WO2020066478A1 - Shaped-sheet manufacturing method - Google Patents

Abstract

A shaped-sheet manufacturing method according to the present invention includes: a step A in which, on a curable-resin-composition layer provided on a support body, a first-shape-part forming area having a functional shape part that gives a function to a shaped sheet and a second-shape-part forming area having a different surface shape from the first-shape-part forming area and serving as position information in a cutting step are simultaneously imparted; a step B in which the curable-resin-composition layer is cured, thus forming a layered product including the support body and a resin layer formed on the support body and having the first-shape-part forming area and the second-shape-part forming area imparted thereto; and a step C in which the second-shape-part forming area in the resin layer is detected, and the layered product is cut on the basis of the position information of the detected second-shape-part forming area.

Description

Manufacturing method of shaped sheet

The present disclosure relates to a method for manufacturing a shaped sheet.

As a method of manufacturing a shaped sheet having a shaped pattern such as a microlens array (MLA), a sheet-fed method in which each sheet is shaped or a roll-to-roll method in which a continuous long roll film is formed One of the methods is used.
When manufacturing a desired shaping pattern by a roll-to-roll method, shaping a film unwound from a roll into various shapes selected from a convex shape and a concave shape, and then cutting the shaped sheet. Thereby, a member of a specific size having a desired shaping pattern can be obtained. For cutting the sheet, for example, a punching process using a punching blade is applied.

In order to impart a function to a shaped sheet having fine irregularities such as a microlens and a tapered structure, a high-definition transfer mold is required. A high-definition transfer mold is manufactured by a special processing machine, and manufacturing a mold for shaping a large area at one time is costly. For this reason, it is desired to improve the area of the effective area of the formed shaped film having the fine unevenness.
At the time of the punching process in the conventional roll-to-roll method, position information is printed separately from the shaping, and the punching process is positioned by reading the position information. However, according to such an embodiment, since two different steps are required to provide the position information, the steps are complicated, and the punching position may be shifted due to a shift in the printing position.
As a conventional method for producing a shaped pattern, for example, those described in JP-A-2003-181918, JP-A-2012-203244, and JP-A-2011-98443 are exemplified.

JP-A-2003-181918 discloses a shaping roller and a method of manufacturing a laminated film using the same. The shaping roller is a metal sheet-shaped mold formed separately from the roller and wound around the roller, and the end portion is fixed by a welded portion. It is an object to suppress defects. For this reason, it is characterized in that the gap between the fixed molds is filled with solder and the surface is polished. It also describes that the polished area of the solder at the seam of the mold can be used for detecting the position of the shaping film.

Japanese Unexamined Patent Application Publication No. 2012-203244 discloses that an uneven pattern is formed on a belt-shaped sheet surface, and that at least both ends in the width direction of the sheet surface are provided along the longitudinal direction of the sheet in the uneven sheet wound up in a roll shape. Thus, there is described a concave-convex sheet in which a tall protruding ridge portion that is taller than the convex portions of the concave-convex pattern is formed.

Japanese Patent Application Laid-Open No. 2011-98443 discloses a mold roll for a shaping film, and a mark is formed as a mark near a roll end outside a region cut for shaping to form a die. It is characterized in that the cause of the defect generated in the mold roll can be easily specified.

Japanese Patent Application Laid-Open No. 2003-181918 also describes that positional information is formed by shaping. However, in the method described in the above-mentioned document, manufacturing of a mold, particularly polishing of a solder portion serving as positional information, is performed. For example, the manufacturing process of the mold roll is complicated. Further, in the mode described in JP-A-2012-203244, the position information is formed only in the longitudinal direction of the sheet, and is not suitable for the position information. In some cases, the punching position of the shaped sheet was shifted.
Further, the inscription formed outside the shaping area of the die roll described in Japanese Patent Application Laid-Open No. 2011-98443 does not pay attention to use as position information at the time of cutting, and is formed for the purpose of specifying a defect position. It is a thing. Therefore, it is difficult to use it in applications requiring high-accuracy position information, such as trimming positioning, in terms of accuracy and contrast.

The problem to be solved by one embodiment of the present invention is to provide a method for manufacturing a shaped sheet in which positional information having high precision that can be used at the time of cutting is provided by a simple process, and positioning accuracy at the time of cutting is improved. It is.

Means for solving the above problems include the following aspects.
<1> The first shape portion forming region and the first shape portion forming region provided with a functional shape portion for imparting a function to the shaping sheet to the curable resin composition layer provided on the support. A step A of simultaneously shaping a second shape portion forming region which is a surface shape and becomes positional information in the cutting step, curing the curable resin composition layer, and forming a first shape on the support and the support Forming a layered product including a resin layer in which a portion forming region and a second shape portion forming region are shaped, and detecting the second shape portion forming region of the resin layer, and detecting the detected second shape portion. And C. cutting the laminate based on the positional information of the shaped part forming region.

<2> The method for producing a shaped sheet according to <1>, wherein the second shape portion forming region exists outside the first shape portion forming region.
<3> The method for producing a shaped sheet according to <1>, wherein the second shape portion forming region exists in the first shape portion forming region.

<4> The second shape portion forming region having a surface shape different from that of the first shape portion forming region has a position information shape portion serving as position information, and the second shape portion forming region has the following (I The method for producing a shaped sheet according to any one of <1> to <3>, wherein the shaped sheet is a surface shape selected from the following.
(I) The position information shape part has a shape similar to the functional shape part.
(II) The position information shape part in the second shape part formation region is arranged with a different number density per unit area from the functional shape part in the first shape part formation region.
(III) The position information shape part has the same shape or a similar shape as the functional shape part, and the position information shape part differs from the functional shape part in the first shape part formation region per unit area. They are arranged in number density.
<5> The method for producing a shaped sheet according to any one of <1> to <4>, wherein in the step C of cutting the laminate, the position of the laminate is corrected.
<6> The method for producing a shaped sheet according to any one of <1> to <5>, wherein the functional shape portion is a microlens.

According to one embodiment of the present invention, there is provided a method of manufacturing a shaped sheet, in which positional information with high accuracy that can be used at the time of cutting is provided by a simple process, and positioning accuracy at the time of cutting with accurate position information is improved. You.

It is the schematic which shows one Embodiment of the shaping apparatus which forms unevenness in the curable resin composition layer formed on the support body, and manufactures the laminated body which has the resin layer shaped on the support body. It is a schematic plan view showing an example of formation position and cutting position of each field in a mode in which the position information field of a layered product was formed outside the field of a functional field. It is a schematic plan view showing an example of a formation position and a cutting position of each field in a mode in which a position information field of a layered product was formed in a field of a functional field. FIG. 10 is a schematic plan view illustrating an example of a modification of the relative positional relationship between the functional area and the position information area, in which the position information area is formed outside the functional area and the cutting section. It is an aspect of a modified example of the relative positional relationship between the functional area and the position information area, and schematically illustrates an example of an aspect in which the position information area is formed inside the functional area and outside the effective area. It is a top view. It is an aspect of the modification of the relative positional relationship between the functional area and the position information area, and schematically illustrates an example of an aspect in which the position information area is formed inside the functional area and inside the effective area. It is a top view. (A-1), which is an example of the functional area, and (B-1), (B-2), and (B-3), which are examples of position information areas having different planar shapes from (A-1). FIG. It is a schematic plan view showing (A-2) which is an example of a functional area, and (B-4) which is an example of a position information area having a different planar shape from (A-2). It is a perspective view which shows the modification of the convex part as a functional shape part. 1 is a schematic configuration diagram illustrating one embodiment of a cutting device that can be used in the manufacturing method of the present disclosure. FIG. 9 is an enlarged view of a cutting unit in the cutting device shown in FIG. 8. It is a schematic sectional drawing of the cutting part shown in FIG.

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 disclosure, “to” indicating a numerical range is used to mean that the numerical values described before and after it are included as the lower limit and the upper limit.
In addition, the term “step” in the present disclosure is not limited to an independent step, and is included in the term even if it cannot be clearly distinguished from other steps if the intended purpose of the step is achieved. It is.
In the present disclosure, “mass%” and “wt%” have the same meaning, and “mass part” and “part by weight” have the same meaning.
In the present disclosure, the amount of each component in the composition means, when a plurality of substances corresponding to each component are present in the composition, unless otherwise specified, means the total amount of the plurality of substances present in the composition. .
In the numerical ranges described stepwise in the present disclosure, an upper limit or a lower limit described in a certain numerical range may be replaced with an upper limit or a lower limit of another numerical range described in a stepwise manner. Further, in the numerical ranges described in the present disclosure, the upper limit or the lower limit described in a certain numerical range may be replaced with the value shown in the embodiment.
Further, in the present disclosure, a combination of two or more preferred embodiments is a more preferred embodiment.
Components shown with the same reference numerals in each drawing mean the same components.
Hereinafter, the present disclosure will be described in detail.

(Method of manufacturing shaped sheets)
The method for producing a shaped sheet according to the present disclosure includes a first shape portion forming region including a functional shape portion that imparts a function to the shaped sheet, to the curable resin composition layer provided on the support, and A step A of simultaneously shaping the second shape part forming region, which is a surface shape different from the shape part forming region and serving as positional information in the cutting step, and curing the curable resin composition layer, A step B of forming a laminate including a resin layer having a first shape portion forming region and a second shape portion forming region formed on a support; and a second shape portion forming region of the resin layer. Detecting and cutting the laminated body based on the detected position information of the second shape portion forming region.

工程 In step A of the present disclosure, a first shape portion forming region having a functional shape portion and a second shape portion forming region having a surface shape different from the first shape portion forming region are simultaneously formed. That is, "simultaneously shape" means that, on the same plane as the curable resin composition layer provided on the support, by the same mold, the first shape portion forming region including the functional shape portion is formed. This means that a second shape portion forming region having a surface shape different from the first shape portion forming region is formed in one step.

There is no particular limitation on the “functional shaped portion that imparts a function to the shaped sheet” provided in the first shaped portion forming region. The functional shape portion may have a convex shape or a concave shape.
For example, when the shaping sheet is applied to a microlens array, the first shape portion region is a region in which a plurality of hemispherical functional shape portions each having the shape of a convex lens are formed. Further, when the shaping sheet is applied to a lenticular sheet, the first shape portion forming region is a region where a plurality of semi-cylindrical lens-shaped functional shape portions are formed in parallel in one direction. Become.

Here, the “different surface shape” means that there is a change in the surface shape when the same surface is viewed in one direction, and the first shape portion forming region and the second shape portion forming region Refers to a shape that can be distinguished by at least one of visual observation and optical system observation.
Specifically, the following modes can be given, but the present invention is not limited to the following modes as long as they are combinations of shapes that can be distinguished by visual observation and / or optical system observation. Specific combinations of shapes will be described later.
(1) The second shape portion forming region is a region where a convex portion or a concave portion having a shape different from the functional shape portion in the first shape portion forming region is arranged.
(2) The second shape portion forming region is a region similar to the functional shape portion in the first shape portion forming region, that is, a region in which convex portions or concave portions having the same shape but different sizes are arranged.
(3) The second shape portion formation region is a region in which protrusions or recesses having the same shape as the functional shape portion in the first shape portion formation region are arranged with different number densities per unit area.
(4) The second shape portion forming region has a convex portion or a concave portion having the same shape in plan view as the functional shape portion in the first shape portion forming region, and the first shape portion forming region has a plan view. Are regions arranged at different axial angles.
(5) The second shape portion forming region is a planar region in which no convex portion or concave portion of any shape is arranged.

According to the manufacturing method of the present disclosure, the first shape portion forming region and the second shape portion forming region having different surface shapes are simultaneously formed using the same mold, so that a simple process can be used. Position information is simultaneously formed at a desired accurate position with respect to the formation region of the functional shape portion. For this reason, according to the manufacturing method of the present disclosure, accurate positional information is formed without any gap between the functional shape portion and the positional information in the resin layer on the laminate.
Further, the position information can be easily detected by visual observation or observation using an optical system such as a Charge-Coupled Device (CCD) camera. Even when the shaping sheet is cut, the readability is improved. Therefore, it is considered that the shaped sheet can be cut at a highly accurate position by detecting the position information, and the effective area of the formation area of the functional shape portion formed in the shaped sheet can be improved.
In the present disclosure, one or both of visual observation and observation using an optical system may be collectively referred to as “visual observation or the like”.
Hereinafter, each step in the manufacturing method according to the present disclosure and details of the constituent requirements of the shaped sheet will be described.

<Step A>
In step A, the curable resin composition layer provided on the support has a first shape portion forming region (hereinafter, referred to as a “functional region”) including a functional shape portion that imparts a function to the shaped sheet. And a second shape portion forming region (hereinafter, sometimes referred to as a “position information region”) having a surface shape different from that of the first shape portion forming region and serving as position information in the cutting process. This is the step of shaping.
FIG. 1 is a schematic view showing one embodiment of a shaping apparatus 10 used in a process A and a process B described later. The curable resin composition is supplied from the coating device 16 to the support 14 supplied from the supply roll 12, and a laminate 20 having the curable resin composition layer 18 formed on the support 14 is obtained. Hereinafter, the laminate before curing of the curable resin composition layer is referred to as “laminate (I)”. The obtained laminate (I) 20 is transported to the shaping roll 22.
As shown in FIG. 1, a mold 24 disposed on the surface of the shaping roll 22 has a functional area providing section 26A for forming a functional area and a position information area providing section for forming a position information area. A portion 28A is formed.
When the curable resin composition layer 18 in the laminate (I) 20 comes into contact with the mold 24 on the surface of the shaping roll 22, the mold 24 causes the surface of the curable resin composition layer 18 to be formed on the shaped sheet. The functional area 26B and the position information area 28B to which a function is to be provided are simultaneously formed. Hereinafter, the shaping roll on which the mold is formed may be referred to as an embossing roll 22A.

In detail, for example, as shown in FIG. 1, the laminate (I) 20 has on its surface an inverted shape 26A of a concave-convex shape serving as a functional shape portion and an inverted shape 28A of a position information area as required. Using the embossed roll 22A, the laminate (I) 20 having the support and the curable resin composition layer is pressed against the embossed roll 22A using the nip roll 22B.
Due to the pressing, the functional region 26B and the position information region 28B, which are the inverted shapes of the concavo-convex shape formed on the surface of the embossing roll 22A, are transferred to the surface of the curable resin composition layer 18.
In the case where the position information region is a flat plate having no irregularities, the position information forming region on the surface of the mold 24 is formed into a flat shape having no irregularities, so that the surface of the curable resin composition layer is formed. A position information area having no irregularities can be formed.

In FIG. 1, using a laminate (I) 20 having a support 14 and a curable resin composition layer 18, the surface of the embossing roll 22 </ b> A is pressed in a direction in which the curable resin composition layer 18 comes into contact, and the uneven shape is obtained. An embodiment of shaping is shown. In the example shown in FIG. 1, in order to sufficiently press the laminate (I) 20 against the surface of the embossing roll 22A, a mode in which nip rolls 22B are provided on the upstream side and the downstream side of the region of the embossing roll 22A where the die is pressed, respectively, is shown. Take.
The method of shaping the surface of the curable resin composition layer is not limited to the embodiment illustrated in FIG. 1, and any known method may be used as long as it is a method of pressing a mold against the curable resin composition layer to form an uneven shape. Can be used as appropriate.
For example, the laminate of the support and the curable resin composition layer is made into a sheet-like shape, and irregularities are formed on a first surface, and the laminate is cured between a pair of molds having a planar second surface. The resin composition layer side may be narrowed in the direction in contact with the first mold to form a functional region and a position information region on the surface of the curable resin composition layer at the same time.

[Relative position between functional area and position information area]
The relative positional relationship between the position information area that is the second shape part formation area and the functional area that is the first shape part formation area can be appropriately selected depending on the purpose.
The second shape portion formation region may exist in the first shape portion formation region, or may exist outside the first shape portion formation region.
FIG. 2 is a schematic plan view showing an example of a formation position and a cutting position of a position information area and a functional area of the laminate. In FIG. 2, the position information area 28B formed in a T-shape is formed outside the functional area 26B. A rectangle defined by a solid line 31 on the periphery of the functional region 26B in FIG. 2 indicates a planned cutting position of the shaped sheet.
In the example shown in FIG. 2, the position information area 28B has a T-shape, and is formed at a corner outside the area of the functional area 26B and adjacent to the functional area 26B. In the embodiment shown in FIG. 2, the functional area 26B is a rectangular area when viewed in plan, and the position information area 28B is formed at two opposing corners on the long side of the rectangle.

Note that the position where the position information area is formed is not limited to the position shown in FIG. 2 as long as the cutting position can be accurately determined by detecting the position information. For example, four locations may be formed at the four corners of the rectangular functional area 26B. Further, the shape of the position information area is not limited to the T-shape, but may be various shapes such as an L-shape, a cross shape, and a circular shape.
FIG. 2 illustrates one of the functional region and the position information region formed after the shaping by the embossing roll shown in FIG. 1 is performed. By the shaping by the above-described embossing roll, the same shaping area in which the same mold is formed as shown in FIG. 2 along the conveying direction of the long laminate shown by the arrow in FIG. A plurality is formed continuously. The same applies to FIG. 3 described later.

FIG. 3 is a schematic plan view showing another example of the formation position of the position information area and the functional area of the laminate. In FIG. 3, the position information area 28B is formed in the area of the functional area 26B. In FIG. 3, as in FIG. 2, a rectangular area defined by a solid line 31 on the periphery of the functional area 26B indicates a planned cutting position of the shaped sheet.
In FIG. 3, the position information area 28B has an L shape and is formed at a corner in the area of the functional area 26B. In FIG. 3, the functional area 26 </ b> B is a rectangular area in plan view, and the position information area 28 </ b> B is formed at two opposing corners of the long side of the rectangle. If the cutting position can be accurately determined by detecting the position information, the position where the position information is formed is not limited to the position shown in FIG. 3, and four positions can be formed at the four corners of the rectangular functional area 26B.
As described above, the shape of the position information area is not particularly limited, and may have various shapes such as an L shape, a T shape, a cross shape, and a circle shape.
As shown in FIGS. 2 and 3, the functional area 26B and the position information area 28B are provided adjacent to each other, and the position information area 28B is detected and stacked at the boundary between the functional area 26B and the position information area 28B. Cutting the body is preferable from the viewpoint that a product effective area including the functional area 26B can be efficiently obtained.

(4) When one of the cut pieces of the shaped sheet is incorporated into a product, the functional region in the shaped sheet carries the function of the product. When a shaped sheet is applied to a product, the shaped sheet is incorporated into a product member and fixed. At this time, the fixing part may not necessarily have a functional area.

The relationship between the cutting unit, the functional area, and the position information area will be described with reference to FIGS. 4A, 4B, and 4C. FIGS. 4A, 4B, and 4C are schematic plan views each showing an aspect of a modification of the relative positional relationship between the functional area 26B and the positional information area 28B.
4A, 4B, and 4C, the periphery of the cut portion is indicated by a bold line, and the periphery of the effective region that exhibits a function when the shaping sheet is incorporated into the product is indicated by a broken line.

で は In FIG. 4A, the position information area 28B is formed outside the cut section defined by the thick line. Accordingly, in the embodiment shown in FIG. 4A, the position information area 28B is formed outside the periphery of the effective area existing inside the functional area 26B. In the case where the position information area 28B in FIG. 4A is detected and the shaped sheet is cut at a thick line portion, when the obtained shaped sheet is incorporated into a product, the entire area of the effective area becomes the functional area 26B. Thus, a shaped sheet that can exhibit functions up to the peripheral portion is obtained.

In FIG. 4B, the position information area 28B partially exists inside the functional area 26B, and is formed outside the effective area whose peripheral edge is surrounded by a broken line. By detecting the position information area 28B in FIG. 4B and cutting it at the thick line portion, the obtained shaping sheet has the position information area 28B inside the shaping sheet, but the effective area in the functional area 26B. Will exist outside the When the shaped sheet is cut by detecting the position information area 28B in FIG. 4B, the obtained shaped sheet is, when incorporated into a product, the entire area of the effective area as in FIG. 4A. It becomes the functional region 26B, and becomes a shaped sheet that can express functions up to the peripheral portion.

ＣIn FIG. 4C, the position information area 28B exists inside the functional area 26B, and is formed inside the effective area whose peripheral edge is surrounded by a broken line. By detecting and cutting the position information area 28B in FIG. 4C, the obtained shaped sheet has the position information area 28B in the effective area within the functional area 26B. However, for example, when using a large-area shaped sheet for an application that does not require fine precision up to the periphery, such as an application for a large display, the position information area 28B is formed at the position shown in FIG. 4C. May not be a problem.

According to the method for manufacturing a shaped sheet of the present disclosure, the position information area 28B has a surface shape different from the surface of the functional area 26B, and can be identified by visual observation or the like. However, the functional area 26B and the position information area 28B are simultaneously formed of the same material, and therefore have the same hue. Therefore, the position information area existing at the corner of the effective area hardly affects the effective area of the product as compared with the position information area formed by a method other than the manufacturing method of the present disclosure. Therefore, if the application does not require a high-definition function over the entire effective area, such as a large-area optical material, a position information area as shown in FIG. 4C can be formed, and the functional area 26B can be effectively used. It will be possible to utilize it.

[Shape of location information area]
The area of the position information area is defined by a rectangular shape such as a T-shape or an L-shape from the viewpoint of discriminability by visual observation or the like, and from the viewpoint of reducing the influence of the presence of the position information area on the functional area. In the case of a region having a combined shape, the width and length of the rectangle are preferably 5 mm or less. The lower limit of the size of the position information area is not particularly limited.
From the viewpoint of distinguishability, the width and length of the above-described rectangular shape are preferably 0.1 mm or more.
When a plurality of position information areas are formed on the same surface, the shape of the position information area in plan view may be the same shape as long as the cutting position by the position information area is clear, and two or more types having different shapes from each other May be formed in combination.

[Example of surface shape different from functional shape part in functional area and functional area in position information area]
The position information region having a surface shape different from the functional region has a position information shape portion serving as position information, and the position information region preferably has a surface shape selected from the following (I) to (III). .
(I) The position information shape part has a shape similar to the functional shape part.
In the aspect of (I), each position information shape portion formed in the position information region has a similar shape to each functional shape portion. For example, when the functional shape portion is hemispherical, the position information shape portion The case where the part is a hemisphere having a different size from the hemisphere in the functional shape part is included.
It is preferable that the functional shape portion and the position information shape portion have similar shapes to each other in terms of easiness in manufacturing a mold. That is, since the functional shape portion and the position information shape portion are similar in shape to each other, the same cure is performed when the inverted shape of the functional shape portion and the inverted shape of the position information shape portion are formed in the mold. It can be formed using a tool.

(II) The position information shape part in the position information area is formed with a different number density per unit area from the functional shape part in the functional area.
In the mode (II), the position information shape portion and the functional shape portion may have the same shape or different shapes. Here, the same shape includes a mode in which each position information shape portion and each functional shape portion have the same shape and the same size.
According to the mode (II), the positional information shape portion and the functional shape portion only need to have different number densities formed per unit area.
In the aspect (II), when the position information shape part and the functional shape part have the same shape, the inverted shape of the functional shape part and the position information shape are formed in the mold as in the case of the aspect (I). Since the same jig can be used when forming the inverted shape of the portion, it is preferable from the viewpoint of workability.

(III) The position information shape portion has the same shape or a similar shape as the functional shape portion, and the position information shape portion is formed with a different number density per unit area from the functional shape portion.
In the aspect (III), the position information shape part has the same shape or a similar shape as the functional shape part. Similarly, it can be performed by using the same jig, and since the formation density is different, it becomes easier to distinguish between the position information area and the functional area.

Generally, an ultra-hard jig for cutting used in the manufacture of metal fittings is expensive, and when manufacturing a metal mold using a plurality of different jigs, the metal mold is manufactured using only one kind of metal jig. As compared with the case, there are cases where problems such as a decrease in the productivity for exchanging the jig and a remarkable increase in the manufacturing cost of the mold occur. For this reason, the surface shapes described in the above (I), (II) and (III), which can form different surface shapes by using the same jig in the production of the mold, are all productivity and It can be said that there are great advantages in terms of mold manufacturing costs.

FIG. 5 shows an example of the functional shape portion in the functional region. In FIG. 5A-1, a hemispherical functional shape portion 34 such as a microlens is formed in the functional region.
An example shown in FIG. 5B-1 is an example of a position information area having a different planar shape from FIG. 5A-1. In FIG. 5 (B-1), hemispherical convex portions 34 having the same shape as the hemispherical functional shape portions 34 are formed with a higher number density per unit area than in FIG. 5 (A-1). ing. Therefore, due to the difference in the number density of the functional shape portions 34 per unit area, the functional area shown in FIG. 5A-1 and the position information area shown in FIG. It can be visually identified. The above example is an embodiment of (II) described above.

In the example shown in FIG. 5B-2, the position information area is a hemispherical convex part having a similar shape to the hemispherical functional shape part 34 in the functional area, and the hemispherical convex part in the functional area. A hemispherical convex portion 36 having a larger size than the functional shape portion 34 is formed. Since the convex portion has a similar shape and a different size from the functional shape portion 34 and a different number density per unit area, the functional region shown in FIG. The position information area shown in B-2) can be identified visually or the like. The above example can be said to be an embodiment of (III) described above.

で は In the example shown in FIG. 5 (B-3), the position information area has a flat plate shape without any unevenness. In the functional region 26B, a hemispherical functional shape portion 34 is formed, and since the position information region 28B has a flat plate shape, the functional region shown in FIG. 5A-1 and the functional region shown in FIG. The position information area shown in ()) can be identified by visual observation or the like.

FIG. 6 shows another example of the functional shape portion in the functional region. In the functional region shown in FIG. 6 (A-2), hexagonal convex portions in a plan view are formed adjacent to each other as functional shape portions. On the other hand, in the example of the position information area shown in FIG. 6 (B-4), the hexagonal projection in the same plan view as the functional shape part is different from the arrangement in FIG. 6 (A-2) in the plan view. The shaft angle is formed at an angle of 90 °. In the functional area and the position information area, since the hexagonal convex portions 38 are formed by changing the axial angle by 90 ° in the same plan view, the functional area shown in FIG. The position information area shown in FIG. 6 (B-4) can be identified by visual observation or the like.
As shown in FIG. 6, an area that can be identified by visual observation or the like is formed by arranging the convex portions such as hexagons and triangles in plan view by changing the axis angle by 90 ° in plan view. Further, by arranging the convex portions having a square shape in a plan view by changing the axial angle by 45 ° in a plan view, an area that can be identified by visual observation or the like is formed.

The surface shape in the position information area, which can be identified by visual observation and the surface shape of the functional area, is not limited to a mode having the same or similar shape as the functional shape section, and is completely different from the functional shape section. It may have differently shaped surfaces.
For example, when the functional area has the surface shape shown in FIG. 5 (A-1) or FIG. 6 (A-2), a position information area which can be visually identified from the functional area is formed. Examples of the surface shape that can be performed include an aggregate of fine convex portions called a moth-eye structure, an aggregate of cylindrical convex portions having a fine diameter called a pillar structure, and an aggregate of a moth-eye structure having a lens shape. And the like. In any of the surface shapes exemplified above, a position information region that can be identified by visual observation or the like is different from the above-described functional region shown in FIG. 5 (A-1) or FIG. 6 (A-2). Can be formed.

The most common shape of the functional shape portion in the functional region includes a hemispherical lens shape (micro lens), a semi-cylindrical lens shape (cylindrical lens), and the like. Especially, it is preferable that a functional shape part is a micro lens.
In a preferred embodiment, the functional region in which the general shape is formed is a region in which the microlenses or the cylindrical lenses are continuously arranged.
The arrangement of the lens shape in the functional shape portion when the functional region forms the microlens array is not particularly limited, and may be arranged in a square lattice shape or may be arranged in a honeycomb structure shape. Good.

機能 It is preferable that the functional shape portion to be shaped is a fine shape portion. For example, in the case of forming a concavo-convex shape having continuous convex portions on the reference surface, specifically, on the surface of the curable resin composition layer opposite to the support, the distance between adjacent convex portions is set. Is preferably 300 μm or less. Further, for example, in the case of a concavo-convex shape in which concave portions and convex portions are alternately repeated with respect to the reference plane, the maximum value of the interval between adjacent concave and convex portions is preferably 300 μm or less.

In particular, when the functional shape portion has 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 a distance between vertices of convex portions of a lens shape.
When the shaped sheet is applied to a microlens array, the accuracy of positioning at the time of punching is important because the lens pitch is small. According to the method for manufacturing a shaped sheet according to the present disclosure, the functional region and the positional information region in the shaped sheet are formed simultaneously. For this reason, the accuracy of the punching by the position information area is high, the deviation of the punching position in the obtained shaped sheet is suppressed, and the manufacturing method of the present disclosure is remarkably applied to the manufacturing of the microlens array having a small lens pitch. We think that effect can be obtained.

The functional shape portion in the present disclosure is not limited to the above-mentioned hemispherical shape or a convex shape having a semi-cylindrical diameter, and may take various shapes depending on purposes.
FIG. 7 is a perspective view showing a modified example of the convex portion as the functional shape portion.
As shown in FIG. 7, examples of the shape of the convex portion which can function as the functional shape portion include (A-5), (A-6), and (A-7) in addition to the hemispherical shape (A-1). , (A-8), and (A-9), but are not limited to the above examples, and may be arbitrarily selected as long as the shapes exhibit necessary functions.

The functional shape portion may be not only a convex shape but also a concave shape in which a concave portion is formed on the surface of the curable resin composition layer. When forming a functional region having a concave shape, the mold is a mold having a convex portion that is the inverted shape of the concave portion.
In addition, in the functional region, it goes without saying that not only the shape of the functional shape portion but also the formation density of each functional shape portion can be appropriately selected according to the purpose of use of the shaped sheet.

[Shape sheet material]
In the production method of the present disclosure, a laminate of a support and a curable resin composition layer is used.

-Support-
The support of the shaped sheet is preferably a sheet-like or film-like support.
The support is preferably a resin base material from the viewpoint of high-temperature stretchability.
Examples of the resin base material include polymethyl methacrylate resin (PMMA), polycarbonate resin (PC), polystyrene resin, methacrylate-styrene copolymer resin (MS resin), acrylonitrile-styrene copolymer resin (AS resin), and polypropylene resin ( PP), a polyethylene resin, a polyester resin such as polyethylene terephthalate resin (PET), a glycol-modified polyethylene terephthalate resin (PETG), a polyvinyl chloride resin (PVC), a thermoplastic elastomer, or a copolymer thereof, a cycloolefin polymer, or the like. Substrate.
A known method can be used for forming a sheet-like or film-like support using a resin. Among them, the melt extrusion method is preferred from the viewpoint of easy formation of a sheet having a uniform thickness.

When the melt extrusion method is applied to the formation of the support, from the viewpoint that the melt extrusion can be performed more easily, as the resin to be used, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate -A resin having a relatively low melt viscosity such as a styrene copolymer resin (MS resin), a polyethylene resin, a polyethylene terephthalate resin, a glycol-modified polyethylene terephthalate resin, and the like are preferable, and a polyethylene terephthalate resin is more preferable.
Further, from the viewpoint of transparency (visible light transmittance) and heat resistance of the obtained support, as the resin to be used, a polyethylene terephthalate resin, a glycol-modified polyethylene terephthalate resin or a cycloolefin resin is preferable, and a polyethylene terephthalate resin is more preferable. .

From the viewpoints of smoothness and uniformity of thickness, the support is preferably a stretched resin base material, more preferably a uniaxially stretched resin base material or a biaxially stretched resin base material.
The thickness of the support is not particularly limited, and is appropriately selected depending on the purpose of use of the shaped sheet. Generally, the thickness of the support is preferably in the range of 50 μm or more and 300 μm or less, and more preferably in the range of 50 μm or more and 200 μm or less from the viewpoint that uniform (shaping) can be performed at a high temperature. When the thickness of the support is in the above range, the resin base material is not easily torn, and cracks and the like are unlikely to occur during transportation during molding and three-dimensional molding.

When the shaped sheet obtained by the production method of the present disclosure is used, for example, as an optical member such as a microlens array, the support preferably has transparency to visible light, and the support has a wavelength of 400 nm. The light transmittance at a wavelength of 700 nm is preferably 70% or more. The upper limit of the light transmittance is not particularly limited, and may be 100% or less.
Visible light transmittance can be measured using a spectrophotometer. In the present disclosure, the light transmittance is measured using a spectrophotometer V-560 (manufactured by JASCO Corporation) equipped with an integrating sphere attachment device ARV-474.

In addition, when the curable resin composition layer described below is cured by applying energy such as ultraviolet rays, it is considered that the support may be irradiated with ultraviolet rays from the side opposite to the side on which the curable resin composition layer is formed. For example, the support preferably has a transmittance of ultraviolet light having a wavelength of less than 400 nm, and the support preferably has an ultraviolet transmittance of 70% or more at a wavelength of less than 400 nm. There is no particular upper limit on the ultraviolet transmittance, and it may be 100% or less.
The ultraviolet transmittance can be measured by changing the wavelength to be measured from visible light to ultraviolet light in the same manner as the above-described visible light transmittance.

市 販 A commercially available product may be used as the resin base material. Commercially available products that can be used as the resin substrate include, for example, an acrylic resin film (Acryprene HBS010P, thickness: 125 μm) manufactured by Mitsubishi Chemical Corporation, and a polyethylene terephthalate resin film (Lumirror S10, thickness: 100 μm) manufactured by Toray Industries, Inc. And 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 Ltd., and the like.

-Curable resin composition-
The resin that can be included in the curable resin composition used to form the curable resin composition layer is not particularly limited as long as it is a curable resin. The curable resin that can be used for forming the curable resin composition layer is preferably a photocurable (for example, ultraviolet curable) or thermosetting resin, and has a productivity, for example, a cooling mechanism after heat curing. It is more preferable that the resin is a photo-curable resin from the viewpoint that it is unnecessary and the equipment required for curing can be simplified.
As the curable resin, an ultraviolet curable resin such as a urethane acrylate resin, a polyester acrylate resin, an epoxy acrylate resin, a polyether acrylate resin, an acrylic acrylate resin, a polythiol resin, and a butadiene acrylate resin can be used.
Examples of the thermosetting resin include glycol-modified polyethylene terephthalate resin (PETG).

The curable resin composition may contain a known additive as necessary in addition to the curable resin described above.
Examples of the additive include known components generally used in a method for producing a shaped sheet, such as a release agent, a polymerization inhibitor, a curing accelerator, and a stabilizer. The type and content of these additives can be appropriately selected and used depending on the purpose of use of the shaped sheet.

A curable resin composition containing a curable resin is applied to one surface of the support described above to form a curable resin composition layer.
FIG. 1 illustrates an embodiment in which the curable resin composition layer 18 is formed by supplying the curable resin composition to the support 14 by the coating device 16.
As the coating device 16, a known device can be arbitrarily used.
The method for forming the curable resin composition layer 18 on the support 14 to obtain the laminate (I) 20 is not limited to this. For example, a method in which a curable resin composition layer formed in advance is laminated on the support To form a laminate.

The thickness of the curable resin composition layer may be appropriately determined according to the size of the functional shape portion to be formed.
The thickness of the curable resin composition layer is preferably from 2 μm to 130 μm, more preferably from 2 μm to 110 μm, from the viewpoints of workability and ease of shaping of the functional shape portion and the like.

In the step A, the laminate (I) is pressed against the embossing roll against the surface of the curable resin composition layer of the laminate (I) having the curable resin composition layer on the support. The nip rolls provided on both sides of the mold forming portion of the embossing roll enable the laminate (I) to be stably transported and pressed, and the embossing roll simultaneously forms the functional area and the position information area.

<Step B>
In step B, the curable resin composition layer in which the functional region and the positional information region are simultaneously formed in step A is cured, and the support and the functional region and the positional information region are formed on the support. And forming a laminated body (II) including the cured resin layer. Here, a laminate having the resin layer after the curable resin composition layer formed in the step A is cured on the support is referred to as a laminate (II).
The laminate (I) in which the functional region 26B and the position information region 28B are simultaneously formed in the step A is, as shown in FIG. 1, from the side of the support 14 where the curable resin composition layer 18 is not provided. Ultraviolet irradiation is performed by the ultraviolet irradiation device 30 to cure the curable resin composition layer 18, and the functional region 26 </ b> B and the position information region 28 </ b> B are formed on the support 14, and the cured resin layer 18 </ b> B is provided. The laminate (II) 20 is obtained.
As described above, when the curable resin composition layer is cured to obtain a cured resin layer, it is also preferable to apply ultraviolet ray curing, that is, an ultraviolet curing process called 2P method (Photo Polymer method). It is an aspect.
After the curing, the laminate (II) 20 of the support 14 and the cured resin layer 18B is peeled off from the embossing roll 22A to perform shaping.
In the above example, the curing is performed by ultraviolet irradiation, but the method of curing the curable resin composition layer is not limited to this, and is appropriately selected according to the composition of the curable resin composition.

In the embodiment shown in FIG. 1, a mode is described in which the laminate (II) 20 peeled off from the embossing roll 22 </ b> A is wound into a roll by the winding device 32 as a strip-shaped shaped sheet. However, the laminate (II) 20 having the shaped resin layer may be directly subjected to the next step, a step C of cutting the shaped sheet, without winding.
Further, once the laminate (II) is wound into a roll, the laminate (II) may be supplied to a step of sequentially cutting the shaped sheet from the winding roll, if necessary.

<Step C>
Step C in the method of manufacturing a shaped sheet according to the present disclosure detects a position information area formed on the resin layer through steps A and B, and cuts the laminate based on the position information of the detected position information area. This is the step of performing
The cutting of the laminate in the step C is also referred to as “punching”.
Hereinafter, the step C will be described in detail with reference to the drawings.

FIG. 8 is a schematic configuration diagram of a cutting device used in the manufacturing method of the present disclosure.
The laminated body (II) 20 having the functional region and the positional information region in the resin layer manufactured through the process A and the process B is supplied from a supply roll 42 existing on the upstream side of the cutting device 40 illustrated in FIG. Then, the sheet is conveyed to the cutting section 44.
In the laminate (II), for example, as shown in FIG. 4A, a T-shaped position information area is formed at two corners of an outer edge of a rectangular functional area.
In FIG. 4A, the functional area 26B is described as a halftone area.
In FIG. 4A, arrows indicate the transport direction of the stacked body 20, and a plurality of functional areas 26 </ b> B and position information areas 28 </ b> B are continuously formed in the stacked body 20 according to the transport direction, although not shown. .

In FIG. 4A, the position information area 28B includes the functional area 26B and is formed outside the cut portion indicated by a solid line. As described above, in the embodiment shown in FIG. 4A, an area defined by a broken line inside the functional area 26B indicates an effective area in the final product including the functional area 26B, and the position information area 28B It is formed outside the functional region 26B and outside the periphery of the effective region indicated by the broken line.
When the position information area in FIG. 4A is detected and the laminate (II) 20 is cut at a solid line portion, the obtained shaped sheet becomes an effective area when incorporated into a product as described above. The entire region becomes a functional region, and becomes a shaped sheet capable of expressing functions up to the peripheral portion.

In FIG. 4A, the center of the area defined by the broken line indicating the effective area of the product and the center of the functional area overlap each other. The cutting position detected by the position information area and shown by a solid line shown in FIG. 4A indicates the most preferable punching position when cutting the shaped sheet into a product.

According to the manufacturing method of the present disclosure, for example, when the position information area 28B exists inside the punched area as shown in FIG. 4B described above, or as shown in FIG. Even when the position information area 28B exists in the broken line area, which is the area, the functional area and the position information area are formed from the same resin layer, and the optical characteristics have the same characteristics except for the surface shape. In addition, the influence of the position information area 28B on the product is extremely low, and the position information area 28B may be formed at the position shown in FIG. 4B and FIG. Can be used effectively.

In step C, for example, when cutting the laminate (II) 20 shown in FIG. 4A, the position information area 28B is detected and the position to be cut is determined.
In step C of the present disclosure, the functional region 26B and the positional information region 28B are simultaneously formed by the same mold, so that the positional deviation between the functional region 26B and the positional information region 28B is suppressed. I have. Accordingly, if the position information is determined using the position information area 28B in the process C, it becomes easy to punch out the laminate in an accurate area. That is, according to the method of manufacturing a shaped sheet of the present disclosure, the position information area is formed by a simple process, and the effect of high punching position accuracy is achieved.

In the step C, the position information area is detected by a detecting means such as a CCD camera, and a punching process is performed after a punching position is determined.

FIG. 9 is an enlarged view of the cutting unit 44 in the cutting device 40 shown in FIG. The laminate (II) 20 is positioned by detecting the position information area 28B in the cutting unit 44 of the cutting device 40, and is cut by the punching blade 46 provided in the cutting unit 44 to obtain a shaped sheet. When positioning, as described above, the position may be corrected using the information in the position information area as necessary, and then cut.
FIG. 10 is a schematic sectional view of the cutting section 44 shown in FIG. The laminate (II) 20 positioned by the position information area 28B in the laminate (II) 20 is cut by the punching blade 46 at the boundary between the functional area 26B and the position information area 28B as shown in FIG. .
The punching blade 46 moves through the stacked body (II) 20 to a position where the punching blade 46 reaches a receiving blade plate 48 provided below the conveying position of the stacked body (II) 20 in the direction of gravity. The punched shaped sheet is carried out of the cutting unit 44 by a known method.
The material of the receiving blade plate is not particularly limited. It may be a relatively soft metal plate such as aluminum or a resin plate having a certain degree of elasticity.
Examples of the resin used for the receiving blade plate include PET, PETG, acrylic resin, silicone resin, polycarbonate resin, polystyrene resin, MS resin, AS resin, polyolefin resin, and PVC.

The cutting method in the process C is not particularly limited, and a known method is used. A general-purpose machine commercially available from several punching machine manufacturers can be used as the punching machine with a punching posture correction function equipped with a CCD camera. . For example, an image positioning press "IPA series" with a CCD camera (manufactured by Fuji Shoko Machinery Co., Ltd.), a roll material positioning die cutting machine "SCP250E-APS series" (manufactured by Sakamoto Zoki Co., Ltd.), and a roll material die cutting machine "T261" Series "(manufactured by Yamaha Fine Tech Co., Ltd.).

In the process C, after detecting the position information area of the resin layer in the laminate, the cutting may be performed after correcting the position of the laminate in the cutting using the position information area.
In other words, from the viewpoint of suppressing the shift of the punching position and the productivity of the obtained shaped sheet, after detecting the position information by the position information area, the position of the laminate is cut using the position information area, or cut. It is preferable to correct at least one of the rotation angles of the region.
The correction may be performed by a punching posture correction function or the like in the above-described punching machine.
The position information area can be detected by, for example, a CCD camera mounted on a punching machine.

Here, the orientation of the laminate refers to at least one of the transport direction and the orthogonal direction of the laminate.
For example, in the step C of cutting the laminate described in FIG. 4A, the angle of the region to be cut is fixed, the posture of the transported laminate is corrected, and the angle of the cut region indicated by a solid line in FIG. (Rotation angle of punched region) and the angle of the product effective region indicated by a broken line on the surface of laminate (II) 20 can be matched.
In the cutting unit 44 shown in FIGS. 9 and 10, the conveying direction of the laminate is pressed and fixed by the fixing members 50A and 50B provided in the cutting unit 44, and the rotation angle of the cut region is set. By performing the correction, the angle of the punched area and the angle of the product effective area of the laminate can be matched.
When cutting the laminate, both the posture of the laminate and the rotation angle of the region to be cut may be corrected.

<Rewinding process and unwinding process>
When the method of manufacturing a shaped sheet according to the present disclosure is performed by a roll-to-roll method, it is preferable to include a winding step of winding the sheet material or an unwinding step of unwinding the sheet material.
The winding step and the unwinding step can be arbitrarily included before or after each step. For example, the steps can be performed in the order described in the following methods (1) to (5).
(1) Step of unwinding the support using a roll-shaped support (2) Forming a curable resin composition layer on the unwound support and forming the curable resin of the obtained laminate (I) Step of shaping a functional area and a position information area in the composition layer (Step A)
(3) Laminate (II) having a shaped resin layer obtained by applying energy to the laminate in which the functional region and the positional information region are shaped to cure the curable resin composition layer Winding step (Step B)
(4) Step of unwinding the wound laminate (II) (5) Step of cutting the unwinded laminate (II) by detecting the position information area (Step C)
In the above method, the winding step and the unwinding step described in (3) and (4) may be omitted, and the steps B and C may be continuously performed while transporting the laminate (II).

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

Hereinafter, the present disclosure will be described in detail with reference to Examples, but the present disclosure is not limited thereto. In this example, “%” and “parts” mean “% by mass” and “parts by mass”, respectively, unless otherwise specified.

(Example 1)
<Preparation of shaped sheet (shaping process)>
The shaping device having the configuration shown in FIG. 1 was used. First, a laminate in which a microlens-shaped functional region and a position information region having a different surface shape from the functional region were formed on the resin layer by roll-to-roll was produced.
A hemispherical lens-shaped convex part having a diameter of 60 μm and a height of 30 μm as a functional region is arranged in a honeycomb structure of a microlens array with a lens pitch of 60 μm and an inverted shape of a pattern having a length of 120 mm and a width of 160 mm. The inverted shape of a pattern in which hemispherical lens-shaped protrusions having a diameter of 150 μm and a height of 75 μm as a position information area are arranged in a honeycomb structure at a lens pitch of 150 μm is combined with a rectangle having a length of 7 mm and a width of 2 mm. A roll mold was arranged in a T-shape and formed at two opposing corners of the above-described functional region.
Thus, an embossing roll capable of forming the functional area and the position information area having the shape shown in FIG. 2 was obtained.

Using a PET film (Cosmoshine (registered trademark) A4300, manufactured by Toyobo Co., Ltd.) having a thickness of 50 μm, a width of 350 mm, and a length of 300 m as a support, an ultraviolet-curable resin (Z-977-7L, manufactured by Aika Kogyo Co., Ltd.) The UV curable resin A) is applied in a thickness of 3 μm, and is pressed by using a nip roll on the embossing roll by the shaping apparatus shown in FIG. 1 equipped with the embossing roll obtained above, thereby inverting the pattern of the mold. Was transferred and cured by irradiating ultraviolet rays, and then the cured laminate (II) was peeled off from the roll mold. Then, the laminate (II) in which the functional region and the position information region were formed on the support was wound into a roll by a winding device.
The light transmittance at a wavelength of 400 nm to 700 nm of the PET film used for the support was measured with a spectrophotometer V-560 (manufactured by JASCO Corporation) equipped with an integrating sphere attachment device ARV-474. The transmittance was 70% or more. (Step A and Step B)

<Punching of shaped sheet (cutting process)>
In a cutting apparatus as shown in FIG. 8 which can continuously punch a base material of a sheet material, the stack obtained through the above steps A and B while detecting the position of the above positional information area using a CCD camera. The body (II) was cut to obtain a shaped sheet. (Step C)
As a result, the position information area was detected and determined by the CCD camera incorporated in the cutting device.
As a punching machine equipped with a punching posture correction function equipped with a CCD camera, a roll material positioning die punching machine “SCP250E-APS series” (manufactured by Sakamoto Zoki Co., Ltd.) was used.

(Evaluation)
<Evaluation of deviation of punching position>
The deviation of the punching position in the punching in the manufacturing method of the shaped sheet of Example 1 is visually evaluated by the pattern arrangement direction, that is, the difference in the angle between the center line of each lens and the long side of the punched sheet. did.
In the microlens array, the center line of each lens refers to a line having a smaller angle with the long side among two straight lines drawn at positions passing through the centers of the most lenses.
As a result, little difference is visually observed between the positions of the long side and the short side of the target punching position and the position of the shaped position information area, and the difference is less than 0.2 °. Met.
According to the manufacturing method of the shaped sheet of the present disclosure, high-accuracy position information that can be used at the time of cutting can be provided by a simple process, and positioning accuracy at the time of cutting with accurate position information is improved, It can be seen that the area of the effective area of the film can be improved.

[Explanation of symbols]
REFERENCE SIGNS LIST 10 shaping device 12 supply roll 14 support 16 coating device 18 curable resin composition layer 18B hardened resin layer 20 laminate 22 shaping roller 22A emboss roll 22B nip roll 24 mold 26A functional area providing section 26B functionality Region 28A Positional information region providing unit 28B Positional information region 30 Ultraviolet irradiation device 32 Winding device 34 Hemispherical convex portion 36 Hemispherical convex portion 38 Hexagonal convex portion 40 in plan view Cutting device 42 Supply roll 44 Cutting portion 46 Cutting blade (punching blade)
48 Receiving blade plate 50A, 50B fixing member

The disclosure of Japanese Patent Application No. 2018-183796 filed on Sep. 28, 2018 is incorporated herein by reference. All documents, patent applications, and technical standards mentioned herein 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 (6)

1. A first shape portion forming region including a functional shape portion that imparts a function to a shaped sheet to a curable resin composition layer provided on a support, and a surface shape different from the first shape portion forming region. And a step A of simultaneously shaping the second shape portion forming region serving as positional information in the cutting step;
   The curable resin composition layer is cured to form a laminate including a support, and a resin layer in which a first shape portion forming region and a second shape portion forming region are formed on the support. Performing step B;
   A step C of detecting the second shape portion forming region of the resin layer and cutting the laminate based on the detected position information of the second shape portion forming region;
   A method for producing a shaped sheet, comprising:
2. 2. The method according to claim 1, wherein the second shape portion forming region exists outside the first shape portion forming region. 3.
3. 2. The method according to claim 1, wherein the second shape portion forming region is present in the first shape portion forming region. 3.
4. The second shape portion forming region having a surface shape different from the first shape portion forming region has a position information shape portion serving as position information,
   The method for producing a shaped sheet according to any one of claims 1 to 3, wherein the second shape portion forming region has a surface shape selected from the following (I) to (III).
   (I) The position information shape portion has a shape similar to the functional shape portion.
   (II) The position information shape portion in the second shape portion formation region is arranged at a different number density per unit area from the functional shape portion in the first shape portion formation region.
   (III) The position information shape part has the same shape or a similar shape as the functional shape part, and the position information shape part is the same as the functional shape part in the first shape part formation region, They are arranged with different number densities per unit area.
5. (5) The method according to any one of (1) to (4), wherein in the step C of cutting the laminate, the position of the laminate is corrected.
6. The method for producing a shaped sheet according to any one of claims 1 to 5, wherein the functional shape portion is a microlens.

Images