WO2012133660A1 - Procédé et dispositif permettant de fabriquer un film de transfert de structure mince - Google Patents

Procédé et dispositif permettant de fabriquer un film de transfert de structure mince Download PDF

Info

Publication number
WO2012133660A1
WO2012133660A1 PCT/JP2012/058387 JP2012058387W WO2012133660A1 WO 2012133660 A1 WO2012133660 A1 WO 2012133660A1 JP 2012058387 W JP2012058387 W JP 2012058387W WO 2012133660 A1 WO2012133660 A1 WO 2012133660A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
film
roll
cooling
width direction
Prior art date
Application number
PCT/JP2012/058387
Other languages
English (en)
Japanese (ja)
Inventor
末宗徹也
箕浦潔
Original Assignee
東レ株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 東レ株式会社 filed Critical 東レ株式会社
Priority to KR1020137017693A priority Critical patent/KR101883193B1/ko
Priority to CN201280015339.8A priority patent/CN103459126B/zh
Priority to JP2013507726A priority patent/JP5924337B2/ja
Publication of WO2012133660A1 publication Critical patent/WO2012133660A1/fr

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets
    • 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

Definitions

  • the present invention relates to a method and an apparatus for producing a microstructure transfer film by transferring a fine concavo-convex pattern structure onto the surface of a thermoplastic film.
  • the microstructure transfer film obtained by this method is used as a member that requires micron-sized to nano-sized microstructures on its surface, such as optical films having optical functions such as diffusion, light collection, reflection, and transmission. It is done.
  • an optical film used for an optical film such as a prism sheet, a light diffusion sheet, or a lens sheet
  • the film is pressed against the surface of a belt-shaped mold having a fine uneven pattern formed on the surface, and the film
  • a method or apparatus that can be applied to a film made of a long thermoplastic material and that is continuously processed from unwinding through a transfer process to winding is proposed.
  • a method for peeling the film after cooling the mold is described.
  • the mold is heated and cooled by bringing the endless belt mold into contact with the heating roll and the cooling roll, and the fine structure is transferred to the film between the heating roll and the nip roll facing the heating roll. It is carried out by sandwiching a mold made of an endless belt and a film.
  • the temperature at the time of transfer and the temperature at the time of peeling can be controlled independently, so even if the mold temperature at the time of transfer is set high, the releasability will not be a problem. Transcription is possible.
  • the object of the present invention is to solve the above-mentioned problems of the prior art, by pressing a mold made of an endless belt having a fine structure formed on a surface of a film made of a thermoplastic resin, and forming a fine structure on the surface of the film.
  • a manufacturing method and manufacturing apparatus for a microstructure transfer film for continuously transferring a film a method for manufacturing a microstructure transfer film that can be stably conveyed without meandering the film even when high-precision shape transfer is performed at high speed And providing a manufacturing apparatus.
  • the present invention has the following configuration. That is, (1) A film having a transferred layer on at least one surface using an apparatus for manufacturing a microstructure transfer film having an endless belt-shaped transfer mold having a microstructure on the surface suspended by a heating roll and a cooling roll, A method for producing a microstructure transfer film, which is processed by passing at least the following steps [I] to [V] in this order under conditions satisfying the following [A1] or [A2]. [I] A mold heating step in which an endless belt-shaped mold having a microstructure formed on the surface is heated while being held in a heated heating roll.
  • the width of the mold is wider than the width of the film, and the width of the region where the film is pressed in the pressure transfer step is narrower than the width of the film.
  • the cooling roll is provided with means for adjusting the position of the mold in the conveying direction and means for detecting the tension applied to the mold, and the tension applied to the mold is always within a predetermined range. Thus, the position of the cooling roll is controlled.
  • a meandering detection sensor for detecting a position in the width direction and a means for adjusting the angle of the cooling roll are installed in the mold so that the position in the width direction of the mold is always within a predetermined range. In addition, the angle of the cooling roll is controlled. (3) The peeling roll for peeling the film from the mold in the peeling step is operated so as to keep the parallelism with the cooling roll following the adjustment of the angle of the cooling roll. Manufacturing method of fine structure transfer film. (4) The fine adjustment according to (2) or (3), wherein the means for adjusting the angle of the cooling roll moves one or both bearings supporting the cooling roll in the conveyance direction of the mold. A method for producing a structure transfer film.
  • the linear pressure applied to the film is 400 kN / m or more
  • An apparatus for producing a microstructure transfer film having an endless belt-shaped transfer mold having a microstructure on the surface suspended by a heating roll and a cooling roll, and at least the following basics [i] to [v] An apparatus for producing a microstructure transfer film having a configuration and satisfying the following [a1] or [a2].
  • Heating means provided on a heating roll in contact with the back surface of the transfer mold [ii]
  • the heating roll, a nip roll arranged in parallel with the heating roll and having a surface covered with an elastic body, and both rolls are used.
  • Pressure means provided with at least a clamping mechanism [iii] cooling means provided on a cooling roll in contact with the back surface of the transfer mold [iv] rotating the heating roll and the cooling roll to rotate the transfer mold [V1]
  • a peeling means [v1] comprising at least a peeling roll disposed in parallel to the cooling roll and rotating in a direction opposite to the cooling roll [a1] Contact between the heating roll and the mold There are steps on the surface of the heating roll at both ends in the width direction so that the roll diameter becomes smaller outside in the width direction.
  • the width of the mold is wider than the width of the nip roll pressing part.
  • a cooling roll for suspending the mold is installed on a slidable base that can be slid in the conveying direction of the mold, and the base and a movable means for sliding the pedestal are connected via a load detector. Control means for adjusting the slide amount of the gantry by the movable means so that the tension applied to the mold obtained from the load detector is always within a predetermined range.
  • the meandering detection sensor for detecting the position in the width direction of the mold and roll tilting means for adjusting the angle of the cooling roll installed on the gantry are installed, and the mold obtained from the meandering detection sensor Control means for adjusting the tilting amount of the cooling roll so that the position in the width direction of the mold is always within a predetermined range.
  • the microstructure transfer film manufacturing apparatus according to any one of (8) to (10), wherein the rubber hardness of the elastic body on the surface of the nip roll is 70 to 97 ° according to ASTM D2240: 2005 standard.
  • the microstructure transfer film manufacturing apparatus according to any one of (8) to (11), wherein the roll diameter gradually decreases toward the outer side in the width direction at both ends in the width direction of the heating roll.
  • the microstructure transfer film manufacturing apparatus according to any one of (8) to (11), wherein the thickness of the mold gradually decreases outward in the width direction at both ends in the width direction of the mold.
  • the microstructure transfer film manufacturing apparatus according to any one of (8) to (11), wherein the roll diameter gradually decreases toward the outer side in the width direction at both ends in the width direction of the nip roll.
  • a microstructure transfer film for continuously transferring a microstructure to the surface of a film by pressing a mold made of an endless belt having a microstructure formed on the surface of a film made of a thermoplastic resin.
  • a high-performance transfer film can be manufactured with high productivity by stably transporting the film without meandering.
  • FIG. 1 It is the schematic which looked at one Embodiment of the microstructure transfer film manufacturing apparatus of this invention from the film width direction for shaping
  • FIG. 1 In another embodiment of the microstructure transfer film manufacturing apparatus of the present invention, the structure in which the molding film is pressed against the mold by the heating roll and the nip roll facing the heating roll is seen from the conveyance direction of the molding film.
  • the film for molding when the roll diameter gradually decreases toward the outer side in the width direction at both ends of the portion where the mold of the heating roll is suspended It is the schematic which shows the structure pressed by a metal mold
  • the molding film becomes a mold when the thickness of the mold gradually decreases toward the outer side in the width direction at both ends in the width direction of the mold. It is the schematic which shows the structure pressed.
  • the forming film is pressed against the mold when the roll diameter gradually decreases toward the outer side in the width direction at both ends in the width direction of the nip roll. It is the schematic which shows a structure.
  • An apparatus for producing a microstructure transfer film according to the present invention includes an endless belt-shaped mold having a microstructure formed on a surface, a heating roll for heating the mold, and a heating roll.
  • a pressure mechanism including at least a nip roll covered with an elastic body, and a pressing means using the both rolls, a cooling roll for cooling the mold, and a film for adhering to the mold
  • An apparatus for producing a microstructure transfer film comprising at least a peeling mechanism and a transport mechanism for rotating the heating roll and the cooling roll to transport the mold, At both ends in the width direction of the contact portion between the heating roll and the mold, there is a step on the surface of the heating roll so that the roll diameter becomes smaller outside in the width direction, or the width of the mold is the nip roll. It is characterized by being wider than the width of the pressurizing part.
  • FIG. 1 shows a schematic cross-sectional view of a microstructure transfer film manufacturing apparatus 1 as seen from the width direction of a forming film, showing an example of an embodiment of the present invention.
  • the microstructure transfer film manufacturing apparatus 1 of the present invention includes a die 3 having the endless belt shape, a heating roll 4 and a cooling roll 5 that suspends the die 3, and a heating roll. 4 and provided with a nip roll 6 for pressure-forming the film and a peeling roll 7 as a peeling mechanism for peeling the film after molding from the mold 3.
  • the heating roll 4 and the nip roll 6 are connected to the pressing means 12 and pressed as a pressurizing mechanism in order to sandwich and press the mold 3 and the molding film 2 between the rolls. Has been.
  • driving means for rotationally driving the heating roll 4 and / or the cooling roll 5 is provided.
  • a conveying device for the forming film 2 an unwinding roll 8 and a winding roll 9 are provided, and further, one or a plurality of guide rolls (not shown) are provided as necessary.
  • the molding film 2 unwound from the unwinding roll 8 is supplied onto the mold 3 heated by the heating roll 4, and at the same time, the mold is pressed by the nip roll 6. 3 is pressed against the microstructure surface 3a of the film 2, and a shape corresponding to the shape of the surface of the mold 3 is transferred to the molding surface 2a of the film 2, that is, a microstructure having a pattern opposite to the microstructure of the mold 3 is transferred and molded.
  • the film 2 is conveyed while being in close contact with the mold 3, cooled by the cooling roll 5, peeled off from the mold 3 by the peeling roll 7, and taken up by the winding roll 9. This operation is performed continuously.
  • FIG. 2 is a schematic diagram showing a structure when the width of the molding film 2 is wider than that of the mold 3 and the steps 4a are provided at both ends of the heating roll 4.
  • FIG. 2 In the pressure transfer process, when the nip roll 6 is in direct contact with the microstructure surface 3a of the mold 3 heated to a high temperature, there are problems such as thermal damage of the elastic layer 10 on the surface of the nip roll 6 and generation of scratches on the microstructure surface 3a. Therefore, it is preferable to make the width of the film 2 wider than that of the mold 3 in order to prevent this.
  • both ends of the film 2 are separated from the heating roll 4, so that the film 2 and the heating roll 4 do not stick locally, and the film 2 is prevented from meandering and can be stably conveyed. .
  • FIG. 3 is a schematic view when the width of the mold 3 is made wider than the width of the molding film 2 and the width of the region pressed by the nip roll 6 is made narrower than the width of the film 2. Contrary to the configuration of FIG. 2, the elastic layer of the nip roll 6 is formed by the direct contact between the microstructure surface 3 a of the mold 3 and the nip roll 6 by making the width of the film 2 wider than the width of the pressure area of the nip roll 6. 10 thermal damage is prevented.
  • the film 2 can be prevented from meandering and stably conveyed.
  • the width of the pressurization region of the nip roll 6 is made wider than the width of the mold 3 and the width of the molding film 2 is wider than the width of the mold 3 so that the mold heated to a high temperature is used.
  • the nip roll 6 has been prevented from coming into direct contact with the microstructure surface 3 a of the mold 3.
  • the heating roll 4 and the film 2 are locally adhered in a region outside the mold 3 in the width direction, and the film 2 is conveyed.
  • the inventors have found that the tension becomes non-uniform in the width direction, causing the film 2 to meander.
  • the molding film 2, the mold 3, the heating roll 4 and the nip roll 6 are arranged so that the respective widths in the pressure molding portion are in a predetermined magnitude relationship, so that the mold 3 and the heating roll 4 are arranged. Even if the film is continuously transferred at a high temperature, the film 2 and the heating roll 4 do not adhere to each other and can be conveyed in a continuously stable tension state. As a result, it is possible to transport the film at a higher temperature or higher speed than before, and it is possible to achieve higher transfer accuracy or to improve productivity by high speed transport.
  • the mold 3 in order to prevent meandering of the molding film 2, it is preferable to prevent meandering of the mold 3 as well as the film 2.
  • the film 2 supported by the mold 3 In the transporting process of transporting the film 2 and the mold 3 in close contact with each other after the pressure transfer process, if the mold 3 meanders, the film 2 supported by the mold 3 also meanders together. This is because there is a case where the conveyance after releasing from the mold becomes unstable.
  • the inventors have found that in the heating process of heating the mold 3 composed of an endless belt, the tension applied to the mold 3 is weakened due to the thermal expansion of the mold 3, and temperature unevenness occurs in the width direction of the mold 3. It was found that meandering occurs due to non-uniform tension in the width direction of the mold 3 due to variations in thermal expansion.
  • a mold that detects and controls the tension applied to the mold 3 and the position in the width direction of the mold 3 on the cooling roll 5 that is one of the rolls around which the mold 3 is suspended.
  • the control may be either manual or automatic, but automatic is preferred.
  • FIG. 4 is a schematic plan view of a first configuration example of a mold meandering prevention mechanism for detecting and controlling the tension fluctuation and meandering of the mold 3 suspended on the heating roll 4 and the cooling roll 5.
  • FIG. 9 shows a schematic view of the same configuration example viewed from the film width direction, and FIG. 9 shows a schematic view of a method for measuring the position of the mold in the width direction using the meander detection sensor 24 for detecting the meander of the mold 3.
  • An endless belt-shaped mold 3 is suspended on a heating roll 4 and a cooling roll 5, and the cooling roll 5 is installed on a pedestal 15 that can be slid in parallel with the conveyance direction of the mold.
  • the distance between the heating roll 4 and the cooling roll 5 changes due to the movement of the gantry 15, and the tension applied to the mold 3 changes.
  • the gantry 15 is moved by a movable means 19 that combines a servo motor 17 and a feed screw 18, and the gantry 15 and the movable means 19 are connected via a load detector 20.
  • the tension applied to the mold 3 is detected by the load detector 20, and the moving amount of the movable means 19 is controlled so that the detected value is within a predetermined range, so that the tension of the mold 3 is kept constant. Be drunk.
  • At least one of the bearings 13 and 14 that support both ends of the cooling roll 5 can be moved in parallel in the conveyance direction of the mold 3 on the mount 15.
  • the movement of the bearing 14 is performed by a movable means 23 that combines the servo motor 21 and the feed screw 22.
  • the cooling roll 5 causes the bearing 13 to move by the movement of the bearing 14. It tilts to the fulcrum and corrects so that the position in the width direction of the mold 3 is the center.
  • the shift of the position in the width direction of the mold 3 is detected by the meandering detection sensor 24, and the movement amount of the movable means 23, that is, the tilt amount of the cooling roll 5 is controlled according to the shift amount.
  • the position in the width direction of the mold 3 is always maintained at the center.
  • the above-described die meandering prevention mechanism prevents the die 3 from meandering due to tension sag due to thermal expansion of the die 3 and uneven tension due to temperature unevenness in the width direction.
  • the film 2 does not meander following the mold 3 in the conveying step after the pressure transfer step, and a highly accurate microstructure transfer film can be more stably molded with high productivity. It becomes possible.
  • FIG. 6 shows a schematic plan view of the second configuration example of the present invention.
  • the gantry 15 and the fluid pressure cylinder 25 are connected via the load detector 20, and the pressure of the fluid pressure cylinder 25 is controlled according to the value detected by the load detector 20.
  • the reason for connecting the load detector is to keep the mold tension constant regardless of fluctuations in sliding resistance due to cylinder deterioration and pressure instability of the working fluid. This is because the tension of the mold is displayed visually in an easily understandable manner.
  • 6 shows a case where both the bearings 13 and 14 supporting the cooling roll 5 are movable on the gantry 15, respectively. This makes it possible to adjust the angle of the cooling roll 5 with finer precision than when only one of the bearings is movable.
  • the peeling roll 7 adjacent to the cooling roll 5 is also tilted so that the cooling roll 5 and the peeling roll 7 are always kept parallel. It is more desirable to do.
  • the peeling roll 7 is inclined with respect to the cooling roll 5, the peeling position when the molding film 2 peels from the mold 3 is different in the width direction, and peeling temperature unevenness occurs in the width direction of the film 2, In some cases, the film 2 and the mold 3 meander due to non-uniform tension.
  • a configuration example for causing the peeling roll 7 to follow the tilt of the cooling roll 5 will be described with reference to the drawings.
  • FIG. 7 shows a schematic plan view of a third configuration example of the tension control and meandering prevention mechanism of the mold of the present invention
  • FIG. 8 shows a schematic view seen from the film width direction.
  • the peeling roll 7 is installed in parallel with the cooling roll 5 on the gantry 15, and at least one of the bearings 26 and 27 that support the peeling roll 7 is one bearing 14 that supports the cooling roll 5.
  • the movable means 23 including the servo motor 21 and the feed screw 22 can be moved in parallel in the conveying direction of the mold 3 on the gantry 15.
  • the distance between the fulcrums of the peeling roll 7 is equal to the distance between the fulcrums of the cooling roll 5, and the center of both rolls is located on the center section in the width direction of the mold 3. It is necessary to When these are not satisfied, when the cooling roll 5 and the peeling roll 7 are tilted using the movable means 23, the tilt angles of the two rolls differ and the parallelism cannot be maintained.
  • the peeling roll 7 is arranged so that the hugging angle of the forming film 2 with respect to the cooling roll 5 is 90 degrees. However, if it is in the range of 0 to 180 degrees, it is arranged at other positions. May be. As the hugging angle of the forming film 2 with respect to the cooling roll 5 increases, the time for cooling the film 2 becomes longer, and the film 2 can be sufficiently cooled.
  • the heating roll 4 and the nip roll 6 constituting the pressure forming portion which is a feature of the present invention, will be described.
  • the nip roll 6 has a structure in which an elastic layer 10 is coated on the outer surface of the core layer.
  • the core layer is required to have strength and processing accuracy. For example, steel, fiber reinforced resin, ceramics, aluminum alloy or the like is applied.
  • the elastic layer 10 is a layer that is deformed by a pressing force, and a resin layer typified by rubber or an elastomer material is preferably applied.
  • the core layer is rotatably supported by bearings 11 at both ends thereof, and the bearing 11 is connected to pressing means 12 such as a cylinder.
  • the nip roll 6 is opened and closed by the stroke of the pressing means 12 to clamp or release the molding film 2.
  • the nip roll 6 may have a temperature control mechanism according to a desired process and film material.
  • the temperature control mechanism is a structure that heats from the inside of the roll by hollowing the inside of the roll and embedding a cartridge heater or induction heating device, or by processing a flow path in the inside and flowing a heat medium such as oil, water, or steam But it ’s okay.
  • an infrared heater may be installed near the outer surface of the roll and heated from the outer surface of the roll.
  • the processing accuracy of the nip roll 6 is preferably 0.03 mm or less in the cylindricity tolerance defined in JIS B 0621 (revised year 1984) and 0.03 mm or less in the circumferential runout tolerance. If these values become too large, there will be a partial gap between the heating roll 4 and the nip roll 6 at the time of pinching, so that the molding film 2 cannot be pressed uniformly, and transfer unevenness is formed on the molding surface 2a of the film 2. May occur.
  • the surface roughness of the elastic layer 10 is JIS The arithmetic average roughness Ra defined by B 0601 (revised year 2001) is preferably 1.6 ⁇ m or less. If Ra exceeds 1.6 ⁇ m, the surface shape of the elastic layer 11 may be transferred to the back surface of the film 2 when pressed.
  • the heat resistance of the elastic layer 10 of the nip roll 6 is preferably a heat resistant temperature of 160 ° C. or higher, more preferably a heat resistant temperature of 180 ° C. or higher.
  • the heat resistant temperature refers to the temperature at which the rate of change in tensile strength when left at that temperature for 24 hours exceeds 10%.
  • the elastic layer 10 As a material of the elastic layer 10, for example, when rubber is used, silicone rubber, EDPM (ethylene propylene diene rubber), neoprene, CSM (chlorosulfonated polyethylene rubber), urethane rubber, NBR (nitrile rubber), ebonite, and the like are used. Can be used. When seeking higher elastic modulus and hardness, use a special prescription for the rubber from the rubber manufacturers as a resin for calender rollers, or use a hard pressure resistant resin (eg polyester resin) with improved toughness. Can do.
  • silicone rubber EDPM (ethylene propylene diene rubber), neoprene, CSM (chlorosulfonated polyethylene rubber), urethane rubber, NBR (nitrile rubber), ebonite, and the like are used.
  • EDPM ethylene propylene diene rubber
  • CSM chlorosulfonated polyethylene rubber
  • urethane rubber urethane rubber
  • FIG. 10 is a schematic view of the nip roll 6 taken out when a pressing force is applied and viewed from the width direction of the forming film 2.
  • a deformation amount ⁇ is generated in the thickness direction of the elastic layer 10, and accordingly, the nip roll 6 and the forming film 2 are in contact with each other with a contact width B.
  • the rubber hardness of the elastic layer 10 is preferably set to ASTM. It is preferably in the range of 70 to 97 ° according to D2240: 2005 (Shore D) standard.
  • the heating roll 4 receives a load at the time of nip, strength and processing accuracy are required, and further includes a heating means.
  • the material include steel, fiber reinforced resin, ceramics, and aluminum alloy.
  • a heating means a structure that heats from the inside of the roll by hollowing the inside and installing a cartridge heater or an induction heating device, or processing a flow path inside and flowing a heat medium such as oil, water, or steam But it ’s okay.
  • an infrared heater or induction heating device may be installed near the outer surface of the roll and heated from the outer surface of the roll.
  • the processing accuracy of the heating roll 4 may be 0.03 mm or less in the cylindricity tolerance defined in JIS B 0621 (revision year 1984) and 0.03 mm or less in the circumferential runout tolerance as in the nip roll 6 described above. preferable. If these values become too large, there will be a partial gap between the heating roll 4 and the nip roll 6 at the time of pinching, so that the molding film 2 cannot be pressed uniformly, and transfer unevenness is formed on the molding surface 2a of the film 2. May occur.
  • the surface roughness of the heating roll 4 is JIS The arithmetic mean roughness Ra defined by B 0601 (revised year 2001) is preferably 0.2 ⁇ m or less. This is because when Ra exceeds 0.2 ⁇ m, the shape of the heating roll 4 is transferred to the back surface of the mold 3, which may be transferred to the molding surface 2 a of the film 2.
  • the surface of the heating roll 4 is subjected to a treatment for forming a hard coating such as hard chrome plating, ceramic spraying, diamond-like carbon coating, or the like. Because the heating roll 4 is always in contact with the mold 3 and is subjected to a pressing force by the nip roll 6, the surface thereof is very easily worn, and the surface of the heating roll 4 is worn or scratched. This is because problems such as the uneven transfer of the molding film 2 as described above and the transfer of the roll surface shape onto the molding surface 2a of the film 2 occur.
  • the width of the region where the molding film 2 is pressed is defined as W
  • the length from the end of the pressed region to the end of the molding film 2 is defined as v
  • the width of the molding film 2 is made longer than the width of the mold 3, that is, the width W of the region where the film 2 is pressed.
  • the reason for this is that the nip roll 6 is in direct contact with the microstructure surface 3a of the mold 3 heated to a high temperature, thereby causing thermal damage of the elastic layer 10 on the surface of the nip roll 6 and scratches on the microstructure surface 3a of the mold. It is for preventing.
  • the length v from the width direction end of the mold 3 to the width direction end of the film 2 is preferably in the range of 5 to 15 mm.
  • a region separated from the film 2 and the heating roll 4 is provided at the end portion of the molding film 2 so as not to contact.
  • a step 4a is provided as a means for separating.
  • the height difference (separation distance) H of the step is preferably in the range of 10 to 30 mm, and the distance u from the end of the mold 3 to the step 4a is preferably in the range of 1 to 3 mm.
  • the inventors have found that the phenomenon in which the forming film 2 bends at the end of the pressurizing portion becomes prominent in the process applying the high pressure condition applied to the present invention. Therefore, by providing the heating roll 4 with the step 4a, the end of the film bent by the bending phenomenon can be prevented from contacting and sticking to the heating roll 4.
  • the film 2 receives a pressing force over the entire width direction of the non-transfer surface by the nip roll 6, whereas the transfer surface is supported only in the range of the mold 3.
  • a bending moment with the end in the width direction of the mold 3 as a fulcrum is generated in a region outside the mold 3 of the film 2 in the width direction, and as a result, as shown in FIG.
  • the end is bent toward the heating roll 4 side.
  • the film 2 can be continuously formed more stably without contacting the heating roll 4. .
  • the width of the mold 3 is made wider than the width of the molding film 2, and the width of the pressing part of the nip roll 6, that is, the width W of the region where the film 2 is pressed is set to the film 2. Narrower than the width. The reason for this is to prevent thermal damage of the elastic layer 10 due to direct contact between the mold 3 and the nip roll 6 and scratches on the microstructure surface 3a of the mold, as in the condition (1).
  • the length v from the widthwise end of the pressure part of the nip roll 6 to the widthwise end of the film 2 is preferably in the range of 5 to 15 mm.
  • the film 2 is supported by the mold 3 over the entire width direction, and the mold 3 and the heating roll 4 are continuously transferred at a high temperature.
  • the film 2 and the heating roll 4 can be conveyed in a continuously stable tension state without sticking. As a result, it is possible to transport the film at a higher temperature or higher speed than before, and it is possible to achieve higher transfer accuracy or to improve productivity by high speed transport.
  • both configurations (1) and (2) it is preferable to gradually reduce the pressure toward the end portion at the end portion in the width direction of the pressurizing portion.
  • the pressure at the end portion By reducing the pressure at the end portion, the bending phenomenon at the end portion of the film for molding 2 and the pressure marks generated at the boundary between the pressurization region and the non-pressurization region are alleviated, and the flatness of the film after molding is deteriorated.
  • the film can be continuously conveyed and formed in a more stable state while suppressing the disorder of the winding form.
  • FIG. 11 to FIG. 13 show an example of means for reducing the pressure at the end of the pressurizing unit.
  • (a) shows an example of a configuration satisfying the condition (1)
  • (b) shows an example of a configuration satisfying the condition (2).
  • FIG. 11 is a schematic diagram showing an apparatus configuration of a pressure forming unit when the roll diameter is gradually reduced at the end of the heating roll 4 in the width direction.
  • the amount of deformation of the elastic layer 10 decreases as it goes outward in the width direction of the pressing portion, and accordingly, the pressure applied to the forming film 2 also decreases as it goes toward the end of the pressing portion in the width direction.
  • the bending phenomenon at the end of the film 2 and the pressure marks generated at the boundary between the pressure area and the non-pressure area are alleviated.
  • FIG. 12 shows a structure in which the thickness of the mold 3 is gradually reduced toward the outside in the width direction at the end
  • FIG. 13 shows a structure in which the roll diameter of the nip roll 6 is reduced toward the end in the width direction. Indicates.
  • FIG. 11 by reducing the pressure applied to the forming film 2 toward the end in the width direction of the pressurizing unit, the bending phenomenon at the end of the film 2 and the pressurizing region Pressurized marks generated at the boundary of the non-pressurized region are alleviated.
  • the preferable pressurizing conditions for the heating roll 4 and the nip roll 6 will be described below.
  • the relative positional accuracy between the heating roll 4 and the nip roll 6 is preferably 0.1 mm or less in the parallelism tolerance defined in JIS B 0621 (revised year 1984). When the parallelism tolerance exceeds 0.1 mm, the pressing force applied to the forming film 2 may not be uniform in the width direction, and transfer unevenness may occur or the film 2 may meander.
  • the total amount of deflection at the time of pressurization of both rolls is preferably 50 ⁇ m or less, more preferably 30 ⁇ m or less, within the width W of the region where the molding film 2 is pressed.
  • a preferable nip pressure is a force P applied to the nip roll 6 by the pressing means 12 as shown in FIG. 10 and a contact length B between the forming film 2 and the nip roll 6, and as shown in FIGS.
  • the pressing distance of the elastic layer 10, that is, the contact length B is preferably in the range of 4 to 8 mm, and more preferably in the range of 5 to 7 mm.
  • the contact length B is smaller than 4 mm, it is not possible to ensure a sufficient pressing time for transferring the fine structure to the film 2.
  • it becomes wider than 8 mm it becomes difficult to ensure the above-mentioned nip pressure with a sufficient value.
  • P / W obtained by dividing the force P applied to the nip roll by the width W of the pressurizing region is defined as a linear pressure, and this value indicates a nip load applied per unit width.
  • the range of the linear pressure P / W is preferably 400 kN / m or more, more preferably 500 kN / m or more.
  • the mold 3 is an endless belt whose surface is processed with a fine structure.
  • the material is preferably a metal having high strength and thermal conductivity, such as nickel, steel, stainless steel, or copper. Moreover, you may use what gave the surface of said metal belt.
  • a method of directly cutting or laser processing on the surface of the metal belt a method of directly cutting or laser processing on the plating film formed on the surface of the metal belt, Examples thereof include a method of electrocasting a cylindrical original plate having a fine structure on the inner surface, and a method of continuously attaching a thin plate having a fine structure surface to the surface of a metal belt.
  • An endless metal belt is a method in which the ends of metal plates having a predetermined thickness and length are butt welded, and a metal plate having a predetermined double thickness is welded to a predetermined half length to make it endless. It is manufactured by a method of rolling later.
  • the thickness is preferably in the range of 0.1 to 0.4 mm for reasons of the strength and handling properties of the metal belt. If the thickness is smaller than this range, the metal belt may be broken or plastically deformed by the tension applied when suspended by the heating roll 4 and the cooling roll 5. On the other hand, when the thickness is larger than this range, the bending rigidity of the metal belt becomes too large, and it becomes difficult to suspend the belt on the heating roll 4 and the cooling roll 5 or to carry it while being suspended on these rolls.
  • the material of the plating is preferably nickel or copper.
  • the metal belt preferably has a thickness of 0.1 to 0.3 mm, and the plating has a thickness of 0.03 to 0.1 mm. If the thickness of the plating is larger than the thickness of the metal belt, peeling may occur at the interface between the metal belt and the plating. On the other hand, if the thickness of the plating is too small, it becomes difficult to process the fine structure with high accuracy.
  • the manufacturing method of the endless belt mold is shown below.
  • the end of a thin stainless steel plate is butt welded and processed into an endless metal belt.
  • the metal belt is fixed on a roll, and the surface is subjected to nickel plating.
  • a predetermined fine structure is cut in the plating layer of the metal belt by a lathe.
  • die which has a predetermined fine structure on the surface is obtained by removing the metal belt which gave the cutting process from a roll.
  • the fine structure refers to a shape in which a convex shape having a height of 10 nm to 1 mm is periodically repeated with a convex shape having a pitch of 10 nm to 1 mm, more preferably a height of 1 ⁇ m to 100 ⁇ m, for example,
  • a plurality of triangular grooves may be arranged in stripes, or may be rectangular, semicircular or semielliptical. Furthermore, the groove does not have to be a straight line, and may be a curved stripe pattern.
  • the ridge line direction is not limited to the circumferential direction of the belt, and may be the width direction.
  • the fine structure is not limited to a continuous linear shape or curved shape, and may be a convex shape such as a hemisphere, a cone, or a rectangular parallelepiped, or a concave shape that is discretely arranged in a dot shape.
  • the mold 3 is suspended by the heating roll 4 and the cooling roll 5, and the cooling roll 5 is installed on the mount 15 in a state where both ends are rotatably supported by bearings 13 and 14.
  • the gantry 15 is slidable in parallel to the conveying direction of the mold 3 by the slide rails 16, and thus the gantry 15 on which the cooling roll 5 is installed is suspended on the cooling roll 5.
  • the position of the mold 3 in the conveyance direction is adjusted.
  • the gantry 15 and the slide rail 16 are installed on a horizontal surface, and it is preferable that the pedestal 15 and the slide rail 16 move with an extremely small resistance against an external force in the movable direction.
  • the gantry 15 is connected to a movable means 19 that is a combination of a servo motor 17 and a feed screw 18 via a load detector 20, and the load detector 20 is applied to the gantry 15 in the moving direction, that is, on the gantry 15. It is connected to the installed cooling roll 5 in a direction for measuring the tension transmitted from the mold 3. Therefore, when the gantry 15 moves and the mold 3 is suspended in a tensioned state between the heating roll 4 and the cooling roll 5, the tension applied to the upper and lower surfaces of the mold 3 is applied to the load detector 20. Is almost the same force.
  • the servo motor 17 and the load detector 20 are connected by a control circuit (not shown), the amount of movement of the movable means 19 is controlled in accordance with the fluctuation of the detection value of the load detector 20, and the tension applied to the mold 3 is always kept constant.
  • the position of the cooling roll 5 is adjusted automatically so that it may lean.
  • One of the bearings 14 that supports both ends of the cooling roll 5 is transported to the mold 3 on the gantry 15 by a movable means 23 comprising a combination of a servo motor 21 and a feed screw 22 installed on the gantry 15. It can be translated in the direction.
  • the other bearing 13 is fixed on the gantry 15, and when the bearing 14 moves on the gantry 15, the cooling roll 5 rotates around the bearing 13 and tilts with respect to the heating roll 4.
  • the position of the bearing 14 that determines the angle at which the cooling roll 5 tilts is controlled according to the position in the width direction of the mold 3. In FIG. 4, the position of the bearing 14 when the heating roll 4 and the cooling roll 5 are parallel is used as a reference.
  • FIG. 9 shows a schematic view of the meandering detection sensor 24 and the mold 3 when viewed from the downstream side in the film transport direction.
  • the meandering detection sensor 24 is a non-contact line sensor such as a light quantity detection type divided into a transmission side 24 a and a reception side 24 b, and the width direction end of the mold 3 so that a part of the transmission signal is blocked by the mold 3. It is installed to cover the part.
  • die 3 is detected with the magnitude of the signal amount which the receiving side 24b receives.
  • the servo motor 21 and the meandering detection sensor 24 are connected by a control circuit (not shown), and the amount of movement of the movable means 23 is determined according to the detection value of the meandering detection sensor 24. Then, the angle of the cooling roll 5 is controlled so that the position in the width direction of the mold 3 is always within a predetermined range, and the meandering of the mold 3 is prevented.
  • both the bearings 13 and 14 that support the cooling roll 5 may be moved on the mount 15 as shown in FIG. 6.
  • the angle of the cooling roll 5 can be adjusted with higher accuracy than when only one of the bearings is moved. Further, in order to position the position of the mold 3 in the width direction with high accuracy, it is preferable to finely control the angle of the cooling roll 5. Specifically, the angular resolution of the cooling roll 5 is set to 0.005 degrees or less. It is preferable. Here, the angular resolution of the cooling roll 5 is the minimum at which the angle of the rotation axis of the cooling roll 5 changes with respect to the rotation axis of the heating roll 4 when the cooling roll 5 is tilted to correct the meandering of the mold 3. Indicates quantity.
  • the position in the width direction of the mold 3 does not sway and diverge at the time of meandering correction, and quickly converges to the center reference position.
  • the mold 3 is always located at the center in the width direction, and the film 2 can be stably and continuously formed.
  • the angular resolution of the cooling roll 5 is determined by the distance between the fulcrums of the bearings 13 and 14 and the moving resolution of the bearing 14 when the bearing 13 is fixed and the bearing 14 is the moving side. If the moving resolution of the bearing 14 is 0.05 mm, the angular resolution of the cooling roll 5 is about 0.0048 degrees.
  • the cooling roll 5 is preferably cooled, for example, by a water-cooled cooling means that is provided with a water passage inside and continuously circulates water at a constant temperature. Then, the mold 3 is cooled by heat conduction at the contact surface with the mold 3.
  • the peeling roll 7 has a built-in cooling means, and cools the molding film 2 from the back surface side and plays a role of assisting the peeling from the mold 3. At this time, when the cooling roll 5 is tilted to prevent meandering of the mold 3, the peeling roll 7 is also tilted following the cooling roll 5 so that the parallelism with the cooling roll 5 is always maintained. It is preferable. For example, as shown in FIGS. 7 and 8, the peeling roll 7 is tilted by the same means as the tilting means of the cooling roll 5. Alternatively, the peeling roll 7 may be configured to be pressed against the cooling roll 5 by a fluid pressure cylinder or the like.
  • the pressing force of the peeling roll 7 against the molding film 2 is not particularly limited as long as the peripheral surface of the peeling roll 7 is in close contact with the back surface of the molding film 2.
  • Both the unwinding roll 8 and the winding roll 9 have a structure capable of fixing the core around which the forming film 2 is wound, and the end portion is connected to a driving means such as a motor and can be rotated while controlling the speed. Yes.
  • a driving means such as a motor and can be rotated while controlling the speed.
  • it is preferable that the tension applied to the molding film 2 can be adjusted by torque control.
  • each roll is supported in rotation by a rolling bearing.
  • the heating roll 4 is connected to driving means such as a motor, and is rotatable while controlling the speed.
  • the cooling roll 5 is preferably rotated by the driving force of the heating roll 4 through a belt mold.
  • the conveyance speed is determined in consideration of the balance between the moldability of the fine structure and the productivity of the molded film. In order to increase the productivity while transferring the fine structure with high accuracy, the speed is 1 to 30 m / min. It is preferable to be determined from the range.
  • the driving means of the nip roll 6 is connected to the end of the heating roll 4 with a chain or a belt, and can be rotated in conjunction with the heating roll 4 or a motor capable of synchronizing the speed with the heating roll 4 is used. However, it may be rotated independently and may be rotated by friction with the forming film 2.
  • the bearing which supports each roll is designed according to the mass of the roll, the load received, a rotational speed, etc., use the alignment type bearing for the bearing which supports the cooling roll 5 and the peeling roll 7. Is desirable. When non-aligning bearings are used for these rolls, the rolls may be damaged when they are tilted.
  • the method for producing a microstructure transfer film of the present invention uses an apparatus for producing a microstructure transfer film having an endless belt-like transfer mold having a microstructure on a surface suspended by a heating roll and a cooling roll, and at least one surface thereof.
  • a film heating process in which an endless belt-shaped mold having a fine concavo-convex structure formed thereon is heated while being held in a heated heating roll; In a state where the microstructure surface of the mold is in close contact with each other, a pressure transfer process in which nip pressurization is performed by a pair of rolls including the heating roll, and until the cooling zone is in contact with the pressed mold and the film.
  • Transport process for transport, cooling process for cooling from the mold side with the mold and film in close contact with each other in the cooling zone, and a peeling process for peeling the mold and film after cooling Is performed by passing the 5 steps, in this order under the conditions satisfying the following (1) or (2).
  • (1) means that the width of the film is wider than the width of the mold and that both end portions in the width direction of the film are separated from the heating roll in the pressure transfer step.
  • (2) means that the width of the mold is wider than the width of the film, and the width of the area where the film is pressed in the pressure transfer step is narrower than the width of the film. It is.
  • the forming film 2 is pulled out from the unwinding roll 8, and the nip roll 6 is opened, along the mold 3 suspended on the heating roll 4 and the cooling roll 5, and the peeling roll 7. Then, the winding roll 9 is in the winding state.
  • the heating means of the heating roll 4 and the cooling means of the cooling roll 5 are operated, and the surface temperature of the heating roll 4 and the cooling roll 5 becomes a predetermined temperature. Adjust the temperature until.
  • the reason why the temperature is controlled while being transported is that if the film is not transported, the portion of the forming film 2 located on the heating roll 4 stores heat, and the film melts and breaks there.
  • the conditions of the surface temperature of the heating roll 4 and the surface temperature of the cooling roll 5 depend on the material of the molding film 2, the shape of the microstructure of the mold 3, the aspect ratio, etc. Tg + 50 ° C.
  • the surface temperature of the cooling roll 5 is preferably set in the range of Tg ⁇ 40 ° C. to Tg ⁇ 100 ° C. of the film 2.
  • Tg indicates the glass transition temperature of the film.
  • the conveying speed during temperature adjustment is preferably 0.1 to 5 m / min, more preferably 0.1 to 1 m / min.
  • the film is conveyed at the molding speed and at the same time the nip roll 6 is closed and the heating roll 4 and the nip roll 6 pressurize the molding film 2 and the mold 3 to transfer the shape of the microstructure surface 3 a of the mold 3 to the molding surface 2 a of the molding film 2.
  • the film forming speed is set in the range of 1 to 30 m / min, and the linear pressure is set in the range of 400 kN / m or more.
  • Continuous film transfer consists of a mold heating process, a pressure transfer process, a transport process, a cooling process, and a peeling process when the processes are arranged in accordance with the rotating operation of the mold.
  • the mold 3 is always heated by heat conduction from the high-temperature heating roll 4 at the portion in contact with the heating roll 4, and the temperature of the mold 3 is changed to the temperature of the heating roll 4 before being sandwiched between the heating roll 4 and the nip roll 6.
  • the temperature is raised to the surface temperature (die heating step).
  • the forming film 2 is pressed against and closely adhered to the heated mold 3 at the clamping portion between the heating roll 4 and the nip roll 6, and the resin constituting the softened film is a pattern of the microstructure surface 3 a of the mold 3.
  • the film pressed against the mold 3 is conveyed to the cooling zone while being in close contact with the mold 3 (conveying step).
  • the cooling zone indicates a range where the mold 3 and the cooling roll 5 are in contact with each other.
  • the film is cooled to the glass transition point or less of the resin constituting the film together with the mold 3 by heat conduction with the cooling roll 5 (cooling step).
  • the film after cooling is released from the cooling roll 5 by the peeling roll 7 (peeling process).
  • the film after peeling is wound up on a winding roll 9.
  • the width of the molding film 2 is made wider than the width of the mold 3 as shown in FIG. Separate.
  • the width of the mold 3 is made wider than the width of the film 2
  • the width of the pressure part of the nip roll 6 is made narrower than the width of the film 2.
  • the tension and width direction position of the mold 3 are always within a predetermined range by the mold tension control and meandering prevention mechanism shown in FIG. It is preferable to keep it constant. By preventing fluctuations in tension and meandering of the mold 3, it is possible to prevent the film 2 from being meandered together by being pulled by the meandering of the mold 3 in close contact with the conveying process after the pressure transfer process. Further, in addition to the above, in the pressure transfer process, the pressure may be gradually decreased outward in the width direction at both ends in the width direction of the pressure region.
  • Bending at the end of the film for molding 2 and pressure marks generated at the boundary between the pressurization region and the non-pressurization region are alleviated, and deterioration of the flatness of the film after molding and disturbance of the winding shape during winding are suppressed. can do.
  • thermoplastic film containing a thermoplastic resin as a main component is used.
  • polyethylene terephthalate, polyethylene-2,6-naphthalate, polypropylene terephthalate, polybutylene terephthalate are preferable.
  • Polyester resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, etc., polyolefin resins, polyamide resins, polyimide resins, polyether resins, polyesteramide resins, polyetherester resins, acrylic Resin, polyurethane resin, polycarbonate resin, or polyvinyl chloride resin.
  • thermoplastic resin is mainly formed from the selected thermoplastic resin, and it is more preferable that the above-mentioned thermoplastic resin is 50% by weight or more.
  • the forming film 2 may be a film made of the above-mentioned resin alone or a laminate made of a plurality of resin layers.
  • surface characteristics such as slipperiness and friction resistance, mechanical strength, and heat resistance can be imparted.
  • the entire film satisfies the requirement that the thermoplastic resin is the main component, but the entire film does not satisfy the requirement, at least If a layer satisfying the above requirements is formed on the surface layer, the surface can be easily formed.
  • the surface layer is a resin having a low glass transition point and easy to transfer a fine structure
  • the core layer is a resin having a high glass transition point and high strength.
  • a die made of an endless belt having a fine structure formed on the surface is pressed, and the film is meandered when the fine structure is continuously transferred to the surface of the film. Therefore, the transfer film can be stably conveyed, and a highly accurate transfer film can be manufactured with high productivity.
  • Example 1 As the molding film 2, a three-layer laminated film in which a polycarbonate resin was used as a core layer and a PMMA resin was laminated on both sides as a molding layer was prepared by coextrusion and used.
  • the total thickness of the film was 200 ⁇ m
  • the lamination ratio of each layer was about 1: 8: 1
  • the width was 220 mm.
  • the mold 3 is obtained by cutting a 0.1 mm thick nickel plating on the surface of a 0.2 mm thick stainless steel belt and cutting a V groove shape having a pitch of 40 ⁇ m and a depth of 20 ⁇ m in parallel with the circumferential direction of the belt. Created.
  • the belt had a width of 200 mm and a circumferential length of 1200 mm.
  • the heating roll 4 a cylindrical core material made of carbon steel having a hard chrome plated surface was used.
  • the heating roll 4 has a shape having steps 4a at both ends in the width direction of the roll portion, the central portion for suspending the mold 3 has a width of 204 mm and an outer diameter of 180 mm, and the surface of the steps 4a at both ends and the end in the film width direction
  • the separation distance H is 10 mm
  • the length u from the step 4a to the end of the mold 3 is 2 mm
  • the total width of the central portion and the step 4a at both ends is 220 mm.
  • the center part was made into the cylindrical shape which does not have outer diameter changes, such as a taper, over the full width.
  • An infrared lamp heater was used as the heating means, and the surface temperature of the heating roll 4 was heated to 180 ° C.
  • the cooling roll 5 was made of carbon steel as a core material and hard chrome plated on the surface.
  • the cooling roll 5 was always kept at a surface temperature of 20 ° C. by running water circulating inside.
  • a whole surface of a cylindrical core material made of carbon steel having a width of 220 mm and an outer diameter of 160 mm was coated with a polyester resin (hardness: Shore D86 °) with a thickness of 20 mm as the elastic layer 10.
  • a pneumatic cylinder was used as the pressing means 12, and a pressing force of 120 kN was applied to the nip roll 6.
  • the forming speed of the film was 3 conditions of 5 m / min, 10 m / min, and 15 m / min.
  • the microstructure transfer film could be stably and continuously formed up to a conveyance speed of 15 m / min without sticking between the film 2 and the heating roll 4 in the pressure forming section.
  • Example 2 in addition to the configuration of the first embodiment, the roll diameter is wider than the original outer diameter of 180 mm in the range of 12 mm at both ends of the widthwise length 204 mm of the central portion where the mold 3 of the heating roll 4 is suspended.
  • the size was gradually reduced to a maximum of 0.1 mm toward the outside.
  • the separation distance H between the surface of the step 4a and the end in the film width direction, and the length u from the step 4a to the end of the mold 3 are the same as those in the first embodiment.
  • a pneumatic cylinder was used as the pressing means 12, and a pressing force of 120 kN was applied to the nip roll 6.
  • the contact width B between the nip roll 6 and the molding film 2 was measured using a pressure measurement film (Prescale, manufactured by Fuji Film Co., Ltd.). It was confirmed that the nip pressure was gradually reduced at both ends of the film width direction.
  • the forming speed of the film was 3 conditions of 5 m / min, 10 m / min, and 15 m / min.
  • the bending at the film edge after molding is relaxed, and the film having excellent flatness is stabilized.
  • Example 3 As the molding film 2, a three-layer laminated film in which a polycarbonate resin was used as a core layer and a PMMA resin was laminated on both sides as a molding layer was prepared by coextrusion and used. The total thickness of the film was 200 ⁇ m, the lamination ratio of each layer was about 1: 8: 1, and the width was 180 mm.
  • the mold 3 is obtained by cutting a 0.1 mm thick nickel plating on the surface of a 0.2 mm thick stainless steel belt and cutting a V groove shape having a pitch of 40 ⁇ m and a depth of 20 ⁇ m in parallel with the circumferential direction of the belt. Created.
  • the belt had a width of 200 mm and a circumferential length of 1200 mm.
  • the heating roll 4 a cylindrical core material made of carbon steel having a hard chrome plated surface was used.
  • the heating roll 4 has a cylindrical shape with no change in shape such as a step and a taper over the entire width of the roll portion, and has an outer diameter of 180 mm and a width of 220 mm. Further, an infrared lamp heater was used as the heating means, and the surface temperature of the heating roll 4 was heated to 180 ° C.
  • the cooling roll 5 was made of carbon steel as a core material and hard chrome plated on the surface. The cooling roll 5 was always kept at a surface temperature of 20 ° C. by running water circulating inside.
  • nip roll 6 As the nip roll 6, a whole surface of a cylindrical core material made of carbon steel having a width of 160 mm and an outer diameter of 160 mm was coated with a polyester resin (hardness: Shore D86 °) with a thickness of 20 mm as the elastic layer 10.
  • a pneumatic cylinder was used as the pressing means 12, and a pressing force of 96 kN was applied to the nip roll 6.
  • the forming speed of the film was 3 conditions of 5 m / min, 10 m / min, and 15 m / min.
  • the microstructure transfer film could be stably and continuously formed up to a conveyance speed of 15 m / min without sticking between the film 2 and the heating roll 4 in the pressure forming part.
  • Example 4 in addition to the configuration of Example 3, in the range of 30 mm at both ends of 220 mm in the width direction length of the central part where the mold 3 of the heating roll 4 is suspended, the roll diameter is wider than the original outer diameter of 180 mm. It gradually decreased to a maximum of 0.2 mm toward the outside.
  • the configuration other than the heating roll 4 is the same as that of the third embodiment.
  • a pneumatic cylinder was used as the pressing means 12 and a pressing force of 96 kN was applied to the nip roll 6.
  • the contact width B between the nip roll 6 and the molding film 2 was measured using a pressure measurement film (Prescale, manufactured by Fuji Film Co., Ltd.). It was confirmed that the nip pressure gradually decreased at both ends and the nip pressure gradually decreased at both ends in the film width direction.
  • the film forming speed was 3 conditions of 5 m / min, 10 m / min, and 15 m / min.
  • Example 5 in addition to the configuration of Example 1, the tension of the mold 3 and the meandering prevention mechanism as shown in FIG. 4 were used to control the tension of the mold 3 and the position in the width direction.
  • the tension applied to the mold 3 was 6 kN / m, and the position of the gantry 15 was controlled so as to always maintain this value during the operation of the apparatus.
  • the position in the width direction of the mold 3 was monitored by the meandering detection sensor 24, and the angle of the cooling roll 5 was controlled in units of 0.005 degrees so that the position in the width direction of the mold 3 was always in the center.
  • Other configurations and molding conditions are the same as those in the first embodiment.
  • the microstructure transfer film in the same manner as Example 1, in addition to the fact that the film 2 and the heating roll 4 were not adhered in the pressure forming part, the microstructure transfer film could be stably continuously formed up to a conveyance speed of 15 m / min.
  • the transport state after releasing the film 2 from the mold 3 was also stable, and a roll of a molded film having a small winding deviation could be obtained.
  • Example 6 in addition to the configuration of the fifth embodiment, in the range of both ends 12 mm in the width direction length 204 mm of the heating roll 4, the roll diameter is increased up to 0.1 mm from the original outer diameter 180 mm toward the outer side in the width direction. I gradually made it smaller.
  • a pneumatic cylinder is used as the pressing means 12, and the contact width B between the nip roll 6 and the molding film 2 when a pressing force of 120 kN is applied to the nip roll 6 is determined as a pressure measurement film (Prescale, manufactured by Fuji Film Co., Ltd.). ) was 6 mm at the center of the nip, but gradually decreased at both ends to a width of 5.5 mm at the extreme end. From this, the nip pressure at both ends in the film width direction was It was confirmed that it gradually decreased.
  • Other configurations and molding conditions are the same as in Example 5.
  • Example 7 in addition to the configuration of Example 3, the tension of the mold 3 and the meandering prevention mechanism as shown in FIG. 4 were used to control the tension of the mold 3 and the position in the width direction.
  • the tension applied to the mold 3 was 6 kN / m, and the position of the gantry 15 was controlled so as to always maintain this value during the operation of the apparatus.
  • the position in the width direction of the mold 3 was monitored by the meandering detection sensor 24, and the angle of the cooling roll 5 was controlled in units of 0.005 degrees so that the position in the width direction of the mold 3 was always in the center.
  • Example 3 Other configurations and molding conditions are the same as in Example 3.
  • the transport state after releasing the film 2 from the mold 3 was also stable, and a roll of a molded film having a small winding deviation could be obtained.
  • Example 8 In this example, in addition to the configuration of Example 7, in the range of 30 mm at both ends of the length 220 mm in the width direction of the heating roll 4, the roll diameter is increased up to 0.2 mm from the original outer diameter 180 mm toward the outer side in the width direction. I gradually made it smaller.
  • a pneumatic cylinder is used as the pressing means 12, and the contact width B between the nip roll 6 and the molding film 2 when a pressing force of 96 kN is applied to the nip roll 6 is determined as a pressure measurement film (Prescale, manufactured by Fuji Film Co., Ltd.). ) was 6 mm at the center of the nip, but gradually decreased at both ends to a width of 5.6 mm at the extreme end. It was confirmed that it gradually decreased.
  • Comparative Example 1 As the molding film 2, a three-layer laminated film in which a polycarbonate resin was used as a core layer and a PMMA resin was laminated on both sides as a molding layer was prepared by coextrusion and used. The total thickness of the film was 200 ⁇ m, the lamination ratio of each layer was about 1: 8: 1, and the width was 220 mm.
  • the mold 3 is obtained by cutting a 0.1 mm thick nickel plating on the surface of a 0.2 mm thick stainless steel belt and cutting a V groove shape having a pitch of 40 ⁇ m and a depth of 20 ⁇ m in parallel with the circumferential direction of the belt. Created.
  • the belt had a width of 200 mm and a circumferential length of 1200 mm.
  • the heating roll 4 is a cylindrical core material made of carbon steel with a hard chrome plated surface.
  • the heating roll 4 has a cylindrical shape with no change in shape such as a step and a taper over the entire width of the roll portion, and has an outer diameter of 180 mm and a width of 220 mm. Further, an infrared lamp heater was used as the heating means, and the surface temperature of the heating roll 4 was heated to 180 ° C.
  • the cooling roll 5 was made of carbon steel as a core material and hard chrome plated on the surface.
  • the cooling roll 5 was always kept at a surface temperature of 20 ° C. by running water circulating inside.
  • a whole surface of a cylindrical core material made of carbon steel having a width of 220 mm and an outer diameter of 160 mm was coated with a polyester resin (hardness: Shore D86 °) with a thickness of 20 mm as the elastic layer 10.
  • the forming film 2 was nipped over the entire width, and both end portions in the width direction of the film were in direct contact with the heating roll 4.
  • the forming speed of the film was 3 conditions of 5 m / min, 10 m / min, and 15 m / min.
  • the microstructure transfer film of Comparative Example 1 was slightly meandered at a conveyance speed of 5 m / min, and could not be stably continuously formed. When the conveying speed was 10 m / min or more, the film abruptly meandered immediately after pressing, and could not be continuously formed.
  • Microstructure transfer film manufacturing apparatus 2 Molding film 2a: Molding film molding surface 3: Mold 3a: Mold microstructure surface 4: Heating roll 4a: Stepped portion 5 of heating roll: Cooling roll 6 : Nip roll 7: Peeling roll 8: Unwinding roll 9: Winding roll 10: Elastic layers 11, 13, 14, 26, 27: Bearing 12: Pressing means 15: Mount 16: Slide rail 17, 21: Servo motor 18, 22: Feed screw 19, 23: Moving means 20: Load detector 24: Meander detection sensor 24a: Meander detection sensor transmission side 24b: Meander detection sensor reception side 25: Fluid pressure cylinder 28: Film path W: Molding film The width direction length H of the region where the pressure is applied by the mold and the nip roll: the height (space between the surface of the heating roll mold portion and the surface of the stepped portion on both ends Away) v: Length from the end of the region to be pressed of the forming film to the end in the width direction of the forming film u: From the end of the mold suspended on the heating

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

La présente invention a trait à un procédé et à un dispositif permettant de fabriquer un film de transfert de structure mince qui transfère en continu et de façon rapide une structure mince sur la surface d'un film en pressant de façon stable un film constitué d'une résine thermoplastique sur un moule constitué d'une courroie sans fin moulée avec la structure mince sur la surface, sans autoriser aucun défaut d'alignement. Le procédé permettant de fabriquer le film de transfert de structure mince inclut une étape consistant à traiter un film qui est doté d'une couche destinée au transfert sur au moins une surface en passant par au moins cinq étapes dans un certain ordre dans des conditions spécifiées, à l'aide d'un dispositif permettant de fabriquer un film de transfert de structure mince doté d'un moule de transfert se présentant sous la forme d'une courroie sans fin dotée d'une structure mince sur la surface qui a été suspendue sur un rouleau de chauffage et un rouleau de refroidissement.
PCT/JP2012/058387 2011-03-31 2012-03-29 Procédé et dispositif permettant de fabriquer un film de transfert de structure mince WO2012133660A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
KR1020137017693A KR101883193B1 (ko) 2011-03-31 2012-03-29 미세구조 전사 필름의 제조 방법 및 제조 장치
CN201280015339.8A CN103459126B (zh) 2011-03-31 2012-03-29 微细结构转印膜的制造方法及制造装置
JP2013507726A JP5924337B2 (ja) 2011-03-31 2012-03-29 微細構造転写フィルムの製造方法および製造装置

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2011077714 2011-03-31
JP2011-077714 2011-03-31
JP2011-077713 2011-03-31
JP2011077713 2011-03-31

Publications (1)

Publication Number Publication Date
WO2012133660A1 true WO2012133660A1 (fr) 2012-10-04

Family

ID=46931362

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2012/058387 WO2012133660A1 (fr) 2011-03-31 2012-03-29 Procédé et dispositif permettant de fabriquer un film de transfert de structure mince

Country Status (5)

Country Link
JP (1) JP5924337B2 (fr)
KR (1) KR101883193B1 (fr)
CN (1) CN103459126B (fr)
TW (1) TWI576254B (fr)
WO (1) WO2012133660A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014151636A (ja) * 2013-02-14 2014-08-25 Toray Ind Inc エンドレスベルト状金属金型およびその製造方法
JP2014168878A (ja) * 2013-03-04 2014-09-18 Toray Ind Inc 微細構造フィルムの製造方法および製造装置
JP2014172331A (ja) * 2013-03-11 2014-09-22 Meisho Kiko Kk 微細パターン熱転写装置
JP2015016665A (ja) * 2013-07-12 2015-01-29 新日鉄住金マテリアルズ株式会社 扁平繊維強化プラスチックストランド、扁平繊維強化プラスチックストランドシート及びその製造方法
KR20160019300A (ko) * 2014-08-11 2016-02-19 에스케이씨 주식회사 시트 이송 장치

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101779690B1 (ko) * 2013-09-26 2017-09-18 와이케이케이 가부시끼가이샤 면 파스너 성형 장치 및 그 동작 방법, 및 면 파스너의 제조 방법
KR101463415B1 (ko) * 2014-03-21 2014-11-20 (주)코이즈 광학필름 제조장치
EP3130445B1 (fr) 2014-04-10 2021-06-30 Mitsubishi Gas Chemical Company, Inc. Rouleau de façonnage pour moulage par extrusion à l'état fondu, ensemble rouleau de façonnage pour moulage par extrusion à l'état fondu, et procédé de moulage par extrusion à l'état fondu
TWI601622B (zh) * 2014-04-28 2017-10-11 三菱瓦斯化學股份有限公司 Melt extrusion molding and shaping rollers, melt extrusion molding and shaping roller assembly, and melt extrusion molding method
CN106649924B (zh) * 2016-09-18 2022-03-01 南京理工大学 一种橡胶基复合靶板抗射流侵彻机理测定方法
JP6694101B1 (ja) * 2019-08-09 2020-05-13 Ａｉメカテック株式会社 微細構造転写装置及び微細構造転写方法
CN110978482B (zh) * 2019-12-24 2022-05-31 含山县华侨鞋业有限公司 一种鞋子生产用鞋底高效印模装置
CN114714610B (zh) * 2022-03-11 2024-01-30 晋江荣森新材料科技有限公司 一种真空式连续生产微棱镜反光膜的方法及装置

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4814671Y1 (fr) * 1972-02-19 1973-04-23
JPH07232339A (ja) * 1994-02-23 1995-09-05 Mitsubishi Heavy Ind Ltd ベルトキャスト製膜装置及びベルトキャスト製膜装置用ベルト
JPH08103942A (ja) * 1994-10-04 1996-04-23 Canon Inc シートの成形方法
JPH08103941A (ja) * 1994-10-04 1996-04-23 Canon Inc 押し出し成形方法
JP2001277354A (ja) * 2000-04-04 2001-10-09 Idemitsu Petrochem Co Ltd エンボスシートの製造方法およびエンボスシート
WO2009110139A1 (fr) * 2008-03-04 2009-09-11 シャープ株式会社 Élément optique, appareil de nano-impression de type rouleau et procédé de production d'un rouleau de matrice

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10202722A (ja) * 1997-01-23 1998-08-04 Mitsubishi Heavy Ind Ltd ベルト式キャスティング機のベルト蛇行制御方法
CA2285926A1 (fr) * 1997-04-04 1998-10-15 Atsushi Fujii Procede de fabrication de feuille de resine thermoplastique multicouches, et feuille de resine thermoplastique multicouches
JP4450078B2 (ja) 2007-03-16 2010-04-14 ソニー株式会社 光学シートの製造方法
JP2010100031A (ja) * 2008-09-26 2010-05-06 Sekisui Chem Co Ltd 樹脂シートの製造装置
JP5289891B2 (ja) * 2008-10-28 2013-09-11 出光興産株式会社 熱可塑性樹脂シートの製造装置およびその製造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4814671Y1 (fr) * 1972-02-19 1973-04-23
JPH07232339A (ja) * 1994-02-23 1995-09-05 Mitsubishi Heavy Ind Ltd ベルトキャスト製膜装置及びベルトキャスト製膜装置用ベルト
JPH08103942A (ja) * 1994-10-04 1996-04-23 Canon Inc シートの成形方法
JPH08103941A (ja) * 1994-10-04 1996-04-23 Canon Inc 押し出し成形方法
JP2001277354A (ja) * 2000-04-04 2001-10-09 Idemitsu Petrochem Co Ltd エンボスシートの製造方法およびエンボスシート
WO2009110139A1 (fr) * 2008-03-04 2009-09-11 シャープ株式会社 Élément optique, appareil de nano-impression de type rouleau et procédé de production d'un rouleau de matrice

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014151636A (ja) * 2013-02-14 2014-08-25 Toray Ind Inc エンドレスベルト状金属金型およびその製造方法
JP2014168878A (ja) * 2013-03-04 2014-09-18 Toray Ind Inc 微細構造フィルムの製造方法および製造装置
JP2014172331A (ja) * 2013-03-11 2014-09-22 Meisho Kiko Kk 微細パターン熱転写装置
JP2015016665A (ja) * 2013-07-12 2015-01-29 新日鉄住金マテリアルズ株式会社 扁平繊維強化プラスチックストランド、扁平繊維強化プラスチックストランドシート及びその製造方法
KR20160019300A (ko) * 2014-08-11 2016-02-19 에스케이씨 주식회사 시트 이송 장치
KR101606884B1 (ko) * 2014-08-11 2016-03-28 에스케이씨 주식회사 시트 이송 장치

Also Published As

Publication number Publication date
CN103459126B (zh) 2015-11-25
CN103459126A (zh) 2013-12-18
TWI576254B (zh) 2017-04-01
KR101883193B1 (ko) 2018-07-30
TW201249668A (en) 2012-12-16
JPWO2012133660A1 (ja) 2014-07-28
JP5924337B2 (ja) 2016-05-25
KR20140031174A (ko) 2014-03-12

Similar Documents

Publication Publication Date Title
JP5924337B2 (ja) 微細構造転写フィルムの製造方法および製造装置
JP5712733B2 (ja) 微細構造転写フィルムの製造方法および製造装置
JP4135768B2 (ja) 間欠式フィルム成形装置及び成型方法
TWI698320B (zh) 表面構造薄膜之製造方法及製造裝置
KR20090073101A (ko) 간헐식 필름 성형 장치 및 간헐식 필름 성형 방법
JP5884596B2 (ja) 微細構造転写フィルムの製造方法および製造装置
JP6064667B2 (ja) 両面構造フィルムの製造方法および製造装置
JP6738743B2 (ja) 表面構造フィルムの製造方法および製造装置
CN112654487B (zh) 压花成型用有机硅橡胶辊、使用其的塑料膜的制造方法及制造装置、以及表面保护膜
WO2012102178A1 (fr) Procédé et appareil de production d'un film de résine
US20080088052A1 (en) Method Of Producing A Resin Sheet
JP4135769B2 (ja) 間欠式フィルム成形装置および成形方法
JP6311395B2 (ja) 凹凸構造フィルムの製造方法および製造装置
JP6075103B2 (ja) エンドレスベルト状金属金型およびその製造方法
JP6085193B2 (ja) 微細構造フィルムの製造方法および製造装置
JP2010221561A (ja) 樹脂シートの製造装置
JP2008137380A (ja) 微細形状転写シートの製造装置および微細形状転写シートの製造方法
JP2010221560A (ja) 樹脂シートの製造装置
JP4929006B2 (ja) 間欠式フィルム成形装置および成型方法
JP2010221562A (ja) 樹脂シートの製造装置
JP2010221559A (ja) 樹脂シートの製造装置
JP2010100031A (ja) 樹脂シートの製造装置
JP2024152096A (ja) エンボス成型用ゴムローラー、プラスチックフィルムの製造方法、ならびに表面保護フィルム
JP2006056219A (ja) 樹脂シートの製造方法

Legal Events

Date Code Title Description
ENP Entry into the national phase

Ref document number: 2013507726

Country of ref document: JP

Kind code of ref document: A

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 12765037

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 20137017693

Country of ref document: KR

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 12765037

Country of ref document: EP

Kind code of ref document: A1