WO2019177029A1

WO2019177029A1 - Method for manufacturing shaped sheet

Info

Publication number: WO2019177029A1
Application number: PCT/JP2019/010289
Authority: WO
Inventors: 浅倉　孝郎; 隆志清水; 信一郎岡田
Original assignee: 富士フイルム株式会社
Priority date: 2018-03-14
Filing date: 2019-03-13
Publication date: 2019-09-19
Also published as: JPWO2019177029A1; JP6887559B2; CN111770822A; TW201940307A; CN111770822B

Abstract

According to one embodiment of the present invention, there is provided a method for manufacturing a shaped sheet, the method having: a step for using a sheet-form material including a support and a resin layer, and using the same mold to shape a relief pattern on the resin layer and position information for the purpose of cutting; and a step for detecting the position information and performing cutting. In detection of the position information, a material for which L* in the CIE-Lab color system is less than 28 is used as an underlay during cutting of the sheet-form material that was shaped through the shaping step.

Description

Manufacturing method of shaped sheet

This disclosure relates to a method for manufacturing a shaped sheet.

In the production of a shaping pattern such as a microlens array (MLA), a roll-to-roll method may be used to improve productivity.
Here, when manufacturing the said pattern by a roll-to-roll system, after shaping | molding uneven | corrugated shape to the sheet | seat unwound from the roll, the sheet | seat is cut (punching process), The specific magnitude | size which has the said pattern The following member is obtained.
Examples of a conventional method for producing a shaping pattern include those described in Japanese Patent Application Laid-Open No. 2017-149033 or Japanese Patent Application Laid-Open No. 2012-203244.

Japanese Patent Application Laid-Open No. 2017-149033 discloses an inversion surface pattern layer corresponding to the surface pattern layer of the mother plate by releasing the ultraviolet curable resin cured on the surface pattern layer of the mother plate from the mother plate. A mold plate production step for producing the formed mold plate, and the reverse surface pattern layer generated at the time of releasing the mold plate production step by heating the reverse surface pattern layer formed on the mold plate with warm air. And a shape correcting step for correcting the shape of the mold plate.

Japanese Patent Application Laid-Open No. 2012-203244 discloses that a concavo-convex pattern is formed on a belt-like sheet surface, and the concavo-convex sheet is wound up in a roll shape, along at least both ends in the width direction of the sheet surface along the longitudinal direction of the sheet. In addition, there is described a concavo-convex sheet characterized in that a tall ridge that is taller than the convex part of the concavo-convex pattern is formed.

At the time of punching in the conventional roll-to-roll system, position information is printed separately from the shaping, and the position of the punching is determined by reading the position information. However, according to such an aspect, the punching position may be displaced due to the displacement of the printing position.
The prior art also describes forming position information by shaping (Japanese Unexamined Patent Application Publication Nos. 2017-149033 and 2012-203244). In such an aspect, the contrast of positional information is described. However, it is difficult to detect the position information. As a result, the punching accuracy is low, and the punched position may be misaligned in the resulting shaped sheet.

The problem to be solved by the embodiments of the present invention is to provide a method for manufacturing a shaped sheet that has high punching accuracy and suppresses the displacement of the punched position in the resulting shaped sheet.

Means for solving the above problems include the following aspects.
<1> Using a sheet-like material having a support and a resin layer, forming a concavo-convex shape and positional information for cutting on the resin layer using the same mold, and detecting and cutting the positional information And having a process of
In the detection of the position information, a member having an L ^* of less than 28 in the CIE-Lab color system is used as an underlay when cutting the sheet-shaped material shaped by the shaping step.
Manufacturing method of shaped sheet.
<2> The method for producing a shaped sheet according to <1>, wherein the position information is an alignment mark.
<3> The method for producing a shaped sheet according to <1> or <2>, wherein the position information is a boundary portion between a formation range of the uneven shape on the resin layer and a non-formation range.
<4> The method for producing a shaped sheet according to any one of <1> to <3>, wherein the underlay is a black member.
<5> The method for producing a shaped sheet according to any one of <1> to <4>, wherein the uneven shape is a lens shape.
<6> The method for producing a shaped sheet according to <5>, wherein the maximum lens pitch of the lens shape is 200 μm or less.
<7> The method for producing a shaped sheet according to any one of <1> to <6>, wherein the support has a light transmittance of 85% or more at a wavelength of 400 nm to 700 nm.
<8> After the position information is detected, the position information is used to correct at least one of the orientation of the sheet material and the rotation angle of the region to be cut in the cutting step, < The method for producing a shaped sheet according to any one of 1> to <7>.

According to the embodiment of the present invention, there is provided a method for manufacturing a shaped sheet that has high punching accuracy and suppresses the displacement of the punched position in the resulting shaped sheet.

FIG. 1 is a schematic view of a sheet-like material in which a lens shape is shaped as an uneven shape. FIG. 2 is an enlarged view of a region where the uneven shape is formed in the sheet material shown in FIG. FIG. 3 is a schematic view showing another aspect of a sheet-like material in which a lens shape is shaped as an uneven shape. FIG. 4 is a schematic diagram illustrating a method for evaluating the deviation of the punching position in the embodiment.

Hereinafter, the contents of the present disclosure will be described in detail. The description of the constituent elements described below may be made based on typical embodiments of the present disclosure, but the present disclosure is not limited to such embodiments.
In the present specification, “to” indicating a numerical range is used in a sense including numerical values described before and after the numerical value as a lower limit value and an upper limit value.
In addition, the term “process” in this specification is not limited to an independent process, and even if it cannot be clearly distinguished from other processes, the term is used as long as the intended purpose of the process is achieved. included. In the present disclosure, “mass%” and “wt%” are synonymous, and “part by mass” and “part by weight” are synonymous.
Furthermore, in the present disclosure, a combination of two or more preferred embodiments is a more preferred embodiment.
Hereinafter, the present disclosure will be described in detail.

(Method for manufacturing shaped sheet)
The method for producing a shaped sheet according to the present disclosure uses a sheet-like material having a support and a resin layer, and forms the concave and convex shape and position information for cutting on the resin layer using the same mold, And a step of detecting and cutting the position information, and in the detection of the position information, in the CIE-Lab color system as an underlay at the time of cutting the sheet-like material shaped by the shaping step , L ^* is less than 28.

As a result of intensive studies, the present inventors have found that according to the manufacturing method according to the present disclosure, the accuracy of punching of the obtained member is high, and the displacement of the punching position is suppressed in the resulting shaped sheet.
Specifically, it is considered that the deviation between the position of the position information and the position of the concavo-convex shape is suppressed by shaping the concavo-convex shape and the position information for cutting using the same mold. .
Further, in the detection of the position information, by using a member having L ^* of less than 28 in the CIE-Lab color system as an underlay when cutting the sheet-shaped material shaped by the shaping step Since the contrast of the position information is increased and the readability by the punching machine is excellent, it is considered that the punching position of the obtained shaped sheet is suppressed because the punching accuracy of the obtained member is high.
Hereinafter, the details of each component in the manufacturing method according to the present disclosure will be described.

<Shaping process>
The manufacturing method of the shaped sheet which concerns on this indication uses the sheet-like material which has a support body and a resin layer, and forms the uneven | corrugated shape and the positional information for cutting on the said resin layer using the same type | mold ( A shaping step).

[Shaping method]
The shaping method used in the shaping step in the present disclosure is not particularly limited as long as it is a method of shaping a concavo-convex shape by pressing a mold against the resin layer, and a known shaping method can be used.
For example, a method of forming a concavo-convex shape in a resin layer by inserting a sheet-like material between an embossing roll (roll mold) on which a mold is formed and a nip roll can be mentioned.
In this case, the embossing roll is formed with an uneven shape mold and a position information mold, or an uneven shape mold is formed, and the uneven shape itself is detected as position information in the cutting process described later. The mode to do is mentioned.

Specifically, for example, the inverted shape of the uneven shape such as the lens shape, and the inverted shape of the position information as necessary (if the uneven shape itself is the position information, it is different from the inverted shape of the uneven shape, (It may not be necessary to have a reversal shape of the position information) The embossing roll formed on the surface is used, and the sheet-like material having the support and the resin layer is narrowed between the embossing roll and the nip roll. It is done.
Due to the narrow pressure, the inverted shape of the concavo-convex shape formed on the surface of the embossing roll and, if necessary, the position information are transferred to the surface of the resin layer.
After the transfer, the resin layer is cured by ultraviolet curing, heat curing or the like, and the resin layer and the support are peeled off from an embossing roll, thereby forming the sheet-like material. The curing method may be selected according to the composition of the resin layer.

-P method-
Moreover, you may perform the effect of the said resin layer by 2P method.
In the 2P method, a curable resin is applied as a resin layer to a support, and then wrapped on a roll on which a mold is formed, and the resin layer is cured by irradiating ultraviolet (UV) light while being wrapped. Then, the inverted shape of the concavo-convex pattern formed on the mold roll is transferred to the resin layer in the sheet-like material, and the transferred sheet-like material is peeled from the mold roll. Then, it is a method of winding the peeled strip-shaped uneven sheet into a roll by a winding device.

-Shaping position-
When the irregular shape to be shaped is a lens shape to be described later, the shaping is not parallel or orthogonal to the direction of lens arrangement in the irregular shape as shown in FIG. May be shaped in the direction, or as shown in FIG. 3 to be described later, the arrangement direction of the lenses in the concavo-convex shape may be shaped as a direction orthogonal to the conveying direction of the sheet material, The arrangement direction may be shaped as a direction parallel to the conveying direction of the sheet material.
In the present disclosure, the lens arrangement direction means the direction of a straight line connecting the vertices of each lens so that the density of the lenses included in the straight line is maximized in the microlens array. In the plane including the apex of the cylindrical lens, the direction perpendicular to the longitudinal direction of each cylindrical lens is indicated.

[Uneven shape]
The uneven shape to be shaped is preferably a fine shape. For example, in the case of an uneven shape in which concave portions are continuous with respect to a reference surface, the maximum value of the distance between adjacent concave portions is 300 μm or less. For example, in the case of a concavo-convex shape in which concave and convex portions are alternately repeated with respect to the reference surface, it is more preferable that the maximum value of the distance between adjacent concave and convex portions is 300 μm or less.
The uneven shape to be shaped is not particularly limited, but is preferably a lens shape.
Examples of the lens shape include a hemispherical lens shape (microlens) and a semicylindrical lens shape (cylindrical lens).
Moreover, as the uneven | corrugated shape formed, it is preferable that it is the shape in which the said micro lens or the cylindrical lens was continuously arranged, and it is more preferable that it is a micro lens array.
The arrangement in the microlens array is not particularly limited, and may be arranged in a square lattice shape or may be arranged in a honeycomb structure.

When the concavo-convex shape is a lens shape, the maximum value of the lens pitch is preferably 200 μm or less, and more preferably 160 μm or less.
The minimum value of the lens pitch is not particularly limited, but is preferably 5 μm or more.
In the present disclosure, the lens pitch refers to the distance between the vertices of the lens shape.
Thus, when the lens pitch is small, the accuracy of alignment at the time of punching is important. Since the manufacturing method of the shaped sheet according to the present disclosure has a high punching accuracy of the obtained shaped sheet and the displacement of the punching position is suppressed in the obtained shaped sheet, such a lens-shaped lens pitch is small. Suitable for manufacturing irregular shapes.

〔location information〕
The position information may be an alignment mark formed using the same mold as the uneven shape shaping, or a part of the uneven shape may be used as the position information. It is preferable to use the boundary portion between the uneven shape forming range and the non-formed range as position information.

-Alignment mark-
The alignment mark is not particularly limited. However, in a sheet-like material, alignment such as a convex shape (cylindrical convex shape), a convex shape (cylindrical convex shape), a convex triangular shape (triangular prism shape convex shape), a convex cross shape, etc. Mark is used.
When shaping is performed using the embossing roll described above, the embossing roll is provided with a concave ○ type (indented cylindrical concave), concave ● type (indented cylindrical concave) to form these alignment marks. ), A concave Δ mold (indented triangular prism-shaped recess), and a concave cross mold, respectively.
The size, shape and the like of the alignment mark are not particularly limited, and may be changed according to the apparatus to be used.
Further, the alignment mark is preferably formed at a position where the uneven shape is not formed.
The size of the alignment mark (diameter of the circumscribed circle circumscribing the alignment mark) is preferably 5 mm or less from the viewpoint of detectability. The lower limit of the size of the alignment mark is not particularly limited, but is preferably 0.1 mm or more from the viewpoint of detectability.
These alignment marks may be used alone or in combination of two or more.
For example, as shown in FIG. 1 to be described later, a mode in which a convex circle alignment mark and a convex cross alignment mark are used in combination is exemplified.

-Boundary part-
Moreover, when using the boundary part of the said uneven | corrugated shaped formation range and non-formation range as positional information, the shape of a boundary part is not specifically limited, What is necessary is just a shape which can be detected, for example, formation Examples include a method of using the corners of the range (for example, four corners described by arrows L in FIG. 2 described later).

[Sheet material]
The sheet-like material used in the present disclosure includes a support and a resin layer.

-Support-
The support is preferably a sheet-like or film-like support.
Moreover, as a support body, a resin base material is mentioned preferably from a high temperature stretchable viewpoint.
Examples of resin base materials include polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), acrylonitrile-styrene copolymer resin (AS resin), polypropylene resin, polyethylene resin, Examples thereof include polyester resins such as polyethylene terephthalate resin (PET), glycol-modified polyethylene terephthalate resin (PETG), polyvinyl chloride resin (PVC), thermoplastic elastomers, copolymers thereof, and cycloolefin polymers.
Considering ease of melt extrusion, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), polyethylene resin, polyethylene terephthalate resin, glycol modified polyethylene terephthalate resin, etc. It is preferable to use a resin having a low melt viscosity, and it is more preferable to use a polyethylene terephthalate resin.
From the viewpoints of transparency and heat resistance, polyethylene terephthalate resin, glycol-modified polyethylene terephthalate resin or cycloolefin resin is preferable, and polyethylene terephthalate resin is more preferable.
Moreover, from the viewpoint of smoothness and uniformity of thickness, the support is preferably a stretched resin substrate, and more preferably a uniaxial or biaxially stretched resin substrate.
There is no restriction | limiting in particular in the thickness of a support body, The range of 50 micrometers or more and 300 micrometers or less is preferable, and the range of 50 micrometers or more and 200 micrometers or less is more preferable from a viewpoint of shape | molding (shaping) uniformly at high temperature. When it is in the above range, the resin base material is not easily torn, and cracks are hardly generated during handling (for example, during transportation) during molding processing, and are also difficult to crack during three-dimensional molding.

Further, from the viewpoint of forming a lens shape as an uneven shape and using the resulting shaped sheet as a microlens array, the support is preferably transparent to visible light, and the support has a wavelength of 400 nm to wavelength. The light transmittance at 700 nm is preferably 85% or more. The upper limit of the light transmittance is not particularly limited and may be 100% or less.
The said light transmittance is measured by the method as described in an Example.

Commercially available products may be used as the resin substrate, for example, an acrylic resin film (Acryprene HBS010P, thickness: 125 μm) manufactured by Mitsubishi Rayon Co., Ltd., a polyethylene terephthalate resin film (Lumirror S10, thickness manufactured by Toray Industries, Inc.). : 100 μm), a cycloolefin polymer film (product name: ARTON) manufactured by JSR Corporation, a polycarbonate resin film (Iupilon H-3000, thickness 125 μm) manufactured by Teijin Chemicals Limited, etc. can be used.

-Resin layer-
The resin layer is not particularly limited as long as it is a resin-containing layer, but is preferably a curable resin layer, and more preferably a photocurable (for example, ultraviolet curable) or thermosetting resin layer. Preferably, from the viewpoint of abrasion resistance, a photocurable resin layer is more preferable.
Examples of resins that form such a curable resin layer include urethane acrylate resins, polyester acrylate resins, epoxy acrylate resins, polyether acrylate resins, acrylic acrylate resins, polythiol resins, butadiene acrylate resins, and the like. UV curable resin can be used.
Examples of the thermosetting resin include glycol-modified polyethylene terephthalate resin (PETG).
As the sheet-like material having a non-curable resin, the sheet-like material described in International Publication No. 2016/114367 and the like can be used.

The resin layer may further contain other components known in the method for producing a shaped sheet, such as a mold release agent, a polymerization inhibitor, a curing accelerator, and a stabilizer.

The thickness of the resin layer may be appropriately changed according to the uneven shape to be formed, but is preferably 2 μm to 130 μm, and more preferably 2 μm to 100 μm.

<Cutting process>
The manufacturing method of the shaped sheet which concerns on this indication has the process (cutting process) of detecting and cutting the said positional information.
Cutting in the cutting process is also referred to as “punching”.
The details of the cutting process will be described below with reference to FIG.

[Sheet-like material with lens shape]
FIG. 1 is a schematic diagram of a sheet-like material in which a lens shape is shaped as a concavo-convex shape used in the method for producing a shaped sheet according to the present disclosure.
In FIG. 1, the sheet-like material 10 is formed with an uneven shape (lens shape arranged in a honeycomb structure) 12, a convex circular alignment mark 22, and a convex cross-shaped alignment mark 24 in the above-described shaping process. Has been.
In FIG. 1, an arrow A indicates a conveyance direction of the sheet-like material 10, and a plurality of uneven shapes 12 and alignment marks 22 and 24 are formed on the sheet-like material 10 according to the conveyance direction.
In FIG. 1, the conveyance direction A and the arrangement direction in the concavo-convex shape 12 are described as different angles.

In FIG. 1, a region 16 indicated by a broken line indicates a product effective region, and a region 14 indicated by a solid line indicates a product size. In the cutting process in the present disclosure, it is necessary to punch the sheet-like material 10 having the size of the region 14 indicating the product size in the uneven shape 12 inside the region 16 that is the product effective region.
The area 14 indicating the product size in FIG. 1 is described so that the center of the area 14 and the center of the product effective area 16 overlap. A one-dot chain line in FIG. 1 indicates the centers of the region 14 and the region 16. The position of the region 14 described in FIG. 1 is the most preferable punching region position for punching the product sheet.
If the area to be punched out includes an area that is not included in the area 16 that is a product effective area, it becomes a defective product. Therefore, in manufacturing a shaped sheet, it is very important to determine the position at the time of cutting. .
In the cutting process in the present disclosure, when the sheet-like material shown in FIG. 1 is used in the cutting process, the alignment marks 22 and 24 are detected as position information, and the position for cutting is determined.
In the shaping step according to the present disclosure, the alignment marks 22 and 24 are shaped by the same mold as the concavo-convex shape 12, so that the positional deviation between the concavo-convex shape 12 and the alignment marks 22 and 24 is suppressed. . Accordingly, if the position information is determined using the alignment marks 22 and 24 in the cutting step, it becomes easy to punch out the size corresponding to the region 14 so as to be included in the region 16. That is, it is considered that the method for manufacturing a shaped sheet according to the present disclosure has high punching accuracy and suppresses the displacement of the punching position in the obtained shaped sheet.

The positional relationship among the uneven shape 12, the alignment marks 22 and 24, the region 14, and the region 16 will be further described with reference to FIG.
FIG. 2 is an enlarged view of a region where the uneven shape 12 is formed in the sheet material 10 shown in FIG.
In FIG. 2, the position of the area 14 indicating the product size is described at a position where the center of the area 14 and the center of the product effective area 16 are the same.
In FIG. 2, the convex alignment mark 22 and the convex cross alignment mark 24 have L1 = 7.5 mm in the short side direction and L2 = 10 mm in the long side direction from the corner of the region 14 in FIG. Position.

In the cutting step, position information such as the alignment mark is detected by a detecting means such as a CCD (Charge Coupled Device) camera and the punching process is performed after the punching position is determined.
In addition, an underlay is used at the time of cutting, but by using a member having an L ^* of less than 28 in the CIE (International Certification Committee) -Lab color system as the underlay, the detection sensitivity at the time of detection is improved. The precision of punching of the resulting shaped sheet is high, and the displacement of the punching position is easily suppressed in the resulting shaped sheet.

[Underlay]
Underlay, in CIE-Lab color system, ^{L *} is a member is less than 28, preferably ^{L *} is less than 24, and more preferably less than 20. In the CIE-Lab color system, the lower limit of L ^* is 0.
The L ^* is measured using SM-T-H1 manufactured by Suga Test Instruments Co., Ltd.
Moreover, as an underlay, a black member, a dark blue member, etc. are mentioned, It is preferable that it is a black member.
The material of the underlay is not particularly limited, and a member having a certain degree of elasticity is used, such as PET, PETG, acrylic resin, silicone resin, polycarbonate resin, polystyrene resin, MS resin, AS resin, polyolefin resin, PVC, and the like. Can be mentioned.
As the underlay, for example, a known underlay colored in the punching process can be used.

[Another aspect of shaped sheet material]
FIG. 3 is a schematic diagram illustrating another aspect of a sheet-like material in which a lens shape is shaped as an uneven shape, which is used in the method for producing a shaped sheet according to the present disclosure.
In FIG. 3, the uneven shape 12 is formed in the sheet-like material 10, and the punching is performed in a region 14 indicating the product size.
In FIG. 3, the alignment marks 22 and 24 and the product effective area 16 are omitted.
In FIG. 3, the arrangement direction of the microlens array in the concavo-convex shape 12 is described so as to be orthogonal to the conveyance direction A, and the region 14 that is a punched region has an angle with respect to the conveyance direction A. It is described in.

[Cutting method]
A cutting method in the shaping process is not particularly limited, and a known method is used. A punching machine with a punching posture correction function equipped with a CCD camera may use a general-purpose machine commercially available from several punching machine manufacturers. it can. For example, “IPA series” image positioning press with CCD camera (manufactured by Fuji Shoko Machinery Co., Ltd.), roll material positioning die cutting machine “SCP250E-APS series” (manufactured by Sakamoto Seiki Co., Ltd.), roll material die cutting machine “T261” Series "(manufactured by Yamaha Finetech Co., Ltd.).

In the cutting process in the present disclosure, from the viewpoint of suppression of deviation of the punching position in the obtained shaped sheet and the viewpoint of productivity, after detecting the position information, the position of the sheet-like material using the position information, Or it is preferable to correct | amend at least any one of the rotation angle of the area | region cut in the said cutting process.
The correction is performed by a punching posture correction function or the like in the punching machine. The position information is detected by, for example, a CCD camera mounted on the punching machine.
The orientation of the sheet-like material refers to the conveying direction and / or the orthogonal direction of the sheet-like material.
For example, in the cutting step of cutting the sheet-like material described in FIG. 1 above, the angle of the region 14 indicating the product size by fixing the angle of the region to be cut and correcting the posture of the conveyed sheet-like material. It is possible to match the (rotational angle of the punched area) with the angle of the product effective area 16 on the sheet-like material.
Further, in the cutting step of cutting the sheet-like material described in FIG. 3, the sheet conveyance direction is fixed, and the rotation angle of the area to be cut is corrected to correct the angle of the punched area and the sheet shape. The angle of the product effective area on the material can be matched.
Further, in the cutting step of cutting the sheet-like material described in FIG. 1 or FIG. 3, both the sheet posture and the rotation angle of the region to be cut may be corrected.

<Winding process, unwinding process>
When performing the manufacturing method of the shaped sheet which concerns on this indication by a roll-to-roll system, it is preferable to include the winding-up process which winds up a sheet-like material, or the unwinding process which unwinds a sheet-like material.
The winding step and the unwinding step can be optionally included before or after each step, and can be performed, for example, in the order described in Method A below.
(Method A)
(1) A step of unwinding the sheet-like material using a roll-like sheet-like material (2) A step of forming an uneven shape on the unwound sheet-like material (the above-mentioned shaping step)
(3) Step of winding up the sheet-like material having an irregular shape (4) Step of unwinding the wound-up sheet-like material (5) Step of cutting the unrolled sheet-like material (described above Cutting process)
In the method A, the winding process and the unwinding process described in (3) and (4) may be omitted, and the shaping process and the cutting process may be continuously performed while being conveyed.

<Other processes>
The method for manufacturing a shaped sheet according to the present disclosure may further include other steps.
Other processes include, for example, a process of forming a protective film on the shaped sheet, and when the shaped sheet is used as a lenticular sheet, the surface of the shaped sheet is opposite to the surface on which the lens is formed. And a step of forming the ink receiving layer.

Hereinafter, the present disclosure will be described in detail by way of examples, but the present disclosure is not limited thereto. In this example, “%” and “part” mean “% by mass” and “part by mass”, respectively, unless otherwise specified.

Example 1
<Production of shaped sheet (shaped process)>
A 2P method was used to produce a shaped sheet by roll-to-roll.
A roll mold having a pattern in which microlens arrays (MLA) having a lens pitch of 20 μm arranged in a honeycomb structure (lens pitch of 20 μm) and an alignment mark having a concave ○ shape was prepared.
The alignment mark is in a region where the microlens array pattern is not formed, and is positioned 7.5 mm in the short side direction and 10 mm in the long side direction from the corner of the region to be punched out as a product sheet (the alignment shown in FIG. 2

Marks

22 and 24, 4 places in total).
A UV curable resin (manufactured by Aika Kogyo Co., Ltd., Z-977-) with a PET film (Toyobo Co., Ltd., Cosmo Shine A4300, light transmittance 95%) having a thickness of 50 μm, a width of 350 mm and a length of 300 m as a support. 7L, UV curable resin A) was applied at a thickness of 3 μm, the roll mold was pressed to transfer the pattern inversion, and the film was irradiated with ultraviolet rays and cured, and then the cured sheet material was peeled off from the roll mold. . And the sheet-like material in which the alignment mark and the micro lens array pattern were shaped on the PET film was wound up in a roll shape by a winding device.
Since the shape of the alignment mark formed on the roll mold is the above-described concave ○ shape, the shape of the alignment mark formed on the sheet-like material is a cylindrical shape (convex ○) having a bottom diameter of 3 mm.
The light transmittance at a wavelength of 400 nm to 700 nm of the PET film as the support is shown in Table 1.
The light transmittance was measured using a spectrophotometer V-560 (manufactured by JASCO Corporation) with an integrating sphere attachment device ARV-474.

<Punching of shaped sheet (cutting process)>
In the sheet material continuous punching machine, the base material was a black polyethylene terephthalate (PET) base material, and the sheet-like material obtained by the above shaping process was punched while detecting the position using alignment marks as positional information using a CCD camera. .
As a PET base material used for the underlay of the punching machine, Lumirror (manufactured by Toray Industries, Inc., H10 # 500, hazy (milky white with high turbidity, L ^* = 55)) was used. Alignment mark detection, which is positional information, is detected and discriminated by a CCD camera built into the punching machine, so ensuring visibility is important, but the shaping part of the shaping sheet is low haze (close to white) For this reason, it is difficult to distinguish the shaped alignment mark.
Therefore, in order to improve the visibility of the CCD camera, a black lumirror (X30 # 250, L ^* = 12, manufactured by Toray Industries, Inc.) is used as an underlay, so that the substrate portion (transparent) and the shaping are made more than before. Part (low haze) can be increased, and the detection stability can be improved.
As a punching machine equipped with a CCD camera and having a punching posture correction function, a roll material positioning die cutting machine “SCP250E-APS series” (manufactured by Sakamoto Seiki Co., Ltd.) was used.

(Example 2)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the alignment mark in the roll mold was a concave ten. The shape of the alignment mark formed on the sheet-like material is a 2.5 mm square convex cross shape (convex +).

(Example 3)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the alignment mark in the roll mold was a concave mold. The shape of the alignment mark formed on the sheet-like material is a cylindrical shape (convex ●) having a diameter of 3.0 mm.

Example 4
A shaped sheet was produced and punched in the same manner as in Example 1 except that the alignment mark in the roll mold was a concave Δ mold. The shape of the alignment mark formed on the sheet-like material is a triangular prism shape (convex Δ) having a side of 3.0 mm.

(Example 5)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the position information was the boundary portion (MLA fine shape pattern) between the formation range and non-formation range of the microlens array pattern. As the boundary portion, four corners of the pattern (four places indicated by arrows L in FIG. 2) were used.

(Example 6)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the function of correcting the orientation of the sheet-like material during punching and the rotation angle of the region to be cut in the cutting process was used.

(Example 7)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the thickness of the PET film (Cosmo Shine A4300, manufactured by Toyobo Co., Ltd.) was 100 μm.

(Example 8)
A shaped sheet was produced and punched out in the same manner as in Example 1 except that the material of the support was COP film (ARTON manufactured by JSR Corporation).

Example 9
A shaped sheet was prepared and punched out in the same manner as in Example 1 except that the ultraviolet curable resin was changed to a resin with high hardness (Z-977-8L, UV curable resin B, manufactured by Aika Industry).

(Example 10)
A shaped sheet was prepared and punched out in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was 2 μm.

(Example 11)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was changed to 5 μm.

(Example 12)
A shaped sheet was prepared and punched in the same manner as in Example 1 except that the thickness of the ultraviolet curable resin was 8 μm.

(Example 13)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the lens pitch of the microlens array was 40 μm.

(Example 14)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the lens pitch of the microlens array was set to 100 μm.

(Example 15)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the lens pitch of the microlens array was 200 μm.

(Example 16)
The pattern is a cylindrical lens having a pitch of 127 μm (200 LPI, LPI is the number of cylindrical lenses per inch, and 1 inch is 2.54 cm), and the direction in which the axial direction of one half cylinder of each cylindrical lens is parallel to the conveying direction A shaped sheet was produced and punched out in the same manner as in Example 1 except that it was formed into a shape.

(Example 17)
A shaped sheet was produced and punched in the same manner as in Example 1 except that the ultraviolet curable resin forming the resin layer was changed to a thermosetting resin (glycol-modified polyethylene terephthalate PETG, thermosetting resin C). It was.

(Example 18)
A shaped sheet was produced and punched in the same manner as in Example 1 except that in the sheet material continuous punching machine, the underlay was changed to an amber polyethylene terephthalate (PET) base material (L ^* = 22).

(Comparative Example 1)
Position information such as the boundary portion between the formation range and the non-formation range of the alignment mark and pattern was not given, and the shaped sheet was punched with a sheet material continuous punching machine. The underlay was a milky white PET substrate (L ^* = 55).

(Comparative Example 2)
A mold having a pattern in which microlens arrays having a lens pitch of 20 μm were arranged in a honeycomb structure on the surface was prepared. Using a PET film having a thickness of 50 μm (manufactured by Toyobo Co., Ltd., Cosmo Shine A4300) as a support, an ultraviolet curable resin (manufactured by Aika Kogyo Co., Ltd., Z-977-7L) is applied at a thickness of 3 μm on one side. After pressing the mold, it was cured by irradiating with ultraviolet rays.
The cured resin was peeled from the mold, and the microlens array pattern was shaped on a PET film. An alignment mark was printed using an inkjet printer at a position 7.5 mm from the corner of the product sheet in the short side direction and 10 mm in the long side direction.
In the sheet material continuous punching machine, the underlay was a milky white PET base material (L ^* = 55), and the shaped sheet was punched while detecting the position using a CCD camera.

(Comparative Example 3)
The shaped sheet produced in the same manner as in Example 1 was subjected to position detection using an alignment mark, which is position information, using a CCD camera with a sheet material continuous punching machine with the underlay as a milky white PET base material (L ^* = 55). The shaped sheet was punched out.

(Evaluation)
<Evaluation of displacement of punching position>
Regarding the displacement of the punching positions in the manufacturing method of the shaped sheet according to each example or comparative example, the difference in angle between the pattern arrangement direction, that is, the center line of each lens and the long side of the punched sheet Evaluated by. The center line of each lens refers to the one of the two straight lines drawn so as to pass through the center of the most lenses in the microlens array, and the angle with the long side is smaller. The axial direction of two semi-cylinders.
FIG. 4 shows details of the evaluation method.
The left diagram in FIG. 4 shows the sheet-like material before punching, and θ1 shows the angle between the long side of the target punching position and the center line of each lens.
The right-side view in FIG. 4 shows the shaped sheet after punching, and θ2 shows the angle between the long side of the punched sheet and the center line of each lens.
The absolute value (| θ1−θ2 |) of the difference between the θ1 and the θ2 is used as an evaluation index, and the evaluation results are shown in Table 1 according to the following evaluation criteria. The evaluation result is preferably AA, A, B or C, more preferably AA, A or B, still more preferably AA or A.
For the evaluation, a digital microscope VHX-500F (manufactured by Keyence Corporation) was used.

〔Evaluation criteria〕
AA: | θ1-θ2 | is 0 ° or more and less than 0.2 °.
A: | θ1-θ2 | is 0.2 ° or more and less than 0.4 °.
B: | θ1−θ2 | is not less than 0.4 ° and less than 0.6 °.
C: | θ1-θ2 | is 0.6 ° or more and less than 1.0 °.
D: | θ1-θ2 | is 1.0 ° or more and less than 1.2 °.
E: | θ1-θ2 | is 1.2 ° or more.

<Evaluation of abrasion resistance>
In accordance with the pencil hardness evaluation method prescribed in JIS K 5600-5-4 (1999), the surface property measuring machine “HEIDON TYPE 14FW” (manufactured by Shinto Kagaku Co., Ltd.) ) And pencil “Uni” (manufactured by Mitsubishi Pencil Co., Ltd.), and scratching was repeated 10 times with a pencil of each hardness with a weight of 500 g, and the hardest pencil scale with no scar was determined.
If the evaluation of the pencil hardness is A or B, it is preferable because scratches on the alignment mark are suppressed due to rubbing with the underlay at the time of punching, and the alignment mark detection accuracy is excellent.

〔Evaluation criteria〕
A: The pencil hardness is F or more.
B: Pencil hardness is 2B or more and HB or less.
C: Pencil hardness is 3B or less.

As shown in Table 1, the method for producing a shaped sheet according to the present disclosure was excellent in suppressing the displacement of the punching position in the shaped sheet obtained from the obtained shaped sheet. Moreover, the manufacturing method of the shaped sheet which concerns on the said Example was excellent also in abrasion resistance and productivity.

The disclosure of Japanese Patent Application No. 2018-046461 filed on Mar. 14, 2018 is incorporated herein by reference in its entirety.
All documents, patent applications, and technical standards mentioned in this specification are to the same extent as if each individual document, patent application, and technical standard were specifically and individually stated to be incorporated by reference, Incorporated herein by reference.

Claims

Using a sheet-like material having a support and a resin layer, and forming the concave and convex shape and position information for cutting on the resin layer using the same mold, and detecting and cutting the position information Have
In the detection of the positional information, a member having an L * of less than 28 in the CIE-Lab color system is used as an underlay for the sheet-shaped material shaped by the shaping step.
Manufacturing method of shaped sheet.
The method for producing a shaped sheet according to claim 1, wherein the position information is an alignment mark.
The method for producing a shaped sheet according to claim 1 or 2, wherein the position information is a boundary portion between the formation range and the non-formation range of the uneven shape on the resin layer.
The method for producing a shaped sheet according to any one of claims 1 to 3, wherein the underlay is a black member.
The method for producing a shaped sheet according to any one of claims 1 to 4, wherein the uneven shape is a lens shape.
The method for producing a shaped sheet according to claim 5, wherein a maximum value of the lens pitch of the lens shape is 200 µm or less.
The method for producing a shaped sheet according to any one of claims 1 to 6, wherein the support has a light transmittance of 85% or more at a wavelength of 400 nm to 700 nm.
After detecting the position information, the position information is used to correct at least one of an attitude of the sheet-like material and a rotation angle of a region to be cut in the cutting step. Item 8. The method for producing a shaped sheet according to any one of Items 7 to 9.