upper temperature control plate 15a.
- the film fixing part 54 and the film fixing part 65 are each in an activated state, and thereby the movement of the film 2 is restricted.
- Conditions for forming a concavo-convex pattern on the film surface depend on the material of the film and the concavo-convex pattern shape, particularly the concavo-convex aspect ratio in the concavo-convex pattern.
- the molding temperature is set to 100 ° C. to 180 ° C.
- the press pressure is set to 1 MPa to 10 MPa
- the pressurization time is set to 1 second to 60 seconds
- the pressurization speed is set to a range of 0.05 MPa / second to 1 MPa / second.
- the cooling unit 40 is operated, and the upper temperature control plate 15a and the lower temperature control plate 15b are cooled.
- the mold surface 3a is preferably cooled until the temperature of the mold surface 3a is equal to or lower than the glass transition temperature of the film.
- 3A to 3C schematically show the movement process of the auxiliary roll 22 from the standby position 22P of the main roll 21 and the auxiliary roll 22 to this hugging state.
- the operation of the film fixing unit 65 is stopped.
- the operation stop state of the film fixing unit 65 is indicated by blackening the rectangle indicating the film fixing unit 65 in FIG.
- the operation stop state of the film fixing portion 54 is similarly indicated by blackening the rectangle indicating the film fixing portion 54.
- the main roll rotation driving means 23 and the film gripping device are set so that the peripheral speed of the main roll 21 and the moving speed of the film gripping device 20 are the same. It is preferable to synchronize the respective speeds with the moving drive means 29.
- the film gripping device 20 moves while being guided by a pair of pedestal movement guides 25a and 25b. By the movement of the film gripping device 20, the film (processed film) 2 that is in close contact with the mold surface 3a is peeled from the mold surface 3a as shown in FIG. 3 (d).
- the transport drive roll 64 it is preferable to apply an appropriate tension to the film 2 by the transport drive roll 64 in order to prevent the film 2 from being loosened on the downstream side of the auxiliary roll 22 and suppressing the generation of wrinkles.
- the main roll 21 is released from the main roll rotation driving means 23, the main roll 21 is switched from driving rotation to driven rotation, and the main roll 21 is allowed to rotate freely. It can also be performed by rotating the transport drive roll 64 on the side.
- the film fixing portion 54 is put into an operating state.
- the operating state of the film fixing part 54 or the film fixing part 65 is indicated by the fact that the rectangles for displaying the film fixing part 54 or the film fixing part 65 are shown only by drawing the frame.
- the main roll 21 is rotated in the reverse rotation direction (the direction of arrow D in FIG. 3G) by the main roll rotation driving means 23, and at the same time, the main roll 21 and the auxiliary roll are auxiliary by the film gripping device movement driving means 29.
- the roll 22 moves downstream (in the direction of arrow B in FIG. 3 (g)) while the relative position between the two rolls is maintained, that is, the state in which the film 2 is held, and the mold surface 3a.
- a new film (processed film) 2 having a predetermined length is supplied.
- the main roll rotation driving means 23 and the film gripping device are set so that the peripheral speed of the main roll 21 and the moving speed of the film gripping device 20 are the same. It is preferable to synchronize the respective speeds with the moving drive means 29.
- an unwinding buffer unit 53 having a tension adjusting function on the upstream side, conveyance rolls 52b, 52c, It is preferable that the tension acting on the film is adjusted by any of 52d.
- the film 2 is easily subjected to a heat load at the end of the mold 3.
- the elastic modulus of the film is lowered at the portion subjected to the thermal load, and the film may be locally stretched at the portion. This problem is solved by keeping a slight clearance between the peripheral surface of the main roll 21 and the mold surface 3a in consideration of the thickness of the film 2.
- the transport driving roll 64, the transport rolls 62a and 62b, and the winding buffer having a tension adjustment function on the downstream side are provided so that the film positioned downstream from the downstream end of the mold 3 is not excessively tensioned. It is preferable that the tension acting on the film is adjusted by any of the portions 63.
- the tension acting on the film can be adjusted by adjusting the turning timing of the auxiliary roll 22 and the operation of the film fixing 65. If too much tension is applied to the film 2, the film 2 is easily subjected to a heat load at the end of the mold 3. When the thermal load is applied, the elastic modulus of the film is lowered at the portion subjected to the thermal load, and the film may be locally stretched at the portion.
- the supply state of the film 2 into the box 55 is detected by the sensor 57b. Based on this detection, the operation of the unwinding roll rotation driving means 51 is stopped, and the film is fed from the film roll 2Sa into the box 55. Supply stops. On the other hand, the processed film having a predetermined length, which has been formed from the pattern conveyed from the upstream side, is temporarily accommodated in a U-shape in the box 66 of the winding buffer unit 63. This accommodation state is detected by the sensor 68b.
- step (I) By the operation in the above-mentioned step (I), it is possible to incorporate a smooth film feeding operation into the intermittent film molding cycle, and it is possible to produce a molded film with less conveyance wrinkles.
- the film can be smoothly supplied to the mold surface, and the film can be supplied to the mold surface without wrinkles.
- the film positioned on the mold surface from the downstream side is not subjected to tension for peeling, and the film is prevented from wrinkling when the film is supplied to the mold surface. Since it is performed in a state where no tension is generated so that wrinkles are generated, it is possible to produce a molded film in which the undulation in the film after the molding process is also suppressed.
- FIG. 4 is a partial schematic side view of an example of the second embodiment of the film manufacturing apparatus of the present invention.
- FIG. 5 is a diagram for explaining the operating states of the main operating elements when the second embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (h) are diagrams for explaining a time-series change in the operating state.
- FIG. 6 is a diagram for explaining the operating states of the main operating elements when the third embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. )
- To (g) are diagrams for explaining a time-series change in the operating state.
- FIG. 4 shows a film manufacturing apparatus 401 according to the present invention.
- the only difference between the film manufacturing apparatus 401 and the film manufacturing apparatus 1 shown in FIG. 1 is the wrinkle generation preventing apparatus. Therefore, here, the structure and operation of the wrinkle prevention device in the film manufacturing apparatus 401 will be mainly described. Accordingly, in FIG. 4, the device elements in the film manufacturing apparatus 401 that are the same as those in the film manufacturing apparatus 1 are indicated by the same reference numerals as those in the film manufacturing apparatus 1. Yes.
- the film manufacturing apparatus 401 includes the film peeling apparatus 20A in the film manufacturing apparatus 1. That is, the film manufacturing apparatus 401 includes the film gripping apparatus 20 including the main roll 21 and the auxiliary roll 22.
- the main roll 21 is attached to the pair of bases 26a and 26b by a pair of main roll support arms 21Aa and 21Ab
- the auxiliary roll 22 is attached by a pair of auxiliary roll support arms 22Ca and 22Cb.
- the pair of pedestals 22Ca and 22Cb is movable along the pair of pedestal movement guides 25a and 25b.
- film gripping device movement drive means 29 is provided for actively moving the pair of bases 22Ca and 22Cb along the pair of base movement guides 25a and 25b as necessary.
- the wrinkle stretching roll 421 is rotatably supported by a pair of wrinkle stretching roll support arms 22Da and 22Db at both ends thereof.
- the lower ends of the pair of wrinkle stretching roll support arms 22Da and 22Db are fixed to the pair of bases 26a and 26b, respectively. Accordingly, the wrinkle stretching roll 421 is movable in the longitudinal direction of the film 2 according to the movement of the pair of bases 26a and 26b. Thereby, the wrinkle generation preventing apparatus 420B in the film manufacturing apparatus 401 is formed.
- the main roll 21 generates wrinkles of the film together with peeling of the film from the mold surface, supply of the film to the mold surface, and supply of the film to the mold surface. It has a role to prevent.
- peeling of the film from the mold surface and supply of the film to the mold surface are performed by the main roll 21, but the film is applied to the mold surface by the main roll 21.
- the wrinkle generation prevention of the film performed together with the supply is performed by a wrinkle stretching roll 421 provided separately from the main roll 21.
- the film gripping apparatus movement driving means 29 is driven while the main roll rotation driving means 23 is kept at a constant torque, and the film peeling apparatus 20A is moved. While moving to the upstream side, the film 2 is peeled off from the mold surface 3a.
- the pair of pedestal movement guides 25a of the film gripping device 20 can be obtained only by the frictional force and the tension acting on the film 2. , 25b is obtained. In this case, the positive movement of the pair of pedestals 26a and 26b by the film gripping device movement driving means 29 is not necessary.
- At least the peripheral surface of the peripheral surface of the wrinkle-stretching roll 421 with which the film 2 is in contact is supplied so that the fine uneven pattern on the mold surface 3a is not damaged even if the film 2 is supplied while being in contact with or pressed against the mold surface 3a.
- the surface of the wrinkle-stretching roll 421 is formed of a foamed sponge mainly composed of a silicone resin or a fluorine resin so that the surface of the wrinkle-stretching roll 421 is not deteriorated by the high-temperature mold surface 3a.
- a higher wrinkle-stretching effect can be obtained by moving the wrinkle-stretching roll 421 while contacting or pressing the film 2 against the mold surface 3a.
- the peripheral surface of the wrinkle stretching roll 421 may be formed of metal, resin, or rubber. Suitable examples of resins and rubbers include fluororesins, ethylene / propylene / diene rubber (EPDM), silicone rubber, and fluororubber. What is hard to receive is preferable. It is also preferable to subject the peripheral surface of the wrinkle-stretching roll 421 to a slip treatment so that the film 2 and the peripheral surface of the wrinkle-stretching roll 421 are not in close contact.
- a slip treatment for example, a surface coating treatment mainly using a diamond-like carbon as a main component or a surface roughness of the peripheral surface is preferably used.
- centerline average roughness (JIS B0601) of the peripheral surface of the wrinkle-stretching roll 421 in the range of 1.0 ⁇ m to 100 ⁇ m can ensure appropriate slipperiness. This is preferable because it is possible.
- the distance (clearance) H between the peripheral surface of the roll and the mold surface is preferably selected in the range of 0.1 mm to 5 mm. A range of 0.1 mm to 1 mm is more preferable.
- the distance (clearance) H between the peripheral surface of the wrinkle-stretching roll and the mold surface is the distance (clearance) H between the peripheral surface of the main roll and the mold surface (clearance) H shown in FIG. Distance (clearance) H.
- this clearance H exceeds 5 mm, the wrinkle-stretching effect by the wrinkle-stretching roll becomes insufficient. If this clearance H is less than 0.1 mm, the possibility that the mold surface and the wrinkle-stretching roll come into contact with each other is increased, and in this case, the fine uneven pattern on the mold surface may be damaged.
- the parallelism between the wrinkle stretching roll and the mold surface is preferably 0.5 mm or less, and more preferably 0.1 mm or less.
- the circumferential surface of the wrinkle-stretching roll 421 is formed of rubber having a certain elasticity and adhesiveness.
- the rubber hardness (JIS K6253) of the rubber is preferably 40 to 70, and more preferably 50 to 60.
- the center line average roughness (JIS B0601) of the circumferential surface of the wrinkle stretching roll 421 is preferably 0.01 ⁇ m to 1.0 ⁇ m. More preferably, the thickness is 0.01 ⁇ m to 0.5 ⁇ m.
- Suitable rubbers include ethylene / propylene / diene rubber (EPDM), silicone rubber, and fluorine rubber.
- the adhesion between the film 2 and the wrinkle stretching roll 421 may not be sufficient.
- slippage may occur between the film 2 and the wrinkle-stretching roll 421, and a wrinkle generation preventing force may be reduced due to a decrease in the tension of the film 2.
- the rubber hardness is less than 40, the deformation of the rubber during the wrinkle generation preventing operation becomes large, and the wrinkle generation preventing operation may become unstable. In this case, wrinkle stretch marks may occur on the film surface.
- a wrinkle-stretching roll having a center line average roughness of less than 0.01 ⁇ m may be difficult to manufacture.
- the film 2 is peeled from the mold surface 3a by holding the film 2 on both rolls while rotating both the main roll 21 and the auxiliary roll 22.
- the main roll 21 is moved in the vicinity of the mold surface 3a in parallel with the mold surface 3a from the downstream side to the upstream side.
- the operation of peeling the film 2 from the mold surface 3a is the same as that in the first embodiment of the film production method of the present invention described above.
- the film 2 is supplied along the mold surface 3a, and wrinkle generation prevention in the supply of the film is performed from the upstream side to the downstream side along the mold surface 3a while the wrinkle stretching roll 421 rotates.
- the wrinkle generation preventing operation is performed by the movement of the main roll 21 as described above, but the second method of the film production method of the present invention is performed. In the case of this embodiment, it is performed by moving the wrinkle-stretching roll 421. In this respect, both embodiments are different.
- the film gripping device 20 Before the peeling operation of the wrinkle film 2 from the mold surface 3a, the film gripping device 20 is on standby at the standby position 22p shown in FIG.
- arrow A indicates the upstream side (film unwinding side)
- arrow B indicates the downstream side (film winding side).
- the auxiliary roll revolving drive means 24 is driven to move the auxiliary roll 22 almost above the main roll 21.
- the main roll rotation driving means 23 rotates the main roll 21 in the normal rotation direction (arrow C direction), while the film holding apparatus movement driving means 29 causes the film holding apparatus 20 to rotate. Is moved upstream (in the direction of arrow A).
- the main roll 21 moves to the upstream side along the mold surface 3a while rotating forward (in the direction of arrow C). With this movement, the film 2 attached to the mold surface 3a is continuously peeled while maintaining the state in which the film 2 is hugged to the main roll 21.
- the main roll 21 does not move upstream and downstream as shown in FIG. 5 (f).
- the film gripping device movement driving unit 29 is operated so that the film gripping device 20 does not move, and the film gripping device 20 is braked.
- the main roll rotation driving means 23 rotates the main roll 21 in the normal rotation direction (arrow C direction) to send the film 2 for the intermittent feed length downstream.
- the conveyance drive roll 64 on the downstream side rotates and tension is applied to the film 2.
- tension By applying this tension, loosening of the film 2 toward the mold surface 3a can be prevented, and generation of wrinkles that are likely to occur during film conveyance to the film 2 can be prevented.
- the main roll 21 is operated in a freely rotatable state by operating the main roll rotation driving means 23 and the transport drive roll 64 is rotated. Can also be done.
- the main roll 21 is rotated in the reverse rotation direction (arrow D direction) by the main roll rotation driving means 23 to supply the film 2 to the mold surface 3a.
- the film gripping device 20 is moved downstream (in the direction of arrow B) by the film gripping device moving drive means 29 while rewinding the film 2 for the intermittently fed length that has been sent out first.
- the wrinkle stretching roll 421 attached to the same bases 26a and 26b as the film gripping device 20 follows the movement of the main roll 20 and rotates along the surface of the film 2 to the downstream side. Moving.
- the main roll 21 and the wrinkle stretching roll 421 may be in contact with the surface opposite to the surface in contact with the mold surface of the film positioned on the mold surface. It may be located with a slight clearance between them.
- the auxiliary roll revolving drive means 24 When the supply of the film 2 to the mold surface 3a is completed and the film gripping device 20 reaches the downstream end of the moving range, the auxiliary roll revolving drive means 24 The auxiliary roll 22 is pivotally moved substantially below the main roll 21, and the film 2 is released from gripping by the main roll 21 and the auxiliary roll 22.
- the operation and the degree of operation are synchronized between the main roll rotation driving means 23 and the film gripping device movement driving means 29. It is preferable to prevent slippage between the surface of the main roll 21 and the film 2 so that the peripheral speed of the main roll 21 and the moving speed of the film gripping device 20 coincide with each other.
- the wrinkle-stretching roll 421 When the film is peeled off from the mold surface or supplied to the mold surface, the wrinkle-stretching roll 421 is opposite to the surface in contact with the mold surface of the film positioned on the mold surface. You may touch the surface. In this way, when the wrinkle stretching roll is in contact with the surface of the film located on the mold surface and the wrinkle generation prevention operation is performed, it is possible to control the pressing force of the film on the mold surface caused by the wrinkle stretching roll. It is preferable to make it.
- wrinkle stretching roll pressing adjusting means made of an elastic member such as an air cylinder or a spring is attached to both ends of the roll shaft of the wrinkle stretching roll, and the pressing force of the wrinkle stretching roll toward the mold surface can be controlled. It is preferable to do so.
- a wrinkle-stretching effect can be increased by bringing the wrinkle-stretching roll into contact with the surface of the film located on the mold surface with an appropriate contact pressure.
- the film 2 is peeled off from the mold surface 3a by holding the film 2 on both rolls while rotating both the main roll 21 and the auxiliary roll 22.
- the main roll 21 is moved in the vicinity of the mold surface 3a in parallel with the mold surface 3a from the downstream side to the upstream side.
- the operation of peeling the film 2 from the mold surface 3a is the same as that in the second embodiment of the film production method of the present invention described above.
- the main roll 21 is moved in the vicinity of the mold surface 3a. It is performed by moving from the upstream side to the downstream side in parallel to the mold surface 3a. That is, the supply of the film 2 to the mold surface 3a is performed by moving the film gripping device 20 in a state where the rotation of the main roll 21 and the auxiliary roll 22 is blocked from the upstream side to the downstream side.
- the operation of supplying the film 2 to the mold surface 3a is different from that of the second embodiment of the film manufacturing method of the present invention described above.
- the film 2 for the intermittent feed length is once fed into the upper space of the mold 3 by the rotation of both rolls, and then the film 2 once fed.
- both rolls move along the mold surface 3a as the rolls rotate in opposite directions.
- the third embodiment of the film manufacturing method of the present invention there is no operation in which the film 2 is fed in advance, and the film 2 is in a state where both rolls are prevented from rotating. Is moved along the mold surface 3a and directly supplied along the mold surface 3a.
- the wrinkle generation prevention of the film 2 supplied to the mold surface 3a is performed by the wrinkle stretching roll 421 that moves along the mold surface 3a while rotating while supplying the film 2.
- the operation of preventing wrinkle generation by the wrinkle stretching roll 421 is the same as that of the second embodiment of the film production method of the present invention described above.
- FIGS. 6A to 6E are the same as the operations described with reference to FIGS. 5A to 5E, and thus the description thereof is omitted here.
- FIG. 6 (f) shows a state where the upstream film fixing portion 54 is opened and the rotation of the main roll 21 is braked.
- both rolls, that is, the film gripping device 20 are moved downstream by the film gripping device moving drive means 29, and intermittently.
- the film 2 corresponding to the feeding length is pulled out from the unwinding buffer unit 53, and the drawn film 2 is supplied along the mold surface 3a.
- the wrinkle stretching roll 421 moves while rotating along the mold surface 3a, so that wrinkles are prevented from occurring in the film 2.
- the transport driving roll 64 on the downstream side is rotated so that tension is applied to the film 2.
- tension By applying this tension, loosening of the film 2 toward the mold surface 3a can be prevented, and generation of wrinkles that are likely to occur when the film is transported to the film 2 can be prevented.
- the auxiliary roll revolving drive means 24 assists.
- the roll 22 is pivotally moved substantially below the main roll 21, and the film 2 is released from gripping by the main roll 21 and the auxiliary roll 22.
- FIG. 7 is a schematic side view of an example of the third embodiment of the film manufacturing apparatus of the present invention.
- 8 is a cross-sectional view taken along the line YY in FIG.
- FIG. 9 is a diagram for explaining the operating states of the main operating elements when the second embodiment of the film manufacturing method of the present invention is carried out using the apparatus shown in FIG. (A) thru
- FIG. 7 shows a film manufacturing apparatus 701 according to the present invention.
- the main roll rotation driving means 23 is provided for the main roll 21, but the film manufacturing apparatus 701 has the main roll 21, but the main roll 21 has the main roll 21. 21 is not equipped with a main roll rotation drive means.
- the film manufacturing apparatus 701 includes a film tension adjusting means for adjusting the film tension in the film transport path 2A between the mold 3 and the transport driving roll 64 provided on the downstream side of the mold 3. Have However, the film manufacturing apparatus 401 does not have this film tension adjusting means.
- the film manufacturing apparatus 701 and the film manufacturing apparatus 401 are different.
- Other apparatus elements are common to the film manufacturing apparatus 701 and the film manufacturing apparatus 401. Accordingly, the same reference numerals as those in FIGS. 1, 2, and 4 are used in FIG. 7 for the common device elements. Since device elements common to both devices have already been described, description thereof is omitted here.
- the main roll 21 does not have the main roll rotation driving means 23 that engages with the main roll 21 shown in FIG.
- the main roll 21 is rotatably supported by a pair of main roll support arms 21Aa and 21Ab at both ends thereof. That is, the main roll 21 is supported by the pair of main roll support arms 21Aa and 21Ab so as to be driven to rotate by contact with a moving object (for example, a traveling film).
- a moving object for example, a traveling film
- a film tension adjusting means 70 for appropriately applying tension to the film 2 is provided downstream of the main roll 21 in the film transport direction.
- the film tension adjusting means 70 includes a guide roll 71, a tension detection roll 72, a conveyance drive roll 64, and the like arranged along the film conveyance path 2 ⁇ / b> A from the upstream side to the downstream side.
- the tension detecting means 73 detects tension based on the operation of the tension detecting roll 72. Based on the value of the film tension detected by the film tension detecting means 73, the driving of the transport drive roll 64 is adjusted, and the degree of tension applied to the film by the film tension adjusting means 70 is controlled.
- the film manufacturing apparatus 701 is used, similarly to the film manufacturing apparatus 401, the second embodiment of the film manufacturing method of the present invention described above and the third embodiment of the film manufacturing method of the present invention described above are used. Each of the embodiments can be implemented. Next, the state of implementation of the second embodiment of the film manufacturing method of the present invention will be described using a film manufacturing apparatus 701.
- the main roll 21 and the auxiliary roll 22 are waiting at the standby position 22p. That is, the film gripping device 20 stands by with the main roll 21 and the auxiliary roll 22 positioned at the standby position 22p.
- arrow A indicates the upstream side
- arrow B indicates the downstream side.
- the film gripping device movement driving means 29 is operated, and the film gripping device 20 is moved upstream. That is, the main roll 21 moves upstream.
- the transport drive roll 64 on the downstream side operates simultaneously, and tension is applied to the film 2.
- the main roll 21 rotates along the film 2 on which the pattern formation on the mold surface 3a has been completed, and peels the film 2 from the mold surface 3a toward the upstream side from the downstream side.
- the upstream film fixing portion 54 is opened as shown in FIG. 9F.
- the film gripping device movement drive unit 29 prevents the main roll 21 from moving upstream and downstream, that is, the film gripping device 20 does not move along the pair of pedestal movement guides 25a and 25b.
- the film gripping device 20 is brought into a stopped state.
- the film 2 hugged by the rotatable main roll 21 and the rotatable auxiliary roll 22 is taken up by driving the conveyance drive roll 64 for the intermittent feed length.
- the main roll 21 and the auxiliary roll 22 are driven to rotate by the frictional force with the film.
- the upstream film fixing portion 54 is in an operating state, that is, closed, the film gripping device moving drive means 29 is operated, and the main roll 21 is moved downstream.
- the film 2 is supplied along the mold surface 3 a by applying a certain tension to the film 2 by the operation of the transport drive roll 64.
- the rotatable main roll 21 and the rotatable auxiliary roll 22 are driven to rotate by the frictional force with the film 2.
- the wrinkle-stretching roll 421 that moves along the film 2 while rotating prevents generation of wrinkles on the film 2 supplied along the mold surface 3a.
- the film production method and production apparatus of the present invention are used, and the film used for forming a fine concavo-convex pattern on the surface is preferably a film mainly composed of a thermoplastic resin.
- the glass transition temperature Tg is preferably in the range of 40 ° C to 180 ° C. This range is more preferably 50 ° C. to 160 ° C., and further preferably 50 ° C. to 120 ° C.
- the glass transition temperature Tg When the glass transition temperature Tg is less than 40 ° C., the heat resistance of the molded product is lowered, and the shape thereof may change with time. Moreover, when glass transition temperature Tg exceeds 180 degreeC, a molding temperature must be made high. High molding temperatures are energetically inefficient. Moreover, the volume fluctuation
- polyester resins such as polyethylene terephthalate, polyethylene-2,6-naphthalate, polypropylene terephthalate, polybutylene terephthalate, polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, polyamide resins, polyimide resins , Polyether resins, polyester amide resins, polyether ester resins, acrylic resins, polyurethane resins, polycarbonate resins, or polyvinyl chloride resins.
- Polyester resins such as polyethylene terephthalate, polyethylene-2,6-naphthalate, polypropylene terephthalate, polybutylene terephthalate, polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, polyamide resins, polyimide resins , Polyether resins, polyester amide resins,
- the film used contains 50% by weight or more of the thermoplastic resin described above.
- An original film on which a pattern is formed using the film production method and production apparatus of the present invention is a single-layer film made of a single resin listed above. It may also be a laminated film made up of a plurality of resin layers. In the case of a laminated film, it is easier to impart surface characteristics such as slipperiness and friction resistance, mechanical characteristics such as strength, and thermal characteristics such as heat resistance to the film as compared to a single layer film. In the case of a laminated film, it is preferable that the entire film satisfies the above-mentioned requirements. However, even if the film as a whole does not satisfy the above-mentioned requirements, at least a layer satisfying the above-mentioned requirements is formed on the surface layer. The desired pattern can be easily formed on the surface.
- the thickness (film thickness) of the film to be processed (processed film) is preferably in the range of 0.01 mm to 1 mm. If the thickness is less than 0.01 mm, there is not sufficient thickness for molding, and if the thickness exceeds 1 mm, the film may be difficult to transport in the production apparatus due to the rigidity of the film.
- Films to be processed are, for example, organic fine particles, inorganic fine particles, dispersants, dyes, fluorescent brighteners, antioxidants, weathering agents, antistatic agents, release agents, thickeners, plasticizers, It may contain a pH adjuster and a salt.
- carboxylic acids having a low surface tension such as long-chain carboxylic acids or long-chain carboxylates and derivatives thereof, and long-chain alcohols and their
- a small amount of a low surface tension alcohol compound such as a derivative or a modified silicone oil is preferably contained in the film to be processed (processed film).
- a release layer is laminated on the surface on which the pattern forming of the film to be processed (processed film) is performed.
- the durability of the release coating applied to the mold surface (repeated use) by providing a release layer in advance on the outermost surface of the film to be processed (processed film), that is, the surface in contact with the mold surface Frequency) can be improved. Even when a mold that partially loses the mold release effect is used, the release layer is present on the film side, so that the film is uniformly peeled from the mold surface. Even if the mold surface is not subjected to any mold release treatment, the film is smoothly peeled off from the mold surface due to the presence of the release layer on the film side. In this case, the mold release processing cost can be reduced.
- the release layer is present on the film side, it is possible to prevent the collapse of the molding pattern due to resin adhesion when the film is peeled off from the mold surface. Further, the film can be peeled at a higher temperature, and the cycle time can be shortened. Furthermore, by improving the slipperiness of the film surface, scratch resistance is improved, and defects caused in the manufacturing process can be reduced.
- a release layer may be provided on the surface on which either one of the pattern forming is scheduled, or both outermost layers may be separated.
- a mold layer may be provided.
- the resin constituting the release layer is not particularly limited, but is preferably a resin mainly composed of silicone resin, fluorine resin, fatty acid resin, polyester resin, olefin resin, and melamine resin. Of these, silicone resins, fluorine resins, and fatty acid resins are more preferable.
- an acrylic resin, a urethane resin, an epoxy resin, a urea resin, a phenol resin, or the like may be blended in the release layer.
- the thickness of the release layer is not particularly limited, but is preferably in the range of 0.01 ⁇ m to 5 ⁇ m. When the thickness of the release layer is less than 0.01 ⁇ m, the above-mentioned release property improving effect may be lowered.
- the method for forming the release layer on the surface of the film to be processed (processed film) is not particularly limited, but various coating methods such as reverse coating method, gravure coating method, rod coating method, bar coating method, die coating. Or spray coating can be used.
- the release layer is preferably formed by in-line coating performed simultaneously with the formation of the film to be processed (processed film) from the viewpoint of productivity and coating uniformity.
- a film production apparatus 1 shown in FIG. 1 was used for production of a film having a fine uneven pattern.
- Mold 3 used Size of mold 3: 500 mm (width direction of film 2) ⁇ 800 mm (running direction of film 2) ⁇ 20 mm (thickness).
- Fine concavo-convex pattern formed on the mold surface 3a a plurality of stripes facing the longitudinal direction of the mold surface 3a and spaced in the width direction of the mold surface 3a. Is a right triangle, the height of the right triangle is 10 ⁇ m, the length of the base is 5 ⁇ m, and the bases of adjacent right triangles are adjacent to each other.
- Used film pressing device 10 Pressing device of the hydraulic pump pressurization type with a maximum pressure of 3000 kN.
- the upper temperature control plate 15a and the lower temperature control plate 15b are both made of an aluminum alloy and have a size of 700 mm (the width direction of the film 2) ⁇ 1000 mm (the traveling direction of the film 2).
- Each temperature control plate is engaged with the heating unit 30 and the cooling unit 40, respectively.
- the heating unit 30 is a heat medium circulation system.
- the heat medium is Barrel Therm # 400 (manufactured by Matsumura Oil Co., Ltd.)
- the temperature of the heat medium is 150 ° C., and the flow rate is 100 L / min.
- the cooling unit 40 is a cooling water circulation system.
- the temperature of the cooling water is 20 ° C., and the flow rate is 150 L / min.
- Film gripping device 20 used It consists of a combination of a main roll 21 and an auxiliary roll 22.
- the outer diameter of the main roll 21 is 150 mm.
- the outermost layer is a silicone rubber having a rubber hardness of 60 (JIS K6253) and a surface centerline average roughness of 0.5 ⁇ m (JIS B0601).
- the main roll rotation driving means 23 is composed of a combination of a servo motor and a servo amplifier capable of switching the rotation direction of the main roll 21.
- the outer diameter of the auxiliary roll 22 is 50 mm.
- the outermost layer is a fluororesin.
- the distance (clearance H) between the main roll 21 and the mold surface 3a is 0.5 mm.
- the film gripping device movement driving means 29 for reciprocating the film gripping device 20 including the main roll 21 and the auxiliary roll 22 along the mold surface 3a is composed of a servo motor.
- the forming material of the film 2 is polyethylene terephthalate.
- the film 2 has a thickness of 38 ⁇ m (thickness variation: ⁇ 3 ⁇ m) and a width of 520 mm.
- the film 2 was sent out from the film take-out device 50 installed on the upstream side of the film pressing device 10 and taken up by the film take-up device 60 installed on the downstream side of the film press device 10.
- the auxiliary roll 22 After opening the film fixing portion 65 on the downstream side in the film transport direction, the auxiliary roll 22 is moved to the upper side of the main roll 21 to wind the film 2 around both rolls in an S shape (FIG. 3 (c ) State).
- the servo motor of the film gripping device movement driving means 29 was operated while the main roll 21 was rotated forward so that the peripheral speed was 20 m / min.
- the film 2 was peeled from the mold surface 3a while the main roll 21 moved to the upstream side.
- the film holding device 20 including the main roll 21 and the auxiliary roll 22 is opened.
- the brake was applied so as not to move in the transport direction of the film 2.
- the main roll 21 is rotated forward at a peripheral speed of 20 m / min, the film 2 for an intermittent feed length of 850 mm is passed through the main roll 21 and the auxiliary roll 22, and in the space above the mold 3, I sent it.
- the film 2 for the intermittent feed length to the film manufacturing apparatus 1 was supplied (state shown in FIG. 3F).
- a constant tension was applied to the film 2 by the transport drive roll 64 on the downstream side so that the film 2 fed into the space above the mold 3 was not loosened and contacted with the mold surface 3a.
- the servo motor of the film gripping device moving drive means 29 was operated.
- the film holding apparatus 20 including the main roll 21 and the auxiliary roll 22 moved to the downstream side (state shown in FIG. 3G).
- the film 2 previously fed into the space above the mold 3 is supplied to the mold surface 3a, and wrinkles in the supplied film 2 by the main roll 21 that moves together with the supply of the film 2 are supplied. Occurrence was prevented.
- a constant tension was applied to the film 2 by the downstream transport drive roll 64 so that the film 2 does not come into contact with the mold surface 3a.
- the auxiliary roll revolving drive means 24 was operated to return the auxiliary roll 22 to the standby position 22P (a state from FIG. 3 (h) to FIG. 3 (a)).
- the above operation was repeated 10 times to produce 10 molded films.
- the intermittent feed length of the film and the length of the formed film do not necessarily match, and there may be a portion where no pattern is formed between the respective end portions, or at each end portion. There may be a portion where the pattern is overlapped. These portions are appropriately cut and removed when one molded film having a desired length is finally produced.
- a film production apparatus 401 shown in FIG. 4 was used to produce a film having a fine uneven pattern.
- Film gripping device 20 used It consists of a combination of a main roll 21 and an auxiliary roll 22.
- the outer diameter of the main roll 21 is 150 mm.
- the outermost layer is a silicone rubber having a rubber hardness of 60 (JIS K6253) and a surface centerline average roughness of 0.5 ⁇ m (JIS B0601).
- the main roll rotation driving means 23 is a servo motor.
- the outer diameter of the auxiliary roll 22 is 50 mm.
- the outermost layer is a fluororesin.
- the distance (clearance H) between the main roll 21 and the mold surface 3a is 10 mm.
- the film gripping device movement driving means 29 for reciprocating the film gripping device 20 including the main roll 21 and the auxiliary roll 22 along the mold surface 3a is composed of a servo motor.
- the outer diameter of the wrinkle stretching roll 421 is 50 mm.
- the outermost layer is a silicone sponge.
- the distance (clearance H) between the wrinkle stretching roll 421 and the mold surface 3a is approximately 0 mm. That is, the wrinkle stretching roll 421 is in contact with the surface 2 b of the film 2.
- the auxiliary roll 22 was moved to the upper side of the main roll 21 to wind the film 2 around both rolls in an S shape (FIG. 5 (c ) State).
- the servo motor of the film gripping device movement driving means 29 was operated while the main roll 21 was rotated forward so that the peripheral speed was 20 m / min.
- the film 2 was peeled from the mold surface 3a while the main roll 21 moved to the upstream side.
- the film holding device 20 including the main roll 21 and the auxiliary roll 22 is opened.
- the brake was applied so as not to move in the transport direction of the film 2.
- the main roll 21 is rotated forward at a peripheral speed of 20 m / min, the film 2 for an intermittent feed length of 850 mm is passed through the main roll 21 and the auxiliary roll 22, and in the space above the mold 3, I sent it.
- the film 2 for the intermittent feed length to the film manufacturing apparatus 401 was supplied (state shown in FIG. 5 (f)).
- a constant tension was applied to the film 2 by the transport drive roll 64 on the downstream side so that the film 2 fed into the space above the mold 3 was not loosened and contacted with the mold surface 3a.
- the servo motor of the film gripping device moving drive means 29 was operated. Thereby, the film holding apparatus 20 including the main roll 21 and the auxiliary roll 22 moved to the downstream side (state shown in FIG. 5G). By this movement, the film 2 previously fed into the space above the mold 3 is supplied to the mold surface 3a. On the other hand, wrinkle generation in the film 2 supplied to the mold surface 3a is prevented from the wrinkle-stretching roll 421 that moves with the movement of the film gripping device 20.
- the above operation was repeated 10 times to produce 10 molded films.
- As a result of visual evaluation of the molding surface of the obtained molded film it was confirmed that no peeling trace was observed and a uniform molding surface free from molding wrinkles, conveyance wrinkles and waviness was obtained.
- the time from the start of the peeling operation of the film (processed film) 2 from the mold surface 3a to the completion of the supply of the new film (processed film) 2 was 20 seconds.
- a film production apparatus 401 shown in FIG. 4 was used to produce a film having a fine uneven pattern.
- the auxiliary roll 22 was moved to the upper side of the main roll 21, and the film 2 was wound around both rolls in an S shape (FIG. 6 ( c)).
- the servo motor of the film gripping device movement driving means 29 was operated while the main roll 21 was rotated forward so that the peripheral speed was 20 m / min.
- the film 2 was peeled from the mold surface 3a while the main roll 21 moved upstream (state from FIG. 6 (d) to FIG. 6 (e)).
- the upstream film fixing portion 54 is opened, and the main roll rotation driving means 23 rotates the main roll 21.
- the film gripping device movement driving means 29 was operated in a state where the film was blocked, and the film gripping device 20 was moved to the downstream side at a speed of 20 m / min.
- the wrinkle stretching roll 421 that moves along with the movement of the film gripping device 20 prevented wrinkles from occurring in the film 2 supplied to the mold surface 3a (the state shown in FIG. 6F).
- a constant tension was applied to the film 2 by the transport drive roll 64 on the downstream side so that the film 2 was not loosened and contacted with the mold surface 3a.
- the auxiliary roll revolving drive means 24 was operated to return the auxiliary roll 22 to the standby position 22P (a state from FIG. 6 (g) to FIG. 6 (a)).
- the above operation was repeated 10 times to produce 10 molded films.
- As a result of visual evaluation of the molding surface of the obtained molded film it was confirmed that no peeling trace was observed and a uniform molding surface free from molding wrinkles, conveyance wrinkles and waviness was obtained.
- the time from the start of the peeling operation of the film (processed film) 2 from the mold surface 3a to the completion of the supply of the new film (processed film) 2 was 15 seconds.
- a film manufacturing apparatus 701 shown in FIG. 7 was used for manufacturing a film having a fine uneven pattern.
- Film gripping device 20 used It consists of a combination of a main roll 21 and an auxiliary roll 22.
- the outer diameter of the main roll 21 is 150 mm.
- the outermost layer is a silicone rubber having a rubber hardness of 60 (JIS K6253) and a surface centerline average roughness of 0.5 ⁇ m (JIS B0601).
- the main roll 21 is rotatably attached to a pair of main roll support arms 21Aa and 21Ab.
- the outer diameter of the auxiliary roll 22 is 50 mm.
- the outermost layer is a fluororesin.
- the auxiliary roll 22 is rotatably attached to a pair of auxiliary roll revolving support arms 22Aa and 22Ab.
- the distance (clearance H) between the main roll 21 and the mold surface 3a is 10 mm.
- the film gripping device movement driving means 29 for reciprocating the film gripping device 20 including the main roll 21 and the auxiliary roll 22 along the mold surface 3a is composed of a servo motor.
- the outer diameter of the wrinkle stretching roll 421 is 50 mm.
- the outermost layer is a silicone sponge.
- the wrinkle stretching roll 421 is rotatably attached to the pair of wrinkle stretching roll support arms 22Da and 22Db.
- the distance (clearance H) between the wrinkle stretching roll 421 and the mold surface 3a is approximately 0 mm. That is, the wrinkle stretching roll 421 is in contact with the surface 2 b of the film 2.
- the film tension adjusting means 70 is provided in the film transport path 2 ⁇ / b> A between the film gripping device 20 and the transport drive roll 64.
- a nip roll 64 a may be provided with the film 2 sandwiched between the transport drive roll 64.
- the film tension adjusting means 70 includes a guide roll 71, a conveyance drive roll 64, a tension detection roll 72 that contacts the surface of the film 2 from the guide roll 71 to the conveyance drive roll 64, and the tension detection roll. It comprises tension detecting means (tensometer) 73 engaged with 72. While the film 2 is peeled off, the driving of the transport drive roll 64 is controlled so that the tension value detected by the tension meter 73 is constant.
- the tension meter 73 detects the tension acting on the film 2 by load cells provided at bearing support portions at both ends of a tension detecting roll 72 that is rotatably supported.
- Operation method of main apparatus elements used in the film manufacturing apparatus 701 In advance, the film 2 was passed from the film take-out device 50 to the film take-out device 60 through the film pressing device 10 along the film transport path 2A. Next, after the upper temperature control plate 15a and the lower temperature control plate 15b were both heated to a temperature of 120 ° C., the upper temperature control plate 15a was lowered and the pressing of the film 2 was started. The pressing was performed on the mold surface 3a with a pressing force of 5 MPa and a pressing time of 30 seconds. Thereafter, both the upper temperature control plate 15a and the lower temperature control plate 15b were cooled while the press was continued. Cooling was stopped when each temperature control plate reached a temperature of 70 ° C. After the cooling of each temperature control plate was completed, the press was released. The upper temperature control plate 15a was raised to the upper limit, and then the film release apparatus 20A was operated.
- the auxiliary roll 22 is moved to the upper side of the main roll 21 and wound around both rolls of the film 2 in an S shape (FIG. 9C). State shown in).
- the main roll 21 was moved upstream in a state where the peripheral speed was 20 m / min, and the film 2 was peeled off from the mold surface 3a.
- the film holding device 20 including the main roll 21 and the auxiliary roll 22 is opened.
- the brake was applied so as not to move in the transport direction of the film 2.
- the film 2 having a length of 1000 mm was taken up by the transport drive roll 64 at a speed of 20 m / min as the length of intermittent feed (state shown in FIG. 9F).
- the servo motor of the film gripping device movement driving means 29 was operated to move the film gripping device 20 to the downstream side at a speed of 20 m / min.
- the wrinkle stretching roll 421 moves along the surface of the film 2 to be supplied, and the generation of wrinkles in the film 2 supplied to the mold surface 3a is prevented (state shown in FIG. 9 (g)).
- the film tension adjusting means 70 a tension of 9.8 N was uniformly applied to the entire width of the film 2.
- the auxiliary roll revolving drive means 24 was operated to return the auxiliary roll 22 to the standby position 22P (a state from FIG. 9 (h) to FIG. 9 (a)).
- the above operation was repeated 10 times to produce 10 molded films.
- As a result of visual evaluation of the molding surface of the obtained molded film it was confirmed that no peeling trace was observed and a uniform molding surface free from molding wrinkles, conveyance wrinkles and waviness was obtained.
- the time from the start of the mold release operation of the film (processed film) 2 from the mold surface 3a to the completion of the supply of the new film (processed film) 2 was 20 seconds.
- Method for peeling film 2 from used mold surface 3a The film 2 was peeled off from the mold surface 3a by feeding the film 2 from the mold surface 3a to the downstream side by the conveyance drive roll 64. In response to the delivery of the film, a new film 2 was supplied to the mold surface 3a.
- the apparatus elements and manufacturing conditions other than the apparatus elements and manufacturing conditions related to the film peeling method and the new film supplying method were the same as those in Example 1.
- the peeling of the film 2 from the mold surface 3a and the supply of the film 2 to the mold surface 3a were performed with a tension acting on the film 2 by the transport drive roll 64. This operation was repeated 10 times to produce 10 molded films.
- the method and apparatus for producing a film having a fine concavo-convex pattern on the surface of the present invention are used for producing a film having a fine concavo-convex pattern on the surface used as a material for forming an optical medium or optical product.
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Abstract
Description
(1-b)前記フィルム供給工程において前記金型表面に供給された前記被処理フィルムを、前記金型表面に押圧することにより、前記金型表面の前記パターンを前記被処理フィルムの表面に転写し、前記被処理フィルムの表面に微細な凹凸パターンを成形するパターン成形工程、
(1-c)前記パターン成形工程において表面に前記パターンが成形された処理済みフィルムを、前記金型表面から剥離するフィルム剥離工程、および、
(1-d)前記フィルム剥離工程において前記金型表面から剥離された前記処理済みフィルムを、下流側に位置する長尺のフィルムの収容源へと送給するフィルム送出工程、
からなり、前記パターン成形工程において成形された処理済みフィルムが、前記フィルム剥離工程において前記金型表面から剥離され、その後、次に処理されるフィルムが、前記フィルム供給工程において所定の長さ分間欠的に前記金型表面に供給されることに対応して、前記処理済みフィルムが、前記フィルム送出工程において前記フィルムの収容源へと送給されることにより、前記処理済みフィルムが所定の長さ分順次繰り返されて製造される表面に微細な凹凸パターンを有するフィルムの製造方法であって、
(1-e)前記フィルム剥離工程における前記処理済みフィルムの剥離が、前記処理済みフィルムを把持したフィルム把持手段の前記処理済みフィルムの長手方向の下流側から上流側への移動により行われ、かつ、
(1-f)前記フィルム供給工程における前記被処理フィルムの供給が、前記金型表面に供給される前記被処理フィルムにおけるしわ発生を防止するしわ発生防止手段の前記被処理フィルムの長手方向の上流側から下流側への移動とともに行われる表面に微細な凹凸パターンを有するフィルムの製造方法。
(2-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をもって、互いに平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(2-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(2-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止している間に、前記主ロールと前記補助ロールが回転することにより、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、当該新たな所定の長さの被処理フィルムの供給が完了した後、
(2-d)前記しわ発生防止手段として、前記主ロールが用いられ、
(2-e)前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側へ移動する間に、前記主ロールが回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造方法。
(3-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をもって、互いに平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(3-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(3-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止している間に、前記主ロールと前記補助ロールが回転することにより、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、当該新たな所定の長さの被処理フィルムの供給が完了した後、
(3-d)前記しわ発生防止手段として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触する回転可能なしわ伸ばしロールが用いられ、
(3-e)前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側へ移動する間に、前記しわ伸ばしロールが、前記フィルム把持手段の移動に追従して回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造方法。
(4-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(4-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(4-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止した後、前記主ロールの回転が阻止されている状態で、前記フィルム把持手段が、前記上流側から前記下流側に移動することにより、前記新たな所定の長さの被処理フィルムの供給が行われ、
(4-d)前記しわ発生防止手段として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触する回転可能なしわ伸ばしロールが用いられ、
(4-e)前記被処理フィルムの供給において、前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側への移動する間に、前記しわ伸ばしロールが、前記フィルム把持手段の移動に追従して回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造方法。
(5-b)上流側に位置する長尺のフィルムの供給源から被処理フィルムを取り出すフィルム取出装置と、
(5-c)前記被処理フィルムを前記金型の表面に押圧するフィルム押圧装置と、
(5-d)前記フィルム取出装置により取り出され、かつ、前記金型の表面に間欠的に供給された被処理フィルムが前記フィルム押圧装置により前記金型の表面に押圧されることにより、前記被処理フィルムの表面に前記金型の表面の前記微細な凹凸パターンが転写されて成形された微細な凹凸パターンを有する処理済みフィルムを、前記金型の表面から剥離するフィルム剥離装置と、
(5-e)該フィルム剥離装置により前記金型の表面から剥離され、下流側に送り出された前記処理済みフィルムを、下流側に位置する前記長尺のフィルムの収容源へと引き取るフィルム引取装置、
からなり、前記フィルム押圧装置により処理された処理済みフィルムを、前記フィルム剥離装置により前記金型表面から剥離し、前記フィルム取出装置により取り出された被処理フィルムを、前記フィルム剥離装置により前記金型表面に所定の長さ供給することに対応して、前記フィルム引取装置に前記処理済みフィルムを送り出すことにより、前記所定の長さの処理済みフィルムが順次繰り返されて製造される表面に微細な凹凸パターンを有するフィルムの製造装置であって、
(5-f)前記フィルム剥離装置が、前記処理済みフィルムを把持した状態で、前記処理済みフィルムの長手方向に沿って、下流側から上流側へと移動するフィルム把持装置を含み、かつ、
(5-g)前記フィルム把持装置が、前記金型の表面に供給される前記被処理フィルムにおけるしわ発生を防止するしわ発生防止装置を含み、前記被処理フィルムの供給が、該しわ発生防止装置の前記被処理フィルムの長手方向の上流側から下流側への移動とともに行われる表面に微細な凹凸パターンを有するフィルムの製造装置。
(6-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(6-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(6-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(6-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(6-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(6-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(6-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(6-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(6-i)前記フィルム把持装置が、前記上流側に移動した位置で停止している間に、前記主ロールと前記補助ロールの回転により、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、
(6-j)前記しわ発生防止装置として、前記主ロールが用いられ、
(6-k)前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記主ロールが回転しながら移動することにより、前記主ロールと前記補助ロールを経て前記下流側へと既に供給されている前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に、前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造装置。
(7-a)前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなることが好ましい。
(8-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(8-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(8-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(8-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(8-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(8-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(8-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(8-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(8-i)前記フィルム把持装置が、前記上流側に移動した位置で停止している間に、前記主ロールと前記補助ロールの回転により、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、
(8-j)前記しわ発生防止装置として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触するしわ伸ばしロールが用いられ、
(8-k)該しわ伸ばしロールは、しわ伸ばしロール支持アームに、そのロール軸を中心として回転可能に支持され、該しわ伸ばしロール支持アームは、前記台座に固定され、
(8-l)前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記しわ伸ばしロールが、前記フィルム把持装置の移動に追従して、回転しながら移動することにより、前記主ロールと前記補助ロールを経て前記下流側へと既に供給されている前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に、前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造装置。
(9-a)前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなることが好ましい。
(10-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(10-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(10-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(10-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(10-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(10-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(10-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(10-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(10-i)前記フィルム把持装置が、前記上流側に移動した位置で停止した後、前記主ロールの回転が阻止されている状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って前記上流側から前記下流側に移動せしめられることにより、前記金型の表面に前記新たな所定の長さの被処理フィルムの供給が行われ、
(10-j)前記しわ発生防止装置として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触するしわ伸ばしロールが用いられ、
(10-k)該しわ伸ばしロールは、しわ伸ばしロール支持アームに、そのロール軸を中心として回転可能に支持され、該しわ伸ばしロール支持アームは、前記台座に固定され、
(10-l)前記被処理フィルムの供給において、前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記しわ伸ばしロールが、前記フィルム把持装置の移動に追従して、回転しながら移動することにより、前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に前記新たな所定の長さの被処理フィルムの供給が行われる上記本発明のフィルムの製造装置。
(11-a)前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなることが好ましい。
(12-a)前記主ロールの外表面が、シリコーン系樹脂またはフッ素系樹脂を主成分とする発泡スポンジから形成されていることが好ましい。
(13-a)前記しわ伸ばしロールの外表面が、シリコーン系樹脂またはフッ素系樹脂を主成分とする発泡スポンジから形成されていることが好ましい。
2 フィルム(被処理フィルム)
2A フィルム搬送路
2F フィルム収容源(処理済みフィルムロール)
2Fa フィルムロール
2S フィルム供給源(被処理フィルムロール)
2Sa フィルムロール
2a フィルムのパターンが成形される面(成形面)
2b フィルムのパターンが成形される面(成形面)とは反対側の面
3 金型
3a 金型表面
10 フィルム押圧装置
11 支柱
12 押圧シリンダー
14a 上加圧プレート
14b 下加圧プレート
15a 上温調プレート
15b 下温調プレート
16S 移動基台
16a 上固定基台
16b 下固定基台
17 弾性板
20 フィルム把持装置
20A フィルム剥離装置
20B しわ発生防止装置
21 主ロール(剥離ロール)
21Aa、21Ab 一対の主ロール支持アーム
22 補助ロール
22Aa、22Ab 一対の補助ロール公転支持アーム
22Ba、22Bb 一対の補助ロール公転駆動軸
22Ca、22Cb 一対の補助ロール支持アーム
22Da、22Db 一対のしわ伸ばしロール支持アーム
22p 待機位置(元の位置、初期位置)
23 主ロール(剥離ロール)回転駆動手段
24 補助ロール公転駆動手段
25a、25b 一対の台座移動ガイド
26a、26b 一対の台座
28 主ロール回転制御器
29 フィルム把持装置移動駆動手段
30 加熱ユニット
40 冷却ユニット
50 フィルム取出装置
51 巻出ロール回転駆動手段
52a、52b、52c、52d 搬送ロール
53 巻出バッファ部
54 フィルム固定部
55 ボックス
56 吸引排気手段
57a、57b センサー
60 フィルム引取装置
61 巻取ロール回転駆動手段
62a、62b、62c 搬送ロール
63 巻取バッファ部
64 搬送駆動ロール
64a ニップロール
65 フィルム固定部
66 ボックス
67 吸引排気手段
68a、68b センサー
70 フィルム張力調整手段
71 ガイドロール
72 張力検知用ロール
73 張力検知手段
401 フィルムの製造装置
420B しわ発生防止装置
421 しわ伸ばしロール
701 フィルムの製造装置
A 上流側
B 下流側
C 正回転方向
D 逆回転方向
H 主ロールあるいはしわ伸ばしロールと金型表面の距離(クリアランス)
金型3のサイズ:500mm(フィルム2の幅方向)×800mm(フィルム2の走行方向)×20mm(厚み)。
最大加圧力が3000kNの油圧ポンプ加圧形式の押圧装置。上温調プレート15aおよび下温調プレート15bは、いずれも、アルミ合金製でサイズが700mm(フィルム2の幅方向)×1000mm(フィルム2の走行方向)。各温調プレートは、それぞれ、加熱ユニット30ならびに冷却ユニット40に係合されている。加熱ユニット30は、熱媒循環方式。熱媒は、バーレルサーム#400(松村石油株式会社製)熱媒の温度は、150℃、その流量は、100L/min。冷却ユニット40は、冷却水循環方式。冷却水の温度は、20℃、その流量は、150L/min。
主ロール21と補助ロール22の組み合わせからなる。主ロール21の外径は、150mm。その最外層は、ゴム硬度が60(JIS K6253)、表面の中心線平均粗さが0.5μm(JIS B0601)のシリコーンゴム。主ロール回転駆動手段23は、主ロール21の回転方向の切り替えが可能なサーボモーターとサーボアンプの組み合わせからなる。補助ロール22の外径は、50mm。その最外層は、フッ素樹脂。主ロール21と金型表面3aとの距離(クリアランスH)は、0.5mm。主ロール21と補助ロール22を含むフィルム把持装置20を金型表面3aに沿って往復移動させるフィルム把持装置移動駆動手段29は、サーボモーターからなる。
フィルム2の形成材料は、ポリエチレンテレフタレート。フィルム2の厚みは、38μm(厚みむら:±3μm)、幅は、520mm。フィルム2は、フィルム押圧装置10の上流側に設置したフィルム取出装置50から送り出され、フィルム押圧装置10の下流側に設置したフィルム引取装置60によって巻き取った。
予め、フィルム2を、フィルム取出装置50からフィルム引取装置60まで、フィルム押圧装置10を経由して、フィルム搬送路2Aに沿って、通した。次に、上温調プレート15aと下温調プレート15bがともに温度120℃となるまで加熱した後、上温調プレート15aを下降させて、フィルム2のプレスを開始した。プレスは、金型表面3aで、押圧力5MPa、押圧時間30秒で実施した。その後、プレスを継続したまま、上温調プレート15aおよび下温調プレート15bをともに冷却した。各温調プレートが温度70℃になったときに冷却を停止した。各温調プレートの冷却が完了した後、プレスを開放した。上温調プレート15aを上限まで上昇させ、その後、フィルム剥離装置20Aを作動させた。
主ロール21と補助ロール22の組み合わせからなる。主ロール21の外径は、150mm。その最外層は、ゴム硬度が60(JIS K6253)、表面の中心線平均粗さが0.5μm(JIS B0601)のシリコーンゴム。主ロール回転駆動手段23は、サーボモーター。補助ロール22の外径は、50mm。その最外層は、フッ素樹脂。主ロール21と金型表面3aとの距離(クリアランスH)は、10mm。主ロール21と補助ロール22を含むフィルム把持装置20を金型表面3aに沿って往復移動させるフィルム把持装置移動駆動手段29は、サーボモーターからなる。
しわ伸ばしロール421の外径は、50mm。その最外層は、シリコーンスポンジ。しわ伸ばしロール421と金型表面3aとの距離(クリアランスH)は、ほぼ0mm。すなわち、しわ伸ばしロール421は、フィルム2の表面2bに接触している状態とした。
予め、フィルム2を、フィルム取出装置50からフィルム引取装置60まで、フィルム押圧装置10を経由して、フイルム搬送路2Aに沿って、通した。次に、上温調プレート15aと下温調プレート15bがともに温度120℃となるまで加熱した後、上温調プレート15aを下降させて、フィルム2のプレスを開始した。プレスは、金型表面3aで、押圧力5MPa、押圧時間30秒で実施した。その後、プレスを継続したまま、上温調プレート15aおよび下温調プレート15bをともに冷却した。各温調プレートが温度70℃になったときに冷却を停止した。各温調プレートの冷却が完了した後、プレスを開放した。上温調プレート15aを上限まで上昇させ、その後、フィルム剥離装置20Aを作動させた。
予め、フィルム2を、フィルム取出装置50からフィルム引取装置60まで、フィルム押圧装置10を経由して、フィルム搬送路2Aに沿って、通した。次に、上温調プレート15aと下温調プレート15bがともに温度120℃となるまで加熱した後、上温調プレート15aを下降させて、フィルム2のプレスを開始した。プレスは、金型表面3aで、押圧力5MPa、押圧時間30秒で実施した。その後、プレスを継続したまま、上温調プレート15aおよび下温調プレート15bをともに冷却した。各温調プレートが温度70℃になったときに冷却を停止した。各温調プレートの冷却が完了した後、プレスを開放した。上温調プレート15aを上限まで上昇させ、その後、フィルム剥離装置20Aを作動させた。
主ロール21と補助ロール22の組み合わせからなる。主ロール21の外径は、150mm。その最外層は、ゴム硬度が60(JIS K6253)、表面の中心線平均粗さが0.5μm(JIS B0601)のシリコーンゴム。主ロール21は、一対の主ロール支持アーム21Aa、21Abに回転自在に取り付けられている。補助ロール22の外径は、50mm。その最外層は、フッ素樹脂。補助ロール22は、一対の補助ロール公転支持アーム22Aa、22Abに回転自在に取り付けられている。主ロール21と金型表面3aとの距離(クリアランスH)は、10mm。主ロール21と補助ロール22を含むフィルム把持装置20を金型表面3aに沿って往復移動させるフィルム把持装置移動駆動手段29は、サーボモーターからなる。
しわ伸ばしロール421の外径は、50mm。その最外層は、シリコーンスポンジ。しわ伸ばしロール421は、一対のしわ伸ばしロール支持アーム22Da、22Dbに回転自在に取り付けられている。しわ伸ばしロール421と金型表面3aとの距離(クリアランスH)は、ほぼ0mm。すなわち、しわ伸ばしロール421は、フィルム2の表面2bに接触している状態とした。
フィルム張力調整手段70は、フィルム把持装置20と搬送駆動ロール64との間のフィルム搬送路2Aに設けられている。搬送駆動ロール64に対して、フィルム2を挟んで、ニップロール64aが設けられていても良い。図7において、フィルム張力調整手段70は、ガイドロール71と、搬送駆動ロール64と、ガイドロール71から搬送駆動ロール64に至るフィルム2の表面に接する張力検知用ロール72と、この張力検知用ロール72に係合した張力検知手段(張力計)73からなる。フィルム2が剥離されている間、張力計73で検知される張力値が一定になるように、搬送駆動ロール64の駆動が制御される。この張力計73は、回転自在に支持されている張力検知用ロール72の両端の軸受の支持部に設けられたロードセルにより、フィルム2に作用している張力を検知する。
予め、フィルム2を、フィルム取出装置50からフィルム引取装置60まで、フィルム押圧装置10を経由して、フィルム搬送路2Aに沿って、通した。次に、上温調プレート15aと下温調プレート15bがともに温度120℃となるまで加熱した後、上温調プレート15aを下降させて、フィルム2のプレスを開始した。プレスは、金型表面3aで、押圧力5MPa、押圧時間30秒で実施した。その後、プレスを継続したまま、上温調プレート15aおよび下温調プレート15bをともに冷却した。各温調プレートが温度70℃になったときに冷却を停止した。各温調プレートの冷却が完了した後、プレスを開放した。上温調プレート15aを上限まで上昇させ、その後、フィルム離型装置20Aを作動させた。
搬送駆動ロール64によりフィルム2を金型表面3aから下流側に送り出すことにより、金型表面3aからのフィルム2の剥離を行った。また、このフィルムの送り出しに応じて、新たなフィルム2が金型表面3aに供給された。これらフィルムの剥離方法および新たなフィルムの供給方法に関係する装置要素および製造条件以外の装置要素および製造条件は、実施例1の場合と同じとした。
Claims (13)
- (1-a)上流側に位置する長尺のフィルムの供給源から取り出された被処理フィルムを、微細な凹凸パターンを有する金型表面に所定の長さ分間欠的に供給するフィルム供給工程、
(1-b)前記フィルム供給工程において前記金型表面に供給された前記被処理フィルムを、前記金型表面に押圧することにより、前記金型表面の前記パターンを前記被処理フィルムの表面に転写し、前記被処理フィルムの表面に微細な凹凸パターンを成形するパターン成形工程、
(1-c)前記パターン成形工程において表面に前記パターンが成形された処理済みフィルムを、前記金型表面から剥離するフィルム剥離工程、および、
(1-d)前記フィルム剥離工程において前記金型表面から剥離された前記処理済みフィルムを、下流側に位置する長尺のフイルムの収容源へと送給するフィルム送出工程、
からなり、前記パターン成形工程において成形された処理済みフィルムが、前記フィルム剥離工程において前記金型表面から剥離され、その後、次に処理されるフィルムが、前記フィルム供給工程において所定の長さ分間欠的に前記金型表面に供給されることに対応して、前記処理済みフィルムが、前記フィルム送出工程において前記フィルムの収容源へと送給されることにより、前記処理済みフィルムが所定の長さ分順次繰り返されて製造される表面に微細な凹凸パターンを有するフィルムの製造方法であって、
(1-e)前記フィルム剥離工程における前記処理済みフィルムの剥離が、前記処理済みフィルムを把持したフィルム把持手段の前記処理済みフィルムの長手方向の下流側から上流側への移動により行われ、かつ、
(1-f)前記フィルム供給工程における前記被処理フィルムの供給が、前記金型表面に供給される前記被処理フィルムにおけるしわ発生を防止するしわ発生防止手段の前記被処理フィルムの長手方向の上流側から下流側への移動とともに行われる表面に微細な凹凸パターンを有するフィルムの製造方法。 - (2-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をもって、互いに平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(2-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフイルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(2-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止している間に、前記主ロールと前記補助ロールが回転することにより、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、当該新たな所定の長さの被処理フィルムの供給が完了した後、
(2-d)前記しわ発生防止手段として、前記主ロールが用いられ、
(2-e)前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側へ移動する間に、前記主ロールが回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる請求項1に記載のフィルムの製造方法。 - (3-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をもって、互いに平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(3-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(3-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止している間に、前記主ロールと前記補助ロールが回転することにより、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、当該新たな所定の長さの被処理フィルムの供給が完了した後、
(3-d)前記しわ発生防止手段として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触する回転可能なしわ伸ばしロールが用いられ、
(3-e)前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側へ移動する間に、前記しわ伸ばしロールが、前記フィルム把持手段の移動に追従して回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる請求項1に記載のフィルムの製造方法。 - (4-a)前記フィルム把持手段が、前記フィルムの前記パターンが成形される面とは反対側の面に接触する主ロールと前記フィルムの前記パターンが成形される面に接触する補助ロールの組み合わせからなり、該組み合わせにおいて、前記主ロールと前記補助ロールのそれぞれのロール軸は、前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、かつ、前記主ロールと前記補助ロールのそれぞれは、回転可能なロールであり、
(4-b)前記処理済みフィルムが前記主ロールと前記補助ロールにS字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成され、該把持状態が形成された後、前記フィルム把持手段が、前記金型表面に沿って前記下流側から前記上流側へ移動することにより、前記処理済みフィルムが、前記金型表面から剥離され、
(4-c)前記フィルム把持手段が、前記上流側へ移動した位置で停止した後、前記主ロールの回転が阻止されている状態で、前記フィルム把持手段が、前記上流側から前記下流側に移動することにより、前記新たな所定の長さの被処理フィルムの供給が行われ、
(4-d)前記しわ発生防止手段として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触する回転可能なしわ伸ばしロールが用いられ、
(4-e)前記被処理フィルムの供給において、前記フィルム把持手段が、前記金型表面に沿って前記上流側から前記下流側へ移動する間に、前記しわ伸ばしロールが、前記フィルム把持手段の移動に追従して回転しながら移動することにより、前記被処理フィルムのしわ発生を防止しながら、前記金型表面に前記新たな所定の長さの被処理フィルムの供給が行われる請求項1に記載のフィルムの製造方法。 - (5-a)表面に微細な凹凸パターンを有する金型と、
(5-b)上流側に位置する長尺のフィルムの供給源から被処理フィルムを取り出すフィルム取出装置と、
(5-c)前記被処理フィルムを前記金型の表面に押圧するフィルム押圧装置と、
(5-d)前記フィルム取出装置により取り出され、かつ、前記金型の表面に間欠的に供給された被処理フィルムが前記フィルム押圧装置により前記金型の表面に押圧されることにより、前記被処理フィルムの表面に前記金型の表面の前記微細な凹凸パターンが転写されて成形された微細な凹凸パターンを有する処理済みフィルムを、前記金型の表面から剥離するフィルム剥離装置と、
(5-e)該フィルム剥離装置により前記金型の表面から剥離され、下流側に送り出された前記処理済みフィルムを、下流側に位置する前記長尺のフィルムの収容源へと引き取るフィルム引取装置、
からなり、前記フィルム押圧装置により処理された処理済みフィルムを、前記フィルム剥離装置により前記金型表面から剥離し、前記フィルム取出装置により取り出された被処理フィルムを、前記フィルム剥離装置により前記金型表面に所定の長さ供給することに対応して、前記フィルム引取装置に前記処理済みフィルムを送り出すことにより、前記所定の長さの処理済みフィルムが順次繰り返されて製造される表面に微細な凹凸パターンを有するフィルムの製造装置であって、
(5-f)前記フィルム剥離装置が、前記処理済みフィルムを把持した状態で、前記処理済みフィルムの長手方向に沿って、下流側から上流側へと移動するフィルム把持装置を含み、かつ、
(5-g)前記フィルム把持装置が、前記金型の表面に供給される前記被処理フィルムにおけるしわ発生を防止するしわ発生防止装置を含み、前記被処理フィルムの供給が、該しわ発生防止装置の前記被処理フィルムの長手方向の上流側から下流側への移動とともに行われる表面に微細な凹凸パターンを有するフィルムの製造装置。 - (6-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(6-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(6-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(6-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(6-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(6-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(6-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(6-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(6-i)前記フィルム把持装置が、前記上流側に移動した位置で停止している間に、前記主ロールと前記補助ロールの回転により、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、
(6-j)前記しわ発生防止装置として、前記主ロールが用いられ、
(6-k)前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記主ロールが回転しながら移動することにより、前記主ロールと前記補助ロールを経て前記下流側へと既に供給されている前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に、前記新たな所定の長さの被処理フィルムの供給が行われる請求項5に記載のフィルムの製造装置。 - 前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなる請求項6に記載のフィルムの製造装置。
- (8-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(8-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(8-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(8-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(8-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(8-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(8-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(8-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(8-i)前記フィルム把持装置が、前記上流側に移動した位置で停止している間に、前記主ロールと前記補助ロールの回転により、前記新たな所定の長さの被処理フィルムの供給が、前記主ロールと前記補助ロールを経て前記下流側へと行われ、
(8-j)前記しわ発生防止装置として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触するしわ伸ばしロールが用いられ、
(8-k)該しわ伸ばしロールは、しわ伸ばしロール支持アームに、そのロール軸を中心として回転可能に支持され、該しわ伸ばしロール支持アームは、前記台座に固定され、
(8-l)前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記しわ伸ばしロールが、前記フィルム把持装置の移動に追従して、回転しながら移動することにより、前記主ロールと前記補助ロールを経て前記下流側へと既に供給されている前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に、前記新たな所定の長さの被処理フィルムの供給が行われる請求項5に記載のフィルムの製造装置。 - 前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなる請求項8に記載のフィルムの製造装置。
- (10-a)前記フィルム把持装置が、前記フィルムの前記パターンが成形される面とは反対側の面に接触可能な主ロールと前記フィルムの前記パターンが成形される面に接触可能な補助ロールの組み合わせからなり、
(10-b)前記主ロールのロール軸と前記補助ロールのロール軸は、それぞれ前記フィルムの幅方向を向き、前記主ロールと前記補助ロールは、前記フィルムが通過可能な間隔をおいて平行に位置し、
(10-c)前記主ロールは、主ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(10-d)前記補助ロールは、補助ロール支持アームに、そのロール軸を中心として回転可能に支持され、
(10-e)前記主ロール支持アームと前記補助ロール支持アームは、台座に固定され、
(10-f)該台座は、前記フィルムの長手方向に沿って設けられた台座移動ガイドに、前記フィルムの長手方向に移動可能に、支持され、かつ、
(10-g)前記フィルム把持装置に対し、該フィルム把持装置を前記台座移動ガイドに沿って移動させるフィルム把持装置移動手段が装備され、
(10-h)前記フィルム把持装置において、前記処理済みフィルムが、前記主ロールと前記補助ロールに、S字状に懸架されることにより、前記主ロールと前記補助ロールによる前記処理済みフィルムの把持状態が形成された状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、下流側から上流側へ移動せしめられることにより、前記処理済みフィルムの前記金型の表面からの剥離が行われ、
(10-i)前記フィルム把持装置が、前記上流側に移動した位置で停止した後、前記主ロールの回転が阻止されている状態で、前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って前記上流側から前記下流側に移動せしめられることにより、前記金型の表面に前記新たな所定の長さの被処理フィルムの供給が行われ、
(10-j)前記しわ発生防止装置として、前記主ロールの前記上流側において、前記主ロールに対し間隔をおいて平行に位置し、前記フィルムの前記パターンが成形される面とは反対側の面に接触するしわ伸ばしロールが用いられ、
(10-k)該しわ伸ばしロールは、しわ伸ばしロール支持アームに、そのロール軸を中心として回転可能に支持され、該しわ伸ばしロール支持アームは、前記台座に固定され、
(10-l)前記被処理フィルムの供給において、前記フィルム把持装置が、前記フィルム把持装置移動手段により、前記金型の表面に沿って、前記上流側から下流側へ移動せしめられる間に、前記しわ伸ばしロールが、前記フィルム把持装置の移動に追従して、回転しながら移動することにより、前記被処理フィルムにおけるしわ発生を防止しながら、前記金型の表面に前記新たな所定の長さの被処理フィルムの供給が行われる請求項5に記載のフィルムの製造装置。 - 前記フィルム把持装置移動手段が、前記主ロールと該主ロールを積極的に回転駆動する主ロール回転駆動手段との組み合わせ、および、前記台座と前記台座移動ガイドに沿って前記台座を積極的に移動せしめる台座駆動手段との組み合わせのいずれか一方、あるいは、これらの双方からなる請求項10に記載のフィルムの製造装置。
- 前記主ロールの外表面が、シリコーン系樹脂またはフッ素系樹脂を主成分とする発泡スポンジから形成されている請求項6、8、および、10のいずれかに記載のフィルムの製造装置。
- 前記しわ伸ばしロールの外表面が、シリコーン系樹脂またはフッ素系樹脂を主成分とする発泡スポンジから形成されている請求項8あるいは10に記載のフィルムの製造装置。
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EP09720070.3A EP2263858B1 (en) | 2008-03-14 | 2009-03-06 | Production method and production device of film having fine irregular pattern on surface |
JP2009520329A JP5482202B2 (ja) | 2008-03-14 | 2009-03-06 | 表面に微細な凹凸パターンを有するフィルムの製造方法および製造装置 |
CN2009801090182A CN101970210B (zh) | 2008-03-14 | 2009-03-06 | 在表面具有微细的凹凸图案的膜的制造方法和制造装置 |
US12/922,324 US8911655B2 (en) | 2008-03-14 | 2009-03-06 | Production method and production device of film having fine irregular pattern on surface |
US14/539,431 US9840039B2 (en) | 2008-03-14 | 2014-11-12 | Production method and production device of film having fine irregular pattern on surface |
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US12/922,324 A-371-Of-International US8911655B2 (en) | 2008-03-14 | 2009-03-06 | Production method and production device of film having fine irregular pattern on surface |
US14/539,431 Division US9840039B2 (en) | 2008-03-14 | 2014-11-12 | Production method and production device of film having fine irregular pattern on surface |
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EP (1) | EP2263858B1 (ja) |
JP (1) | JP5482202B2 (ja) |
KR (1) | KR101558956B1 (ja) |
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Also Published As
Publication number | Publication date |
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EP2263858A1 (en) | 2010-12-22 |
EP2263858B1 (en) | 2018-11-07 |
US20110001264A1 (en) | 2011-01-06 |
TWI495556B (zh) | 2015-08-11 |
JPWO2009113453A1 (ja) | 2011-07-21 |
US9840039B2 (en) | 2017-12-12 |
CN101970210B (zh) | 2013-09-04 |
JP5482202B2 (ja) | 2014-05-07 |
KR101558956B1 (ko) | 2015-10-08 |
EP2263858A4 (en) | 2017-08-02 |
CN101970210A (zh) | 2011-02-09 |
TW200944363A (en) | 2009-11-01 |
US20150072039A1 (en) | 2015-03-12 |
US8911655B2 (en) | 2014-12-16 |
KR20110004360A (ko) | 2011-01-13 |
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