JP2015196279A - Method for manufacturing roll plate for optical member - Google Patents

Abstract

Provided is a method for producing a roll plate with high accuracy while improving efficiency when manufacturing an optical member including a two-dimensional shape of unevenness in a plan view and a plurality of types of unevenness.
A mold sheet is wound around a roll without a seam other than a butting part 23, and a plurality of unit mold parts 22a are arranged on the surface of the mold sheet. A mold sheet having a shape including at least one of two or more types of projections and depressions having a two-dimensional shape or a pattern different from one another in view, and having a substrate 30, an etching layer 31, and a resist layer 32. The resist layer of the production stack 33 is exposed to remove the resist layer, the etching layer is removed by etching, the remaining resist layer is removed, and the electroless plating layer 35 is electrolyzed. A step of laminating by casting, a step of laminating the electroplating layer 36 on the electroless plating layer, and a step of removing the laminate for producing the mold sheet.
[Selection] Figure 2

Description

  The present invention relates to a method for producing a roll plate, which is a roll-shaped mold for producing an optical member having irregularities on the surface, and more specifically, a roll plate for producing an optical member including a predetermined irregular pattern. It relates to a method of manufacturing.

  The screens of televisions and the like become larger due to diversification of display devices, while the screens of portable terminals can be suppressed to a certain size due to their properties. However, a high quality image is required even on a small screen. Therefore, finer irregularities are formed on the optical member used, and desired light is emitted using the refraction and reflection to improve the quality.

  As one of the methods for mass-producing such an optical member, there is a form using a roll-shaped mold (roll plate) having unevenness on the surface corresponding to the unevenness of the optical member as described in Patent Document 1, for example. This is to release the mold after supplying the uncured resin to the surface of the roll plate and curing it. Thereby, the unevenness formed on the surface of the roll plate is inverted and transferred to the resin to obtain the desired unevenness.

  In Patent Document 2, a sheet-shaped mold having irregularities corresponding to the irregularities of the optical member is prepared, a plurality of sheet-shaped molds are wound around a roll, and adjacent sheet-shaped molds are bonded to each other. A roll version of is disclosed. After forming the roll plate, an optical member can be obtained in the same manner as described above.

JP 2012-006177 A JP 2008-296466 A

  As described above, although the screen of a portable terminal in recent years is small, the unevenness formed on the surface of the optical member is different depending on the part or is two-dimensional in plan view from the viewpoint of improving the quality of emitted light. Also, since the optical member itself is small, the mold is small for one optical member, but it is not efficient if each one is manufactured with a single wafer. Therefore, it is desired to manufacture an optical member using a roll plate on which a mold capable of continuously forming a plurality of optical members is arranged.

  However, the roll plate disclosed in Patent Document 1 is effective for unevenness having the same cross section and extending in one direction (one-dimensionally), but the unevenness has a two-dimensional shape in a plan view. When it is necessary to form different types of irregularities depending on the shape, it is very difficult to produce a roll plate.

  On the other hand, as described in Patent Document 2, a plurality of molds are arranged like tiles, and the boundary portions are connected to form a sheet shape, which is inevitably “displaced” between the plurality of molds when wound around a roll. May occur, and the final product may be defective.

  Therefore, in view of the above problems, the present invention provides a roll plate with high accuracy while improving efficiency when manufacturing an optical member including unevenness having a two-dimensional shape in a plan view and multiple types of unevenness having different patterns. It is an object to provide a manufacturing method.

  The present invention will be described below. For ease of understanding, reference numerals in the drawings are appended here in parentheses, but the present invention is not limited to this.

  The invention according to claim 1 is a method of manufacturing a roll plate (20) for an optical member by winding a mold sheet (22) around a roll (21), wherein the mold sheet is a butted portion (23 ) Other than the seam, it is wound around the roll without any seams, and the surface of the mold sheet has unevenness corresponding to the unevenness (13) of one optical member (10) as a unit mold part (22a). A plurality of the unit mold parts are arranged along the surface, and the unevenness of the unit mold parts has a shape including at least one of a two-dimensional unevenness or two or more types of unevenness having different patterns in plan view. The production of the mold sheet is based on the pattern of projections and depressions on the resist layer of the mold sheet production laminate (33) having the substrate (30), the etching layer (31), and the resist layer (32). Exposure, the exposed part or The step of removing the resist layer in the part not exposed to expose the etching layer, the step of etching and removing the etching layer in the exposed part, the step of removing the remaining resist layer, and the surface on the etching layer side A step of laminating the electroless plating layer (35) by electroforming, a step of laminating the electroplating layer (36) on the electroless plating layer, and a step of removing the laminate for producing the mold sheet. It is a manufacturing method of the roll plate for members.

  According to the method for producing a roll plate for an optical member of the present invention, an optical member including at least one of two-dimensionally shaped unevenness or a plurality of types of unevenness having different patterns in plan view has high mass productivity and good accuracy. A roll plate intended for use can be easily manufactured.

FIG. 1A is a plan view of the optical member 10, and FIG. 1B is a partial cross-sectional view of the optical member 10. 2 is a perspective view of a roll plate 20. FIG. 3A is a plan view of the mold sheet 22, and FIG. 3B is an enlarged view of a part thereof. FIG. 4A to FIG. 4C are views for explaining each scene for producing the mold sheet 22. FIG. 5A and FIG. 5B are diagrams for explaining each scene for producing the mold sheet 22. FIG. 6A to FIG. 6C are diagrams for explaining each scene for producing the mold sheet 22. It is a figure explaining the scene which winds the type | mold sheet | seat 22 around the roll 21. FIG. It is a figure explaining the shaping sheet. It is a figure explaining one scene of the process which produces the shaping sheet 40 with the roll plate. It is a figure explaining one scene of the process in which the optical member is produced using the shaping sheet. It is a figure explaining the optical member 110 of another form. It is a figure explaining one scene of the process in which the optical member 110 is produced.

  The above-described operation and gain of the present invention will be clarified from embodiments for carrying out the invention described below. Hereinafter, the present invention will be described based on embodiments shown in the drawings. However, the present invention is not limited to these embodiments. In the drawings shown below, the size and ratio of members may be changed or exaggerated for easy understanding. Moreover, the code | symbol which becomes repeated may be abbreviate | omitted for legibility.

First, the optical member 10 will be described. The optical member 10 is an optical member manufactured by a roll plate 20 described later, and is a sheet-like optical member. Here, as the optical member, for example, a general optical member that controls light by unevenness formed on the surface, such as a light guide plate, a prism sheet, a lens sheet, a diffractive structure, and a moth-eye structure can be used.
1A is a plan view of the optical sheet 10, and FIG. 1B is a cross-sectional view taken along line Ia-Ia in FIG.

  The optical member 10 has a light control layer 12.

  The light control layer 12 is a light-transmitting sheet-like member, and has a concavo-convex portion 13 having concavo-convex portions formed on at least one surface.

  As can be seen from FIG. 1A, the uneven portion 13 of this example has a plurality of partitioned unit uneven portions 14, 15, 16, 17, and 18 arranged therein. In each unit uneven | corrugated | grooved part 14, 15, 16, 17, 18, the unevenness | corrugation is repeated in each aspect. For example, as shown in FIGS. 1A and 1B, in the unit concavo-convex portion 16, a convex portion 16a having a rectangular cross section and a concave portion 16b having a rectangular cross section are repeated in the longitudinal direction, and this cross section is maintained. It extends one-dimensionally in the width direction. The unevenness is finely formed, and the depth of the recess is formed to be 0.5 μm or more and 3.0 μm or less. The bottom width of the concave portion and the top width of the convex portion are in the range of 1 μm to 30 μm. For example, in the case of a convex shape, the bottom width of the concave portion is 5 μm to 30 μm and the top width of the convex portion is 1 μm to 10 μm. In the case of the concave shape, the top width of the convex portion is 5 μm to 30 μm. The bottom width is formed to be 1 μm or more and 10 μm or less.

The other unit irregularities 14, 15, 17, 18 also have a rectangular convex portion and a rectangular concave portion in its cross section, and each has the following characteristics.
The unit concavo-convex portion 14 has a concavo-convex pitch smaller than that of the unit concavo-convex portion 16 and has a length in the width direction of about half. And the unit uneven | corrugated | grooved part 14 is an example arrange | positioned near to the one side of the width direction of the light control layer 12. FIG.
The unit concavo-convex portion 15 has the same form as the unit concavo-convex portion 14, but an example in which the unit concavo-convex portion 14 is arranged side by side with a predetermined interval on the other side in the width direction of the light control layer 12. It is.
The unit concavo-convex part 17 extends so as to be inclined with respect to the width direction, and is an example in which the inclination differs between one side and the other side in the width direction. That is, the unit uneven portion 16 has a shape that monotonically extends in one direction (one-dimensionally) in plan view, whereas the unit uneven portion 17 has an uneven shape that extends in two dimensions in plan view.
The unit concavo-convex portion 18 is an concavo-convex portion that extends one-dimensionally in the width direction in plan view and has concavo-convex portions in the longitudinal direction, but the pitch of the concavo-convex portion is an example.

  The irregularities of these unit irregularities 14 to 18 are examples, but the irregularities also have a two-dimensional shape in which a plurality of cone-shaped irregularities are arranged vertically and horizontally in plan view. Concavities and convexities, etc., are also conceivable. Thereby, the light refracted or reflected by the concavo-convex portion can be controlled to emit light in a desired manner.

  Various materials can be used as the material constituting the light control layer 12. However, a material that is widely used as a material for an optical member and has excellent mechanical properties, optical properties, stability, workability, and the like and can be obtained at low cost can be used. For example, a polymer resin having an alicyclic structure, a methacrylic resin, a polycarbonate, a polystyrene, an acrylonitrile-styrene copolymer, a methyl methacrylate-styrene copolymer, an ABS resin, a polyethersulfone, or a thermoplastic resin, Examples thereof include epoxy acrylate and urethane acrylate-based reactive resins (ionizing radiation curable resins and the like).

Next, the roll plate 20 for producing the shaping sheet 40 used when forming the optical member 10 as described above will be described. FIG. 2 is a perspective view schematically showing the appearance of the roll plate 20. 3A is a plan view of the mold sheet 22 provided in the roll plate 20, and FIG. 3B is an enlarged view of a part thereof.
As can be seen from FIG. 2, the roll plate 20 has a roll 21 and a mold sheet 22.

The roll 21 has a cylindrical roll body 21a and a rotating shaft 21b that protrudes along the axis from the end surface of the roll body 21a. Thus, the roll 21 is configured to support the rotating shaft 21b and rotate around the rotating shaft 21b.
The roll body 21a is a part for securing rigidity, and constitutes most of the roll plate 20. From this point of view, the roll body 21a is preferably made of an iron-based material for machine structure. Further, from the viewpoint of reducing the weight while ensuring the necessary rigidity, the roll body 21a may be cylindrical with both sides being bottomed. Moreover, it is common to make a double structure so that cold water, warm water, steam or high-temperature oil can be circulated inside the roll body so that the temperature of the surface of the roll body 21a can be adjusted.

  The mold sheet 22 is a sheet-like member that functions as a mold for transferring the uneven shape corresponding to the uneven portion 13 of the optical member 10 to the shaped sheet 40. FIG. 3A shows a plan view in which the mold sheet 22 is removed from the roll body 21a and developed. FIG. 3B is an enlarged view of the portion indicated by Vb in FIG.

  As can be seen from these drawings, the mold sheet 22 has a plurality of unit mold portions 22a arranged vertically and horizontally on the surface thereof, which are arranged seamlessly. In the drawing, the boundary between adjacent unit mold portions 22a is indicated by a dotted line, but this is for easy understanding and is not a joint. In other words, the mold sheet 22 is a single sheet that is integral with no joint. Therefore, there is no step or unintended displacement between the adjacent unit mold parts 22a, and the unit mold parts 22a can be accurately arranged. And as for the magnitude | size of the type | mold sheet | seat 22, it is preferable that the one side is 800 mm or more and 1500 mm or less. Thereby, many unit mold | type parts 22a can be included in one type | mold sheet | seat, and the outer periphery of the roll 21 can be made to make one round.

  As can be seen from FIG. 3 (b), each unit mold portion 22 a is provided with unevenness corresponding to the shape of the uneven portion 13 of the optical member 10.

Such a mold sheet 22 can be composed of an electroformed plate. Although the production method will be described in detail later, it is composed of a laminate in which an electroless nickel plating layer is formed on an electrolytic nickel plating layer, and irregularities are formed on the surface of the electroless nickel plating layer. Here, the electroplating layer and the electroless plating layer made of nickel will be described, but they may be made of other materials.
The mold sheet 22 is preferably provided with alignment for positioning. This alignment is also transferred and becomes a reference for positioning when the optical member 10 is punched.

  Then, the roll sheet 20 is obtained by winding and fixing the mold sheet 22 around the outer peripheral surface of the roll 21. As described above, since there is no seam in the mold sheet 22, when the roll plate 20 is formed, as shown in FIG. 2, the abutting part 23 where the end parts abut each other becomes the only seam.

Next, a method for producing the mold sheet 22 will be described. The figure which followed the order of preparation to FIG.4 (a)-FIG.6 (c) was represented.
First, as shown in FIG. 4 (a), formed on a substrate 30 made of glass, metal, ceramic, synthetic quartz, plastic, etc., having the required strength and surface accuracy, with low-reflection chrome or the like on the surface. The photomask blank board which laminated | stacked the etched layer 31 (it may be described as "the chrome layer 31" hereafter) was prepared. Then, a resist layer 32 is formed on the chromium layer 31 in a thin film shape. Known resists can be used, and examples thereof include GRX-M220 and GRX-M100 manufactured by Nagase ChemteX Corporation. A laminate of the substrate 30, the etching layer 31, and the resist layer 32 is referred to as a mold sheet manufacturing laminate 33.

  Next, as shown in FIG. 4B, the resist layer 32 is exposed with a pattern based on the uneven portion 13 of the optical member 10. Although this exposure method is not particularly limited, in this embodiment, exposure is performed by scanning with a laser beam L. In addition, scanning with an electron beam may be performed. By this exposure, an easily soluble portion 32a in which the resist resin constituting the resist layer 32 is cured and an unexposed portion 32b are formed. Then, as shown in FIG. 4C, development is performed by spray development performed by spraying a developing solution to remove the easily soluble portion 32a, and a resist pattern patterned by the unexposed portion 32b is obtained.

Using the formed resist pattern, the chrome layer 31 is removed by etching as shown in FIG. 5A, where the unexposed portion 32b of the resist does not exist and is not covered with the resist. . Thereby, the underlying substrate 30 is exposed in the removed portion.
Thereafter, as shown in FIG. 5B, the unexposed portion 32b of the resist is removed by dissolution or the like to obtain a chromium pattern 31a patterned by the chromium layer 31. Then, the mold sheet 22 is produced from the substrate 30 and the chromium pattern 31 a formed on one surface of the substrate 30.

  In the above description, the process using a so-called positive resist is described in which the exposed portion is removed. However, by changing the resist material, the exposed portion remains and the unexposed portion is removed. A process using a negative resist may be employed.

  The process so far is performed by forming a fine shape using a so-called large scale photomask (LSPM).

Next, the mold sheet 22 is produced by electroforming using the obtained substrate 30 and the chromium pattern 31a (molded sheet production laminate 33) laminated thereon.
First, as shown in FIG. 6A, an electroless nickel plating layer 35 is formed by electroforming on the side of the substrate 30 on which the chromium pattern 31a is formed. At this time, the electroless nickel plating layer 35 has a thickness of 10 nm or more and 1 μm or less.
Next, as shown in FIG. 6B, an electrolytic nickel plating layer 36 is formed on the electroless nickel plating layer 35 by electroforming. At this time, the electrolytic nickel plating layer 36 is formed by the electrolytic nickel plating layer 36 so that the total thickness of the electroless nickel plating layer 35 and the electrolytic nickel plating layer 36 is about 0.3 mm.
Then, as shown in FIG. 6C, the mold sheet 22 is obtained by peeling the mold sheet manufacturing laminate 33.

  According to the method for producing the mold sheet 22 described above, even if the unit mold portions 22a are formed by arranging a plurality of unit mold portions 22a vertically and horizontally, a seam is not formed between the unit mold portions 22a, and no step or deviation occurs. Can be easily and reliably produced. And it is possible to manufacture a lot of optical members efficiently with high accuracy.

  The mold sheet 22 produced as described above is wound around the roll body 21a as shown in FIG. 7 to form a roll plate 20 (see FIG. 2).

Next, a method for manufacturing the optical member 10 using the roll plate 20 will be described.
FIGS. 8 to 10 show diagrams for explanation. In this embodiment, prior to manufacturing the optical member 10 by the extrusion method, the shaping sheet 40 capable of shaping the shape of the uneven portion 13 is produced. The form of the shaping sheet 40 was shown with the conceptual perspective view in FIG.

  The shaping sheet 40 is a belt-like sheet that can shape the shape of the uneven portion 13 of the optical member 10 as described above. The shaped sheet 40 is configured to have a base material 41 having translucency and a mold part 42 laminated on one surface of the base material 41. In the mold part 42, a plurality of unit mold parts 42a for forming one uneven part 13 of the optical member 10 are arranged vertically and horizontally.

Such a shaped sheet 40 is produced as follows. FIG. 9 shows an explanatory diagram. As shown in FIG. 9, the base material 41 is sent out between the prepared roll plate 20 and the mold nip roll 45 as indicated by an arrow IX in FIG. 9. Then, the ultraviolet curable resin composition 42 ′ before being cured on the base material 41 is supplied from the nozzle 46. Thereby, the ultraviolet curing resin 42 ′ before curing is filled between the base material 41 and the roll plate 20. Thereby, the ultraviolet curable resin composition 42 ′ before curing is filled in the unevenness formed on the mold sheet 22 of the roll plate 20.
In such a state of being filled, ultraviolet rays are irradiated from the ultraviolet irradiation device 47 and the ultraviolet curable resin composition is cured to form the mold part 42. Then, it molds with the peeling roll 48 and the shaping sheet 40 is obtained. The obtained shaped sheet 40 is wound up into a roll shape.

Next, the optical member 10 is obtained by an extrusion method using the shaping sheet 40. FIG. 10 shows a diagram for explanation.
As shown by the arrow X in FIG. 10, the shaped sheet 40 is sequentially sent out between the first roll 51 and the second roll 52 arranged with a predetermined gap with respect to the first roll 51. A melted thermoplastic resin composition 55 is caused to flow from the nozzle 56 between the shaping sheet 40 and the second roll 52. Here, the feeding direction of the shaped sheet 40 is the longitudinal direction of the shaped sheet 40 having a strip shape. Moreover, it is preferable that the thermoplastic resin composition 55 to be introduced has a belt-like shape having a size (width) that is approximately the same as the size in the width direction of the second roll 52 and the shaped sheet 40. Thereby, uniform material supply in the width direction is possible.

The supplied thermoplastic resin flows in between the second roll 52 and the shaping sheet 40 with a predetermined pressure. Thereby, the thermoplastic resin is filled in the unevenness formed on the surface of the mold part 42 of the shaped sheet 40, and the thermoplastic resin composition 55 has a shape along the unevenness. And it cools through the 3rd roll 53 and the 4th roll 54, and finally the thermoplastic resin composition 55 hardens | cures and a shape is fixed. As a result, an optical member belt-like sheet 10 ′ in which the optical members 10 are seamlessly arranged vertically and horizontally is obtained. And the strip | belt-shaped sheet | seat 10 'for optical members and the shaping sheet 40 are isolate | separated by the peeling roll 57. FIG.
In this state, it is preferable that alignment is included in the belt-like sheet 10 ′ for optical members.

  Finally, the optical member 10 can be obtained by punching or cutting the optical member strip 10 '. In that case, alignment becomes a reference for positioning.

  The optical member 10 manufactured in this way has high positional accuracy of the unevenness, and can perform desired light control with high accuracy.

  FIG. 11 shows another form of the optical member 110. FIG. 11 is a view from the same viewpoint as FIG. The optical member 110 has a two-layer structure in which the light control layer 12 described above is laminated on one surface of the substrate 11. The structure of the light control layer 12 is as described above.

  The base material 11 is a sheet-like member having light transmissivity to be a base material for forming the light control layer 12 on one surface of the base material 11. Examples of the material constituting the substrate 11 include polycarbonate (PC) resin, polyethylene terephthalate (PET) resin, methyl methacrylate / butadiene / styrene (MBS) resin, methyl methacrylate / styrene (MS) resin, acrylic Examples include styrene (AS) resin, acrylonitrile / butadiene / styrene resin (ABS), and the like.

  The optical member 110 can be manufactured as follows. That is, in the same manner as the roll plate 20 described above, the roll plate 120 having unevenness that can directly form the uneven portion 13 of the optical member 110 is produced. And the light control layer 12 is laminated | stacked on the base material 11 as shown in FIG.

That is, as shown in FIG. 12, the base material 11 is sent out between the prepared roll plate 120 and the mold nip roll 45 as shown by an arrow XII in FIG. Then, the ultraviolet curable resin composition 12 ′ before being cured on the substrate 11 is supplied from the nozzle 46. Thus, the ultraviolet curable resin 12 ′ before curing is filled between the base material 11 and the roll plate 120. As a result, the ultraviolet curable resin composition 12 ′ before curing is filled in the unevenness formed on the roll plate 20.
In this filled state, ultraviolet rays are irradiated from the ultraviolet irradiation device 47, and the ultraviolet curable resin composition is cured to form the light control layer 12. Thereafter, the mold is released by the peeling roll 48. As a result, an optical member belt-like sheet 110 ′ in which the optical members 110 are seamlessly arranged vertically and horizontally is obtained.
In this state, it is preferable that the belt-shaped sheet 110 ′ for optical members includes alignment.

  Finally, the optical member 110 can be obtained by punching or cutting the optical member strip 110 '. In that case, alignment becomes a reference for positioning.

DESCRIPTION OF SYMBOLS 10 Optical member 11 Base material 12 Light control layer 13 Concavity and convexity 20 Roll plate 21 Roll 22 Type sheet 30 Substrate 31 Chromium layer (etching layer)
32 Resist layer 33 Type sheet laminate 35 Electroless nickel plating layer (electroless plating layer)
36 Electrolytic nickel plating layer (electrolytic plating layer)

Claims (1)

A method for producing a roll plate for an optical member by winding a mold sheet around a roll,
The mold sheet is wound around the roll without having a seam other than the butt portion between the ends,
On the surface of the mold sheet, when the projections and depressions corresponding to the projections and depressions of one optical member are unit mold parts, a plurality of the unit mold parts are arranged along the surface,
The unevenness of the unit mold part has a shape including at least one of unevenness of a two-dimensional shape in a plan view or two or more types of unevenness having different patterns,
Production of the mold sheet is as follows:
Exposing the resist layer of the laminate for producing a mold sheet having a substrate, an etching layer, and a resist layer on the basis of the uneven pattern, and removing the resist layer in the exposed portion or the unexposed portion Exposing the etching layer;
Etching and removing the etching layer at the exposed site;
Removing the remaining resist layer;
A step of laminating an electroless plating layer on the surface on the etching layer side by electroforming;
Laminating an electroplating layer on the electroless plating layer;
Removing the laminate for producing a mold sheet, and a method for producing a roll plate for an optical member.

Images