WO2014010516A1

WO2014010516A1 - Imprint method, and imprinting device

Info

Publication number: WO2014010516A1
Application number: PCT/JP2013/068430
Authority: WO
Inventors: 寛坂本; 公介高山; 海田　由里子
Original assignee: 旭硝子株式会社
Priority date: 2012-07-10
Filing date: 2013-07-04
Publication date: 2014-01-16
Also published as: JP2015167152A; TW201408472A

Abstract

Provided is an imprint method having a step in which a glass sheet is passed in a flat state between a plurality of sets of a rotary roller and a nip roller, and an endless belt-shaped mold that is looped around a plurality of the rotary rollers is made to revolve. After the glass sheet and the mold are inserted between one set of a rotary roller and a nip roller, and before the glass sheet and the mold have been drawn from between another set of a rotary roller and a nip roller, a molding material layer is pinched between the rollers, and a relief pattern from the mold is transferred to the molding material layer.

Description

Imprint method and imprint apparatus

The present invention relates to an imprint method and an imprint apparatus.

The imprint method is attracting attention as a technology that can produce a fine concavo-convex structure at low cost and in large quantities. In the imprint method, for example, the concavo-convex pattern of the mold is continuously transferred to the surface of the molding material layer while rotating a roll-shaped mold (so-called gravure roll) having the concavo-convex pattern on the outer periphery (see, for example, Patent Document 1). ).

FIG. 11 is a side view of a conventional imprint apparatus. The glass sheet 1 and the layer of the molding material are fed between the transfer roll 3 and the gravure roll 4, and the uneven pattern of the gravure roll 4 is transferred to the layer of the molding material. The layer of the molding material is attached to the gravure roll 4 by the tension applied to the glass sheet 1, and gradually hardens while rotating together with the gravure roll 4 to form an uneven layer. The uneven layer is separated from the gravure roll 4 by passing between the separation roll 5 and the gravure roll 4. Thus, a laminated sheet composed of a glass sheet and an uneven layer is obtained.

International Publication No. 2010/090085

Conventionally, as shown in FIG. 11, the glass sheet 1 is sometimes bent and deformed by the transfer roll 3 or the separation roll 5, and the glass sheet 1 may be damaged.

This invention was made in view of the said subject, Comprising: It aims at provision of the imprint method and imprint apparatus which can reduce the failure | damage of a glass sheet.

In order to solve the above problem, an imprint method according to an aspect of the present invention includes:
Passing the glass sheet between a plurality of sets of rotating rolls and nip rolls in a flat state, and rotating the endless belt-shaped molds wound around the plurality of rotating rolls,
The glass sheet and the mold sandwich a layer of molding material from being inserted between a pair of rotating rolls and nip rolls until being drawn out between the other set of rotating rolls and nip rolls, The uneven pattern of the mold is transferred to the layer of the molding material.

Moreover, an imprint apparatus according to another aspect of the present invention is provided.
Multiple sets of rotating rolls and nip rolls that allow the glass sheet to pass in a flat state,
An endless belt-shaped mold that is wound around a plurality of the rotating rolls and rotated,
The glass sheet and the mold sandwich a layer of molding material from being inserted between a pair of rotating rolls and nip rolls until being drawn out between the other set of rotating rolls and nip rolls, The uneven pattern of the mold is transferred to the layer of the molding material.

According to the present invention, an imprint method and an imprint apparatus that can reduce breakage of a glass sheet are provided.

It is a side view of the imprint apparatus by 1st Embodiment of this invention. FIG. 2 is a cross-sectional view taken along line II-II in FIG. FIG. 3 is a sectional view taken along line III-III in FIG. FIG. 4 is a cross-sectional view taken along IV-IV in FIG. FIG. 5 is a cross-sectional view taken along line VV in FIG. 1. It is a side view of the imprint apparatus by 2nd Embodiment of this invention. FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. 6. FIG. 7 is a cross-sectional view taken along line VIII-VIII in FIG. 6. FIG. 7 is a sectional view taken along line IX-IX in FIG. 6. FIG. 7 is a cross-sectional view taken along line XX in FIG. 6. It is a side view of the conventional imprint apparatus.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. In the drawings, the same or corresponding components are denoted by the same or corresponding reference numerals, and description thereof is omitted.

[First Embodiment]
FIG. 1 is a side view of an imprint apparatus according to a first embodiment of the present invention. 2 to 5 are explanatory diagrams of the imprint method according to the first embodiment of the present invention. 2 is a sectional view taken along the line II-II in FIG. 1, FIG. 3 is a sectional view taken along the line III-III in FIG. 1, FIG. 4 is a sectional view taken along the line IV-IV in FIG. FIG. 5 is a cross-sectional view taken along line VV in FIG. 1.

The imprint apparatus 10 continuously or intermittently forms the uneven layer 17 (see FIG. 5) on the belt-shaped glass sheet 11. A laminated sheet 19 is constituted by the glass sheet 11 and the uneven layer 17. The uneven layer 17 has an uneven pattern in which convex portions are periodically arranged.

Examples of the glass of the glass sheet 11 include non-alkali glass, borosilicate glass, soda lime glass, high silica glass, and other oxide-based glasses mainly composed of silicon oxide.

From the viewpoint of flexibility, the thickness of the glass sheet 11 is, for example, 0.3 mm or less, preferably 0.2 mm or less, more preferably 0.1 mm or less, and even more preferably 0.05 mm or less. Further, the thickness of the glass sheet 11 is preferably 0.0001 mm or more, more preferably 0.001 mm or more, and further preferably 0.005 mm or more from the viewpoint of glass moldability.

The imprint apparatus 10 is a roll-to-roll system, and includes, for example, an unwinding roll 21, a separation roll 22, a collection roll 23, an unwinding roll 24, an overlapping roll 25, and a winding roll 26.

The unwinding roll 21 is fitted with a glass roll formed by winding the glass sheet 11 and the glass protective sheet 12 in a spiral shape. The glass protective sheet 12 is made of a resin film, paper, or the like, and prevents the glass surface from getting foreign matter (for example, dust) or scratches. When the unwinding roll 21 rotates, the glass sheet 11 and the glass protective sheet 12 are unwound from the glass roll.

The outermost layer of the glass roll is preferably a glass protective sheet 12. When the unwinding roll 21 stops temporarily, it can prevent that the glass sheet 11 gets a foreign material or a damage | wound.

The glass protective sheet 12 may have a pressure-sensitive adhesive and may be bonded to the glass sheet 11 or may simply contact without being bonded.

The glass protective sheet 12 may protect the surface of the glass sheet 11 on which the layer 15 of the molding material is formed until it is separated from the glass sheet 11 by the separation roll 22.

The separation roll 22 separates the glass sheet 11 and the glass protective sheet 12 fed out from the glass roll. Separation is performed smoothly by the glass protective sheet 12 being bent and deformed along the separation roll 22. When the glass protective sheet 12 has an adhesive layer, since the adhesive layer and the glass sheet are gradually peeled off, the force required for peeling can be reduced.

The collection roll 23 winds the glass protective sheet 12 separated from the glass sheet 11.

A protection sheet roll formed by winding the uneven protection sheet 13 in a spiral shape is attached to the feeding roll 24. When the feed roll 24 rotates, the uneven protective sheet 13 is fed from the protective sheet roll. The unevenness protection sheet 13 is composed of a resin film, paper, or the like.

The superimposing roll 25 superimposes the uneven protective sheet 13 fed from the protective sheet roll and the laminated sheet 19. Since the concave / convex protective sheet 13 is bent and deformed along the overlapping roll 25, the concave / convex protective sheet 13 and the laminated sheet 19 gradually merge to suppress generation of wrinkles or air entrainment during the overlapping. it can.

The concave / convex protective sheet 13 is provided with an adhesive and may be bonded to the laminated sheet 19 or may be simply contacted without being bonded.

The concave / convex protective sheet 13 covers the concave / convex layer 17 of the laminated sheet 19 and prevents the concave / convex layer 17 from being damaged (for example, dust) or scratched.

The take-up roll 26 rolls up the laminated sheet 19 and the unevenness protection sheet 13 to produce a product roll. The outermost layer of the product roll is preferably an uneven protective sheet 13. When the outermost layer of the product roll is a glass sheet, the product roll may be covered with another protective sheet during storage.

The imprint apparatus 10 is, for example, an optical imprint apparatus, and includes an applicator 31, an endless belt-shaped mold 33, a light source 35, a plurality of (for example, two)

rotating rolls

41 and 42, and a plurality of (for example, two) nip rolls. 43, 44, a guide roll 45, a drawer roll 46, and a plurality of (for example, two) auxiliary rolls 51, 52 are further provided.

The applicator 31 applies the molding material onto the glass sheet 11 after the glass protective sheet 12 is separated, and forms the molding material layer 15 as shown in FIG. Examples of the applicator 31 include a die coater, a roll coater, a gravure coater, a spray coater, a flow coater, and a blade coater.

The glass sheet 11 may be subjected to a surface treatment in advance in order to improve the adhesion between the glass surface and the molding material. Examples of the surface treatment include primer treatment, ozone treatment, plasma etching treatment, and the like. As the primer, a silane coupling agent, silazane or the like is used.

Molding material includes a photo-curable resin. As a photocurable resin, the general thing used for the photoimprint method can be used. The photocurable resin is composed of a monomer, a photopolymerization initiator, and the like. Examples of the monomer include an acrylic monomer and a vinyl monomer in the case of the radical polymerization type, and an epoxy monomer and a vinyl ether monomer in the case of the ionic polymerization type. The photocurable resin is prepared in a liquid state, and is applied onto the glass sheet 11 as shown in FIG. 2, for example. The molding material may include metal oxide particles and the like.

The mold 33 has a concavo-convex pattern transferred to the surface of the layer 15 of the molding material on the outer periphery. The mold 33 may be subjected to a release treatment in order to improve the release property between the mold surface and the molding material. Examples of the mold release treatment include fluorine coat treatment and silicone coat treatment.

The mold 33 is wound around a plurality of

rotating rolls

41 and 42 and a plurality of

auxiliary rolls

51 and 52, and is rotated. The mold 33 is made of, for example, metal (for example, nickel or chromium) or resin (for example, polycarbonate, cyclic olefin resin, or polyester resin), and has flexibility. Note that all or some of the plurality of

auxiliary rolls

51 and 52 may be omitted.

The mold 33 is produced by welding both ends of a belt-like sheet molded using a master mold, and can be duplicated many times. Examples of the duplication method include an imprint method and an electroforming method. The master mold is manufactured by processing a substrate by, for example, a photolithography method or an electron beam drawing method.

The light source 35 irradiates the molding material layer 15 sandwiched between the glass sheet 11 and the mold 33 with light to solidify (harden) the molding material layer 15. The uneven layer 17 formed by curing the molding material layer 15 has an uneven pattern in which the uneven pattern of the mold 33 is substantially inverted.

Examples of light that cures the photocurable resin include ultraviolet light, visible light, and infrared light. Examples of the ultraviolet light source include ultraviolet fluorescent lamps, ultraviolet LEDs, low-pressure mercury lamps, high-pressure mercury lamps, ultrahigh-pressure mercury lamps, xenon lamps, and carbon arc lamps. As a light source for visible light, a visible light fluorescent lamp, a visible light incandescent lamp, a visible light LED, or the like is used.

In the optical imprint method, at least one of the mold 33 and the glass sheet 11 is made of a light transmissive material. The light emitted from the light source 35 passes through the transparent glass sheet 11 and enters the layer 15 of the molding material, for example. The light emitted from the light source 35 may pass through the transparent mold 33 and enter the layer 15 of the molding material.

In the optical imprint method, molding at room temperature is possible, distortion due to a difference in linear expansion coefficient between the mold 33 and the glass sheet 11 hardly occurs, and transfer accuracy is good. In order to accelerate the curing reaction, the molding material layer 15 may be heated.

As shown in FIG. 3, the pair of rotating rolls 41 and nip rolls 43 feeds the glass sheet 11, the molding material layer 15, and the mold 33 in this order from the nip roll 43 side. The rotary roll 41 and the nip roll 43 are relatively separable, and one of them may be pressed toward the other by a fluid pressure cylinder or the like. At least one of the rotating roll 41 and the nip roll 43 may be a roll in which the outer periphery of the metal roll is covered with rubber. By elastically deforming the rubber, it is possible to suppress stress concentration due to biting of foreign matters such as dust and stress concentration due to variation in the thickness of the glass sheet 11. Either one of the rotating roll 41 and the nip roll 43 may be rotated in accordance with the other rotation driven to rotate by a rotating motor or the like. If either one is rotated passively, the peripheral speed difference between the rotating roll 41 and the nip roll 43 is small, and the shear stress is small.

After the glass sheet 11 and the mold 33 are inserted between the pair of rotating rolls 41 and the nip rolls 43, until the glass sheet 11 and the mold 33 are pulled out from between the other pair of rotating rolls 42 and the nip rolls 44, FIG. As shown, the molding material layer 15 is sandwiched by the tension of the glass sheet 11 and the tension of the mold 33 and moves integrally with the molding material layer 15. In the meantime, the layer 15 of the molding material receives light from the light source 35 and gradually cures to become the uneven layer 17. The direction of the tension of the glass sheet 11 is the moving direction of the glass sheet 11. Further, the direction of tension of the mold 33 is the moving direction (rotating direction) of the mold 33.

The other set of rotating rolls 42 and nip rolls 44 feeds the glass sheet 11, the concavo-convex layer 17 and the mold 33 in this order from the nip roll 44 side. The rotating roll 42 and the nip roll 44 can be relatively moved toward and away from each other, and one of them may be pressed toward the other by a fluid pressure cylinder or the like. At least one of the rotating roll 42 and the nip roll 44 may be a roll in which the outer circumference of the metal roll is covered with rubber. Either one of the rotating roll 42 and the nip roll 44 may be driven to rotate in accordance with the other rotation driven to rotate by a rotating motor or the like. If either one is rotated passively, the peripheral speed difference between the rotating roll 42 and the nip roll 44 is small, and the shear stress is small.

The plurality of

rotating rolls

41 and 42 and the plurality of nip rolls 43 and 44 may have the same outer diameter or different outer diameters.

The guide roll 45 changes the direction of the glass sheet 11 fed from the glass roll according to the roll diameter of the glass roll, and inserts the glass sheet 11 between the rotating roll 41 and the nip roll 43 in a flat state. The direction change of the glass sheet 11 is performed by bending and deforming the glass sheet 11 along the guide roll 45.

The drawer roll 46 pulls out the laminated sheet 19 in a flat state from between the rotary roll 42 and the nip roll 44, and changes the direction of the laminated sheet 19 according to the roll diameter of the product roll. The direction of the laminated sheet 19 is changed by bending the laminated sheet 19 along the pulling roll 46.

Next, the operation (imprint method) of the imprint apparatus 10 configured as described above will be described. Various operations of the imprint apparatus 10 are performed under the control of a controller including a microcomputer. In the following description, for convenience, various operations of the imprint apparatus 10 will be described mainly focusing on a part of the glass sheet 11.

First, the unwinding roll 21 rotates, and the glass sheet 11 and the glass protective sheet 12 are continuously fed out from the glass roll. The glass sheet 11 and the glass protective sheet 12 are separated by passing between the separation roll 22 and the guide roll 45.

The guide roll 45 changes the direction of the glass sheet 11 according to the roll diameter of the glass roll, and inserts the glass sheet 11 between the pair of rotating rolls 41 and nip rolls 43 in a flat state. The direction change of the glass sheet 11 is performed by bending and deforming the glass sheet 11 along the guide roll 45.

Then, as shown in FIG. 2, the applicator 31 applies a molding material on the glass sheet 11 to form a layer 15 of the molding material.

Next, as shown in FIG. 3, the rotating roll 41 and the nip roll 43 feed out the glass sheet 11, the molding material layer 15, and the mold 33 in this order from the nip roll 43 side.

As shown in FIG. 1, the glass sheet 11 and the molding material layer 15 are inserted between the rotating roll 41 and the nip roll 43 in a flat state. On the other hand, the mold 33 is inserted between the rotary roll 41 and the nip roll 43 while being bent and deformed along the rotary roll 41 so that air is not caught between the mold material layer 15 and the mold material layer 15. Close to 15.

As shown in FIG. 4, the glass sheet 11 and the mold 33 are inserted between a pair of rotating rolls 41 and a nip roll 43, and then pulled out from between another pair of rotating rolls 42 and a nip roll 44. In the meantime, the layer 15 of the molding material is sandwiched by the tension of the glass sheet 11 and the tension of the mold 33 and moves integrally with the layer 15 of the molding material. In the meantime, the layer 15 of the molding material receives light from the light source 35 and gradually cures to become the uneven layer 17.

Next, the rotating roll 42 and the nip roll 44 feed out the glass sheet 11, the concavo-convex layer 17, and the mold 33 in this order from the nip roll 44 side.

As shown in FIG. 1, the glass sheet 11 and the concavo-convex layer 17 are pulled out from between the rotating roll 42 and the nip roll 44 in a flat state. On the other hand, the mold 33 is bent and deformed along the rotary roll 42 so as to be smoothly separated from the uneven layer 17.

Thus, as shown in FIG. 5, a laminated sheet 19 including the glass sheet 11 and the concavo-convex layer 17 is obtained.

Next, the drawer roll 46 and the overlapping roll 25 overlap the laminated sheet 19 and the unevenness protection sheet 13. The unevenness protection sheet 13 is composed of a resin film, paper, or the like. The concave / convex protective sheet 13 is overlapped with the concave / convex layer 17 of the laminated sheet 19 to prevent the concave / convex layer 17 from being damaged (for example, dust) or scratched.

The drawer roll 46 pulls out the laminated sheet 19 in a flat state from between the rotary roll 42 and the nip roll 44, and changes the direction of the laminated sheet 19 according to the roll diameter of the product roll.

Next, the winding roll 26 overlaps the laminated sheet 19 and the unevenness protection sheet 13 and winds up to produce a product roll.

The laminated sheet 19 is unwound from a product roll at the time of use, cut into a predetermined size, and used for manufacturing an optical panel such as a liquid crystal panel or an organic EL panel. The concave / convex protective sheet 13 may be separated from the laminated sheet 19 during the manufacturing process of the optical panel, and does not have to be a component of the optical panel.

The laminated sheet 19 can be used as a moth-eye type antireflection sheet, a polarizing sheet, a microlens array sheet, a lenticular lens array sheet, and the like when used for manufacturing an optical panel. The laminated sheet 19 may be used for manufacturing an immunoassay chip, a DNA analysis chip, a DNA separation chip, a microreactor, and the like, and the use of the laminated sheet 19 is not particularly limited.

As described above, according to this embodiment, as shown in FIG. 1, the glass sheet 11 passes between the plurality of sets of

rotating rolls

41 and 42 and the nip rolls 43 and 44 while being in a flat state. Therefore, since the fragile glass sheet 11 is held flat at the time of transferring the concavo-convex pattern of the mold 33 or separating the mold 33 and the concavo-convex layer 17, damage to the glass sheet 11 can be suppressed.

In addition, the support sheet which supports the glass sheet 11 may be provided in the surface on the opposite side to the surface which forms the uneven | corrugated layer 17 in the glass sheet 11 of this embodiment. The support sheet is detachably joined to the glass sheet 11. A support sheet is comprised by the adhesion layer formed, for example on a base material and a base material, and is joined with the glass sheet 11 with the adhesive force of the adhesion layer. As the substrate, for example, homopolymers such as polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyester, polyamide, polyimide, and copolymers can be used. Examples of the adhesive for the adhesive layer include vinyl acetate, acetal, acrylic, polyamide, polyester, polyurethane, and rubber. The support sheet reinforces the glass sheet 11 and suppresses breakage of the glass sheet 11 while passing between the plurality of sets of

rotating rolls

41 and 42 and the nip rolls 43 and 44. For example, the support sheet may be unwound together with the glass sheet 11 from a glass roll attached to the unwinding roll 21, and taken up by the take-up roll 26 together with the glass sheet 11. In addition, a support sheet may be comprised only with an adhesive resin film, and the structure of a support sheet is not specifically limited.

[Second Embodiment]
FIG. 6 is a side view of the imprint apparatus according to the second embodiment of the present invention. 7 to 10 are explanatory diagrams of the imprint method according to the second embodiment of the present invention. 7 is a sectional view taken along line VII-VII in FIG. 6, FIG. 8 is a sectional view taken along line VIII-VIII in FIG. 6, and FIG. 9 is a sectional view taken along line IX-IX in FIG. 10 is a cross-sectional view taken along line XX of FIG.

The imprint apparatus 10A forms the first and second uneven layers 17 and 18 (see FIG. 10) on the glass sheet 11 continuously or intermittently. The first and second

uneven layers

17 and 18 are formed on opposite sides of the glass sheet 11. The glass sheet 11 and the first and second

uneven layers

17 and 18 constitute a laminated sheet 19A. The 1st and 2nd uneven |

corrugated layers

17 and 18 have an uneven | corrugated pattern by which a convex part is arranged periodically. The uneven pattern of the first uneven layer 17 and the uneven pattern of the second uneven layer 18 may be the same pattern or different patterns.

The imprint apparatus 10A is a roll-to-roll system, and includes, for example, an unwinding roll 21, a separation roll 22, two collection rolls 23, two unwinding rolls 24, an overlapping roll 25, and a winding roll 26. Is provided.

The unwinding roll 21 is equipped with a glass roll formed by, for example, stacking the glass sheet 11 and the two glass protective sheets 12 in a spiral shape. The glass protective sheet 12 protects the surfaces of the glass sheet 11 on which the

layers

15 and 16 of the first and second molding materials are formed until the glass sheet 11 is separated from the glass sheet 11 by the separation roll 22 and the guide roll 45.

In addition, the glass roll attached to the unwinding roll 21 may be formed by stacking the glass sheet 11 and one glass protective sheet 12 and winding them in a spiral shape.

The take-up roll 26 rolls up the laminated sheet 19A and the two uneven protective sheets 13 to produce a product roll.

The imprint apparatus 10A is, for example, an optical imprint apparatus, and includes first and

second applicators

31, 32, first and

second molds

33, 34, a light source 35, and a plurality of (for example, two) rotating rolls. 41, 42, a plurality (for example, two) of nip rolls 43, 44, a guide roll 45, a drawing roll 46, and a plurality (for example, four) of auxiliary rolls 51 to 54.

The first and

second applicators

31 and 32 apply the molding material on both sides of the glass sheet 11 after the glass protective sheet 12 is separated, and the first and second molding material layers 15 as shown in FIG. , 16 are formed. The first and second molding material layers 15 and 16 include a photocurable resin.

The first mold 33 has a concavo-convex pattern transferred to the surface of the first molding material layer 15. Similarly, the second mold 34 has an uneven pattern that is transferred to the surface of the layer 16 of the second molding material. The first and

second molds

33 and 34 may be subjected to a mold release process in order to improve the mold release property between the mold surface and the molding material.

The first mold 33 has an endless belt shape, is wound around a plurality of

rotating rolls

41 and 42 and a plurality of

auxiliary rolls

51 and 52, and is rotated. Note that all or some of the plurality of

auxiliary rolls

51 and 52 may be omitted.

The second mold 34 has an endless belt shape, and is wound around a plurality of nip rolls 43 and 44 and a plurality of

auxiliary rolls

53 and 54, and is rotated. The auxiliary rolls 53 and 54 may be omitted.

The light source 35 irradiates light to the first molding material layer 15 sandwiched between the glass sheet 11 and the first mold 33 to cure the first molding material layer 15. Further, the light source 35 irradiates the second molding material layer 16 sandwiched between the glass sheet 11 and the second mold 34 to cure the second molding material layer 16.

The light emitted from the light source 35 passes through the transparent second mold 34, the second molding material layer 16, and the transparent glass sheet 11 in this order, and enters the first molding material layer 15. . The light emitted from the light source 35 passes through the transparent first mold 33, the first molding material layer 15, and the transparent glass sheet 11 in this order, and enters the second molding material layer 16. It may be incident. A plurality of light sources may be used.

As shown in FIG. 8, the pair of rotating rolls 41 and nip rolls 43 includes, from the nip roll 43 side, the second mold 34, the second molding material layer 16, the glass sheet 11, and the first molding material layer 15. , And the first mold 33 is fed in this order.

As shown in FIG. 9, the glass sheet 11 and the first mold 33 are inserted between the pair of rotating rolls 41 and the nip roll 43, and then between the other pair of rotating rolls 42 and the nip roll 44. The first molding material layer 15 is sandwiched by the tension of the glass sheet 11 and the tension of the first mold 33 and moved integrally with the first molding material layer 15. Meanwhile, the first molding material layer 15 is gradually cured by receiving light from the light source 35, and becomes the first uneven layer 17. The direction of the tension of the glass sheet 11 is the moving direction of the glass sheet 11. Further, the direction of tension of the first mold 33 is the moving direction (rotation direction) of the first mold 33.

Similarly, after the glass sheet 11 and the second mold 34 are inserted between the pair of rotating rolls 41 and the nip roll 43, the glass sheet 11 and the second mold 34 are pulled out from between the other pair of rotating rolls 42 and the nip roll 44. During this time, the second molding material layer 16 is sandwiched by the tension of the glass sheet 11 and the tension of the second mold 34, and moves together with the second molding material layer 16. In the meantime, the second molding material layer 16 is gradually cured by receiving light from the light source 35 to become the second uneven layer 18. The direction of the tension of the glass sheet 11 is the moving direction of the glass sheet 11. The direction of the tension of the second mold 34 is the moving direction (rotation direction) of the second mold 34.

Another set of rotating rolls 42 and nip rolls 44 sandwich the second mold 34, the second uneven layer 18, the glass sheet 11, the first uneven layer 17, and the first mold 33 from the nip roll 44 side. Send out.

The drawer roll 46 pulls out the laminated sheet 19A from between the rotary roll 42 and the nip roll 44 in a flat state, and changes the direction of the laminated sheet 19A according to the roll diameter of the product roll. The direction change of the laminated sheet 19 </ b> A is performed by bending and deforming the laminated sheet 19 </ b> A along the pulling roll 46.

Next, the operation (imprint method) of the imprint apparatus 10A having the above configuration will be described. Various operations of the imprint apparatus 10A are performed under the control of a controller configured by a microcomputer or the like. In the following description, for convenience, various operations of the imprint apparatus 10 </ b> A will be described mainly focusing on a part of the glass sheet 11.

Next, as shown in FIG. 7, the first and

second applicators

31 and 32 apply the molding material on both sides of the glass sheet 11 to form the first and second molding material layers 15 and 16.

Next, as shown in FIG. 8, the pair of rotating rolls 41 and nip rolls 43 are arranged from the nip roll 43 side with the second mold 34, the second molding material layer 16, the glass sheet 11, and the first molding material. The layer 15 and the first mold 33 are sandwiched in this order and sent out.

As shown in FIG. 6, the glass sheet 11 and the first molding material layer 15 are inserted between a pair of rotating rolls 41 and nip rolls 43 in a flat state. On the other hand, the first mold 33 is inserted between the rotary roll 41 and the nip roll 43 while being bent and deformed along the rotary roll 41 so that air is not caught between the first molding material layer 15. And is in intimate contact with the first molding material layer 15.

As shown in FIG. 9, the glass sheet 11 and the first mold 33 are inserted between the pair of rotating rolls 41 and the nip roll 43, and then between the other pair of rotating rolls 42 and the nip roll 44. The first molding material layer 15 is sandwiched by the tension of the glass sheet 11 and the tension of the first mold 33 and moved integrally with the first molding material layer 15. Meanwhile, the first molding material layer 15 is gradually cured by receiving light from the light source 35, and becomes the first uneven layer 17.

Further, as shown in FIG. 6, the glass sheet 11 and the second molding material layer 16 are inserted between the pair of rotating rolls 41 and the nip rolls 43 in a flat state. On the other hand, the second mold 34 is inserted between the rotating roll 41 and the nip roll 43 while being bent and deformed along the nip roll 43 so that air does not get caught between the second molding material layer 16. , In close contact with the second molding material layer 16.

As shown in FIG. 9, the glass sheet 11 and the second mold 34 are inserted between the pair of rotating rolls 41 and the nip rolls 43, and then between the other pair of rotating rolls 42 and the nip rolls 44. Until it is pulled out, the second molding material layer 16 is sandwiched by the tension of the glass sheet 11 and the tension of the second mold 34 and moves integrally with the second molding material layer 16. In the meantime, the second molding material layer 16 is gradually cured by receiving light from the light source 35 to become the second uneven layer 18.

Next, the rotating roll 42 and the nip roll 44 are fed out from the nip roll 44 side with the second mold 34, the second uneven layer 18, the glass sheet 11, the first uneven layer 17, and the first mold 33 interposed therebetween.

The glass sheet 11 and the first concavo-convex layer 17 are drawn out from between the rotating roll 42 and the nip roll 44 in a flat state. On the other hand, the first mold 33 is bent and deformed along the rotary roll 42 so as to be smoothly separated from the first uneven layer 17.

The glass sheet 11 and the second concavo-convex layer 18 are pulled out from between the rotating roll 42 and the nip roll 44 in a flat state. On the other hand, the second mold 34 is bent and deformed along the nip roll 44 so as to be smoothly separated from the second uneven layer 18.

Thus, as shown in FIG. 10, a laminated sheet 19A including the glass sheet 11 and the first and second

uneven layers

17 and 18 is obtained.

Next, the pull-out roll 46 and the superimposing roll 25 superimpose the uneven protective sheet 13 fed out from the two protective sheet rolls and the laminated sheet 19A. The unevenness protection sheet 13 is composed of a resin film, paper, or the like. The two concavo-convex protective sheets 13 cover both the first and second concavo-

convex layers

17 and 18, and prevent the first and second concavo-

convex layers

17 and 18 from being contaminated (for example, dust) or scratches. .

The drawer roll 46 pulls out the laminated sheet 19A from between the rotary roll 42 and the nip roll 44 in a flat state, and changes the direction of the laminated sheet 19A according to the roll diameter of the product roll.

Next, the winding roll 26 overlaps and winds the laminated sheet 19A and the two uneven protective sheets 13 sandwiching the laminated sheet 19A to produce a product roll.

In addition, the number of the uneven protective sheets 13 may be one. For example, the concave / convex protective sheet 13 may be stacked only on the first concave / convex layer 17 serving as the radially outer layer in the laminated sheet 19 </ b> A when wound in a spiral. One uneven protective sheet 13 can protect both the first and second

uneven layers

17 and 18, the roll diameter of the product roll is reduced, and the product roll can be easily stored. Moreover, the uneven | corrugated protective sheet 13 may be overlaid only on the 2nd uneven | corrugated layer 18 used as the inner layer in the lamination sheet 19A, when winding in a spiral shape. In this case, the product roll is covered and stored with a dedicated protective sheet.

As described above, according to this embodiment, similarly to the first embodiment, a plurality of sets of

rotating rolls

41 and 42 and nip

rolls

43 and 44 with the glass sheet 11 in a flat state as shown in FIG. Pass between. Therefore, a brittle glass sheet at the time of transferring the concavo-convex pattern of the first and

second molds

33 and 34, or at the time of separation between the first and

second molds

33 and 34 and the first and second concavo-

convex layers

17 and 18. Since 11 is held flat, breakage of the glass sheet 11 can be suppressed.

Also, according to the present embodiment, the first and second molding material layers 15 and 16 are formed on the opposite sides of the glass sheet 11, so that the glass sheet 11 is unlikely to warp when the molding material is cured. Moreover, since the force which isolate | separates the 1st uneven | corrugated layer 17 and the 1st mold 33, and the force which isolate | separates the 2nd uneven | corrugated layer 18 and the 2nd mold 34 act on mutually opposite directions, the glass sheet 11 The state of becomes stable. Moreover, since the 1st uneven | corrugated layer 17 and the 2nd uneven | corrugated layer 18 are formed simultaneously, unlike the case where it forms separately, alignment is unnecessary.

Although the imprint method and the imprint apparatus have been described in the first and second embodiments, the present invention is not limited to the above embodiment. Various modifications and changes are possible within the scope of the gist of the present invention described in the claims.

For example, the imprint apparatus of the above embodiment is a roll-to-roll system, but the present invention is not limited to this. For example, the imprint apparatus may cut the laminated sheet into a predetermined size with a cutting machine without winding the laminated sheet on a winding roll. When the laminated sheet is not taken up by the take-up roll, the laminated sheet may not be bent and deformed along the drawing roll. Moreover, the imprint apparatus is a glass that is continuously supplied from a glass forming apparatus (for example, a float forming apparatus, a fusion forming apparatus, a redraw forming apparatus, etc.) instead of forming an uneven layer on a glass sheet fed from a glass roll. An uneven layer may be formed on the sheet. When the glass sheet is supplied from the glass forming apparatus, the glass sheet may not be bent and deformed along the guide roll.

The imprint apparatus according to the above embodiment is an optical imprint apparatus, but may be a thermal imprint apparatus. In this case, the molding material contains a thermoplastic resin instead of the photocurable resin. As the thermoplastic resin, a general resin used in the thermal imprinting method can be used, and examples thereof include an acrylic resin, a polycarbonate resin, an olefin resin, and a polyester resin. The thermoplastic resin may be prepared in the form of a sheet and affixed on the glass sheet, or may be prepared in the form of a solution and applied onto the glass sheet and dried. In addition, the thermoplastic resin may be softened by heating and then coated on a glass sheet and cooled. In the thermal imprint method, a concavo-convex layer is formed by softening a layer of a molding material containing a thermoplastic resin by heating, pressing the mold against the surface of the softened molding material layer, and cooling and solidifying the molding material layer. Form. As the heating source, a light source (for example, a halogen lamp or a laser) that emits heating light, a heater, or the like is used. The heating temperature is equal to or higher than the glass transition temperature of the thermoplastic resin. Either the step of pressing the mold and the step of heating the layer of the molding material may be performed first or simultaneously. The layer of molding material may be heated by heating the mold.

Moreover, although the glass roll of the said embodiment overlaps a glass sheet and a glass protective sheet and is wound spirally, it may be formed by winding only a glass sheet spirally. In this case, a separation roll and a collection roll are not necessary.

In addition, the product roll of the above embodiment is formed by stacking the laminated sheet and the uneven protective sheet and winding them in a spiral shape, but it may be formed by winding only the laminated sheet in a spiral shape. In this case, the feeding roll and the overlapping roll are not necessary.

In the applicator of the above embodiment, the molding material is applied on the glass sheet, but the molding material may be applied on the mold. The layer of the molding material is sandwiched between the glass sheet and the mold in the transfer process, and the uneven pattern of the mold is transferred to the surface of the layer of the molding material.

This application claims priority based on Japanese Patent Application No. 2012-154509 filed with the Japan Patent Office on July 10, 2012. The entire contents of Japanese Patent Application No. 2012-154509 are incorporated herein by reference. To do.

DESCRIPTION OF SYMBOLS 10 Imprint apparatus 11 Glass sheet 15 Molding material layer (1st molding material layer)
16 Second molding material layer 17 Concavity and convexity layer (first concavity and convexity layer)
18 Second uneven layer 33 Mold (first mold)
34

Second mold

41, 42 Rotating

roll

43, 44 Nip roll

Claims

Passing the glass sheet between a plurality of sets of rotating rolls and nip rolls in a flat state, and rotating the endless belt-shaped molds wound around the plurality of rotating rolls,
The glass sheet and the mold sandwich a layer of molding material from being inserted between a pair of rotating rolls and nip rolls until being drawn out between the other set of rotating rolls and nip rolls, An imprint method in which an uneven pattern of the mold is transferred to a layer of the molding material.
The glass sheet is passed between a plurality of sets of rotating rolls and nip rolls in a flat state, and the endless belt-shaped first mold wound around the plurality of rotating rolls is rotated to hang on the plurality of nip rolls. Rotating the endless belt-shaped second mold to be rotated,
The glass sheet and the first mold are inserted between a pair of rotating rolls and nip rolls until being drawn from between another pair of rotating rolls and nip rolls. Sandwiching a layer of material, the uneven pattern of the first mold is transferred to the layer of the first molding material,
The glass sheet and the second mold are inserted between the pair of rotating rolls and the nip rolls until being drawn from between the other pair of rotating rolls and the nip rolls. An imprint method in which a layer of material is sandwiched and an uneven pattern of the second mold is transferred to the layer of the second molding material.
The method further includes a step of drawing out the glass sheet from the glass roll,
The imprint method according to claim 1 or 2, wherein the glass sheet fed from the glass roll is passed between a plurality of sets of rotating rolls and nip rolls in a flat state.
Multiple sets of rotating rolls and nip rolls that allow the glass sheet to pass in a flat state,
An endless belt-shaped mold that is wound around a plurality of the rotating rolls and rotated,
The glass sheet and the mold sandwich a layer of molding material from being inserted between a pair of rotating rolls and nip rolls until being drawn out between the other set of rotating rolls and nip rolls, An imprint apparatus in which a concave / convex pattern of the mold is transferred to a layer of the molding material.
Multiple sets of rotating rolls and nip rolls that allow the glass sheet to pass in a flat state,
An endless belt-shaped first mold that is wound around and rotated around the plurality of rotating rolls;
An endless belt-shaped second mold that is wound around and rotated around the plurality of nip rolls,
The glass sheet and the first mold are inserted between a pair of rotating rolls and nip rolls until being drawn from between another pair of rotating rolls and nip rolls. Sandwiching a layer of material, the uneven pattern of the first mold is transferred to the layer of the first molding material,
The glass sheet and the second mold are inserted between the pair of rotating rolls and the nip rolls until being drawn from between the other pair of rotating rolls and the nip rolls. An imprint apparatus in which a layer of material is sandwiched and an uneven pattern of the second mold is transferred to the layer of second molding material.
Further equipped with an unwinding roll to which a glass roll is attached,
The imprint apparatus according to claim 4 or 5, wherein the glass sheet fed from the glass roll is passed between a plurality of sets of rotating rolls and nip rolls in a flat state.