JP2011148181A - Method for simultaneously forming both sides of optical element sheet and apparatus for forming optical element sheet - Google Patents

Method for simultaneously forming both sides of optical element sheet and apparatus for forming optical element sheet Download PDF

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JP2011148181A
JP2011148181A JP2010010844A JP2010010844A JP2011148181A JP 2011148181 A JP2011148181 A JP 2011148181A JP 2010010844 A JP2010010844 A JP 2010010844A JP 2010010844 A JP2010010844 A JP 2010010844A JP 2011148181 A JP2011148181 A JP 2011148181A
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optical element
roll
mold
roll mold
element sheet
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JP5424116B2 (en
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Hide Hosoe
秀 細江
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Konica Minolta Opto Inc
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<P>PROBLEM TO BE SOLVED: To provide a method for simultaneously forming both sides of an optical element sheet which can cancel the warpage of the formed optical element sheet when a plurality of optical elements are formed simultaneously on the surface and back of a base film and an apparatus for forming the optical element sheet. <P>SOLUTION: The method for simultaneously forming both sides of the optical element sheet in which a first roll mold 3 and a second roll mold 4 are arranged oppositely and horizontally to be separated at a prescribed distance from each other, the base film F is supplied between the roll molds 3 and 4, a plurality of the optical elements La and Lb are molded, formed, or printed simultaneously on both sides of the base film F by the respective roll molds 3 and 4, the optical element sheets formed by the roll molds 3 and 4 are conveyed vertically downward, and the conveyance in the vertical direction is continued at a distance of at least a distance until a resin is cured completely and the apparatus for forming the optical element sheet are disclosed. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、複数の光学素子をベースフィルムの表面と裏面に連続して同時形成する光学素子シートの同時両面形成方法、およびその光学素子シート形成装置に関する。   The present invention relates to a method for simultaneously forming both sides of an optical element sheet, in which a plurality of optical elements are formed simultaneously on the front and back surfaces of a base film, and an optical element sheet forming apparatus.

本発明における光学素子とは、レンズ、プリズム、ミラー素子、回折素子、回折ミラー、グリズム、フレネルレンズ、レンチキュラーシート、レンズシート、マイクロレンズアレイなどであり、さらに絞りや実装時のスペーサーや遮光用の黒インクなどを含む。本発明はこれらの光学素子をベースフィルムの両面に複数形成するものであり、形成物を光学素子シートという。ベースフィルムの表面と裏面に形成する光学素子は、同じ種類の光学素子でなくともよく、例えば、一方の面にレンズを形成し、他方の面に絞りを形成するなどとしても良い。   The optical element in the present invention includes a lens, a prism, a mirror element, a diffraction element, a diffraction mirror, a grism, a Fresnel lens, a lenticular sheet, a lens sheet, a microlens array, and the like. Includes black ink. In the present invention, a plurality of these optical elements are formed on both sides of the base film, and the formed product is called an optical element sheet. The optical elements formed on the front surface and the back surface of the base film need not be the same type of optical elements. For example, a lens may be formed on one surface and a diaphragm formed on the other surface.

レンズなどの光学素子は光学素子シート上にマトリックス状に形成され、完成後切り離されて個別の光学素子として使用される。一方、レンチキュラーシートなどは光学素子シート上では個別に分かれていないが、完成後所定の大きさに切断されて使用されるので、このようなものも複数の光学素子を形成するものとして本発明に含めている。   Optical elements such as lenses are formed in a matrix on an optical element sheet, and are separated after completion and used as individual optical elements. On the other hand, lenticular sheets and the like are not individually separated on the optical element sheet, but are used after being cut into a predetermined size after completion. It is included.

本発明はこのような光学素子をベースフィルムの両面に複数同時形成するのであるが、ここで、光学素子の形成方法としては、「成型」、「成形」、「印刷」を含むものとし、これらを総称して「形成」という。「成型」とは、固体状の被成型物を加熱や加圧によって軟化させ、型の転写面に密着させて転写するプロセスをいい、「成形」とは、液体状の被成形物を型内に流し込み、加熱やＵＶ光照射などで硬化させて転写するプロセスをいう。また、「印刷」とは、ロール状の版型に被印刷材料（インク）を付着させ、この被印刷材料をベースフィルムに転写するプロセスをいう。   In the present invention, a plurality of such optical elements are simultaneously formed on both sides of the base film. Here, the optical element forming method includes “molding”, “molding”, and “printing”. Collectively called “formation”. “Molding” refers to a process in which a solid workpiece is softened by heating or pressurization and is brought into close contact with the transfer surface of the mold to transfer it. “Molding” is a process in which a liquid workpiece is placed in the mold. It is a process in which it is poured into a film, cured by heating or UV light irradiation, and transferred. “Printing” refers to a process in which a printing material (ink) is attached to a roll-shaped plate and the printing material is transferred to a base film.

このような光学素子シート形成方法は、大量の光学素子を連続的に形成できるので、近年、携帯電話やデジタルカメラのストロボ用レンズやＬＥＤ照明の拡散レンズ、あるいは液晶表示装置のバックライト用レンズシートなど各種光学素子の形成に用いられるようになってきた。   Such an optical element sheet forming method can form a large number of optical elements continuously, and in recent years, a strobe lens for a mobile phone or a digital camera, a diffusion lens for LED illumination, or a lens sheet for a backlight of a liquid crystal display device. It has come to be used for forming various optical elements.

光学素子シートの形成方法として、特許文献１は、エネルギー線硬化樹脂をロール金型で型転写することによりレンズシート、特にはプリズムシート、レンチキュラーレンズシート、フレネルレンズシートをベースフィルムの片面に連続的に形成する方法を開示し、特に硬化前と硬化時の温度管理によりレンズシートの反りを解消する形成方法を提案している。   As a method for forming an optical element sheet, Patent Document 1 discloses that a lens sheet, in particular, a prism sheet, a lenticular lens sheet, and a Fresnel lens sheet are continuously formed on one side of a base film by transferring an energy ray curable resin using a roll die. In particular, a method for forming the lens sheet is proposed, which eliminates the warp of the lens sheet by temperature control before and during curing.

特許文献２は、ベースフィルムの一方面に紫外線硬化型樹脂を塗布し、これをレンチキュラーレンズアレイ形成用ロール金型と加圧ロールとの間に導入して加圧し、紫外線照射により硬化させてレンチキュラーレンズアレイを形成し、その後、ベースフィルムの他方面に第２の紫外線硬化型樹脂を塗布し、これを凸状部形成用ロール金型と加圧ロールとの間に導入して加圧し、紫外線照射により硬化させて凸状部を形成し、該凸状部頂面に遮光性インキを塗布することにより透過型リアスクリーンを形成する方法を開示している。   In Patent Document 2, an ultraviolet curable resin is applied to one surface of a base film, and this is introduced between a roll mold for forming a lenticular lens array and a pressure roll, pressurized, cured by ultraviolet irradiation, and lenticular. After forming a lens array, a second ultraviolet curable resin is applied to the other surface of the base film, and this is introduced between a roll mold for forming a convex portion and a pressure roll, and pressurized. It discloses a method of forming a transmissive rear screen by forming a convex part by curing by irradiation and applying a light-shielding ink to the top surface of the convex part.

また、特許文献２は、レンチキュラーレンズアレイ形成用ロール金型の余白部にアライメントマーク成形型部を設けてレンチキュラーレンズアレイの成形と同時にアライメントマークを形成しておき、一方、凸状部形成用ロール金型にも同様のアライメントマークを形成して、この凸状部形成用ロール金型のマークと樹脂層に形成されたアライメントマークとを整合させてシートの両面に形成される光学素子の位置合わせを行う技術を提案している。   Further, Patent Document 2 provides an alignment mark forming mold portion in a blank portion of a lenticular lens array forming roll mold to form an alignment mark at the same time as forming the lenticular lens array, while a convex portion forming roll. Alignment of optical elements formed on both sides of the sheet by forming the same alignment mark on the mold and aligning the marks on the convex mold roll mold with the alignment marks formed on the resin layer We are proposing a technology to do this.

特開２００９−２９２０６０号公報JP 2009-292060 A 特開２００７−２６４１８４号公報JP 2007-264184 A

特許文献２の位置合わせ技術は、具体的には説明されていないので、定かではないが、凸状部形成用ロール金型のアライメントマークと樹脂層に形成されたアライメントマークとが一致するように凸状部形成用ロール金型の回転位相を調整するものと思われ、この調整は形成初期段階で行われると考えられる。   Since the alignment technique of Patent Document 2 has not been specifically described, it is not clear, but the alignment mark of the convex mold forming roll mold matches the alignment mark formed on the resin layer. It is considered that the rotational phase of the convex part forming roll mold is adjusted, and this adjustment is considered to be performed in the initial stage of formation.

しかしながら、ベースフィルムの一方面への光学素子形成に続いて他方面への光学素子形成を行うとき、これら両工程の間でベースフィルムに温度変化があると、長さ方向の膨縮を生じ、他方面の光学素子形成時に縦ズレが生じる。ベースフィルムへの光学素子形成は、ベースフィルムを連続搬送して行うので、ベースフィルムの長さ変化は累積し、放置すると非常に大きな値となってしまう。   However, when performing optical element formation on the other side following optical element formation on one side of the base film, if there is a temperature change in the base film between these two steps, expansion and contraction in the length direction occurs. Vertical misalignment occurs when the optical element on the other side is formed. Since the optical element is formed on the base film by continuously conveying the base film, the length change of the base film is accumulated, and if left as it is, a very large value is obtained.

例えば、シート材料が、ポリエチレンテレフタレート（ＰＥＴ）の場合、線膨張係数が７０ｐｐｍ／℃程度であるが、一方面と他方面との転写形成の間で温度が１℃変化すると、１ｍあたり７０μｍという長さ変化となる。さらにこの状態で１００ｍ送った時点では累積して７ｍｍの長さ変化となって、一方面と他方面の光学素子はズレが大きく使用できないものとなる。   For example, when the sheet material is polyethylene terephthalate (PET), the linear expansion coefficient is about 70 ppm / ° C., but if the temperature changes by 1 ° C. during transfer formation between one side and the other side, the length is 70 μm per meter. It becomes a change. In addition, when 100 m is fed in this state, the accumulated length changes to 7 mm, and the optical elements on the one surface and the other surface are misaligned and cannot be used.

シート材料が厚さ１００μｍ程度の無アルカリガラスの場合、線膨張係数が３ｐｐｍ／℃程度と小さいにもかかわらず、同様の条件で１００ｍ送ったときの縦ズレ量は３００μｍとなり、表裏の偏心量として許容できる値ではない。   When the sheet material is non-alkali glass with a thickness of about 100 μm, the amount of vertical misalignment is 300 μm when it is fed under the same conditions, although the linear expansion coefficient is as small as about 3 ppm / ° C. It is not an acceptable value.

本発明者は、特許文献２のように表面と裏面に順次光学素子を形成する形成方法の上記問題点に鑑み、表面と裏面に同時に光学素子を形成することを思いついた。このように表面と裏面に同時に形成すると、縦ズレの問題は完全に解消される。   The present inventor has come up with the idea of simultaneously forming optical elements on the front surface and the back surface in view of the above-described problem of the forming method in which the optical elements are sequentially formed on the front surface and the back surface as in Patent Document 2. Thus, if it forms simultaneously on the surface and a back surface, the problem of vertical shift will be eliminated completely.

さらに、この同時両面形成方法は、光学素子の厚さに対しても横ズレに対しても初期調整のみでよく、形成段階では調整が不要である。光学素子シートの厚さ（ベースフィルムの厚さと形成される表裏の光学素子の厚さ）は、対向配置される表面用と裏面用とのロール金型の間隔を正確に設定すれば、両ロール金型の間で形成される光学素子シートの厚みは常に一定となる。   Furthermore, this simultaneous double-sided formation method requires only initial adjustment with respect to the thickness and lateral deviation of the optical element, and no adjustment is required at the formation stage. If the thickness of the optical element sheet (the thickness of the base film and the thickness of the formed optical elements on the front and back sides) is set accurately, the distance between the roll molds for the front surface and the back surface that are opposed to each other is set. The thickness of the optical element sheet formed between the molds is always constant.

また、横ズレも対向配置される表面用と裏面用とのロール金型の横方向の位置を正確に設定すれば良い。これら金型の間隔、横方向位置の設定は、形成開始前に両金型の上方から測定機器で測定して調整すれば良い。あるいは少量のテスト形成を行い、出来上がった光学素子シートを測定して調整しても良い。   In addition, the lateral position of the roll dies for the front surface and the back surface, which are also opposed to each other, may be set accurately. The interval between the molds and the horizontal position may be adjusted by measuring with a measuring instrument from above both molds before starting the formation. Alternatively, a small amount of test formation may be performed, and the completed optical element sheet may be measured and adjusted.

このように光学素子シートの同時両面形成方法は優れた形成方法であるが、形成した光学素子シートの反りの点で問題があることが判明した。すなわち、表面と裏面に形成する光学素子はまったく同じ形状ではなく、形も大きさも異なる。そのため、光学素子が硬化するまでの間の表面と裏面の光学素子の膨縮の程度は異なるので、形成した光学素子シートに反りが発生すると考えられる。反りの解決に対しては、もちろん特許文献１の温度管理も重要であるが、温度管理だけでは解決できない問題である。   Thus, although the simultaneous double-sided formation method of the optical element sheet is an excellent formation method, it has been found that there is a problem in terms of warpage of the formed optical element sheet. That is, the optical elements formed on the front surface and the back surface are not exactly the same shape, and are different in shape and size. Therefore, since the degree of expansion / contraction of the optical element on the front surface and the back surface before the optical element is cured is different, it is considered that the formed optical element sheet is warped. Of course, the temperature management of Patent Document 1 is also important for the solution of the warp, but it cannot be solved only by the temperature management.

本発明はこのような課題に鑑み、ベースフィルムの表面と裏面に複数の光学素子を同時に形成するに際して、形成される光学素子シートの反りを解消できる光学素子シートの同時両面形成方法、およびその光学素子シート形成装置を提供することを目的とする。   In view of such a problem, the present invention provides a method for simultaneously forming both sides of an optical element sheet that can eliminate the warp of the optical element sheet formed when simultaneously forming a plurality of optical elements on the front and back surfaces of a base film, and the optical An object is to provide an element sheet forming apparatus.

上記の目的は、以下の方法によって達成される。
１．第１ロール金型と第２ロール金型とを所定間隔を空けて水平方向に対向配置し、両ロール金型の間にベースフィルムを供給してそれぞれのロール金型により複数の光学素子を前記ベースフィルムの両面に同時に成型、成形もしくは印刷するとともに、両ロール金型で形成された光学素子シートを鉛直下方に搬送し、樹脂が完全に硬化するまでの距離以上の距離で鉛直方向の搬送を継続することを特徴とする光学素子シートの同時両面形成方法。
２．前記第１ロール金型または前記第２ロール金型による光学素子形成が、紫外線硬化型樹脂を前記第１ロール金型または前記第２ロール金型に供給し、該樹脂を紫外線で硬化させることにより行われることを特徴とする前記１に記載の光学素子シートの同時両面形成方法。
３．ベースフィルム供給部と、
所定間隔を空けて水平方向に対向配置され、前記ベースフィルム供給部から供給されるベースフィルムの両面に同時に光学素子を成型、成形もしくは印刷する第１ロール金型および第２ロール金型と、
前記第１ロール金型および前記第２ロール金型の鉛直方向下方に配置される少なくとも１対の搬送ローラ対とを有し、
前記第１ロール金型および前記第２ロール金型から前記搬送ローラ対までの距離を樹脂が完全に硬化するまでの距離以上としたことを特徴とする光学素子シート形成装置。
４．前記第１ロール金型または前記第２ロール金型による光学素子形成が、紫外線硬化型樹脂を前記第１ロール金型または前記第２ロール金型に供給し、該樹脂を紫外線で硬化させることにより行われることを特徴とする前記３に記載の光学素子シート形成装置。
５．前記搬送ローラ対が、光学素子形成部分に対応する周方向の溝を有する溝付きローラ、あるいは、光学素子形成部分に対応する窪みを有する窪み付きローラであることを特徴とする前記３または４に記載の光学素子シート形成装置。 The above object is achieved by the following method.
1. The first roll mold and the second roll mold are arranged to face each other at a predetermined interval in the horizontal direction, and a base film is supplied between the two roll molds so that a plurality of optical elements are provided by each roll mold. Simultaneously mold, mold or print on both sides of the base film, transport the optical element sheet formed by both roll molds vertically downward, and transport in the vertical direction at a distance longer than the distance until the resin is completely cured A method for simultaneously forming both sides of an optical element sheet, which is continued.
2. Optical element formation by the first roll mold or the second roll mold is performed by supplying an ultraviolet curable resin to the first roll mold or the second roll mold and curing the resin with ultraviolet rays. 2. The method for simultaneously forming both sides of an optical element sheet as described in 1 above, which is carried out.
3. A base film supply unit;
A first roll mold and a second roll mold, which are arranged opposite to each other in a horizontal direction at a predetermined interval, and simultaneously mold, mold or print optical elements on both surfaces of the base film supplied from the base film supply unit;
And having at least one pair of transport rollers disposed vertically below the first roll mold and the second roll mold,
The optical element sheet forming apparatus, wherein a distance from the first roll mold and the second roll mold to the pair of conveying rollers is equal to or more than a distance until the resin is completely cured.
4). Optical element formation by the first roll mold or the second roll mold is performed by supplying an ultraviolet curable resin to the first roll mold or the second roll mold and curing the resin with ultraviolet rays. 4. The optical element sheet forming apparatus according to 3, wherein the optical element sheet forming apparatus is performed.
5. 3 or 4 above, wherein the conveying roller pair is a grooved roller having a groove in the circumferential direction corresponding to the optical element forming portion or a grooved roller having a recess corresponding to the optical element forming portion. The optical element sheet forming apparatus according to the description.

以上の本発明によれば、ベースフィルムの表面と裏面に複数の光学素子を同時に形成するに際して、形成される光学素子シートの反りを解消できる光学素子シートの同時両面形成方法、およびその光学素子シート形成装置を提供することができる。   According to the present invention described above, when simultaneously forming a plurality of optical elements on the front and back surfaces of a base film, a method for simultaneously forming both sides of an optical element sheet that can eliminate the warp of the formed optical element sheet, and the optical element sheet A forming apparatus can be provided.

本発明の光学素子シート形成装置を示す模式図。The schematic diagram which shows the optical element sheet | seat formation apparatus of this invention. ロール金型３または４を展開して示した模式図。The schematic diagram which expanded and showed the roll metal mold | die 3 or 4. FIG. 本発明の搬送ローラ対を示す斜視図。The perspective view which shows the conveyance roller pair of this invention.

以下、図面を用いて本発明を説明する。図１は本発明の光学素子シート形成装置を示す概略図である。   Hereinafter, the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing an optical element sheet forming apparatus of the present invention.

図１において、ベースフィルムＦはベースフィルム供給ローラ１に巻きつけられており、矢印のように引き出される。ベースフィルムＦの搬送路には、順に、搬送ローラ対２、水平方向に対向配置される表面成形ロール金型３と裏面成形ロール金型４、表面成形ロール金型３の上流側とベースフィルムＦとの間で紫外線硬化樹脂を供給する紫外線硬化樹脂供給部５、裏面成形ロール金型４の上流側とベースフィルムＦとの間で紫外線硬化樹脂を供給する紫外線硬化樹脂供給部６、搬送ローラ対７、搬送ローラ対８、搬送ローラ対９が配置され、最後にスペーサーシート供給ローラ１０から供給されるスペーサーシートＳを成形された光学素子シートに挟み込んで両者を成形品ローラ１１に巻きつけている。   In FIG. 1, a base film F is wound around a base film supply roller 1 and is drawn out as shown by an arrow. In the conveyance path of the base film F, the conveyance roller pair 2, the front surface forming roll die 3 and the back surface forming roll die 4 that are arranged opposite to each other in the horizontal direction, the upstream side of the surface forming roll die 3, and the base film F An ultraviolet curable resin supply unit 5 for supplying an ultraviolet curable resin between the base film F and an ultraviolet curable resin supply unit 6 for supplying an ultraviolet curable resin between the upstream side of the back surface forming roll mold 4 and the base film F, and a pair of conveying rollers. 7, a pair of conveying rollers 8 and a pair of conveying rollers 9 are arranged, and finally the spacer sheet S supplied from the spacer sheet supply roller 10 is sandwiched between the molded optical element sheets, and both are wound around the molded product roller 11. .

表面成形ロール金型３、および裏面成形ロール金型４の周面には、図２に示すように形成すべき光学素子の型（図中まる印）がマトリックス状に形成されており、また、それぞれの内部にはヒータが設けられ、紫外線硬化樹脂の温度を一定に管理するように構成される。   On the peripheral surfaces of the surface molding roll mold 3 and the back molding roll mold 4, optical element molds (marked in the figure) to be formed as shown in FIG. 2 are formed in a matrix, Each is provided with a heater, and is configured to keep the temperature of the ultraviolet curable resin constant.

表面成形ロール金型３および裏面成形ロール金型４とベースフィルムＦとの間に供給された紫外線硬化樹脂は、搬送路の両側に配置される紫外線照射ランプＵＶ１、ＵＶ２、ＵＶ３、ＵＶ４、ＵＶ５、ＵＶ６、ＵＶ７、ＵＶ８で照射され硬化される。   The ultraviolet curable resin supplied between the surface molding roll mold 3 and the back molding roll mold 4 and the base film F is composed of ultraviolet irradiation lamps UV1, UV2, UV3, UV4, UV5, which are arranged on both sides of the conveyance path. It is irradiated and cured with UV6, UV7, and UV8.

図１の例では、拡大図で示すように、表面側に凸レンズＬａが、裏面側に凹レンズＬｂがそれぞれ形成される。   In the example of FIG. 1, as shown in an enlarged view, a convex lens La is formed on the front side and a concave lens Lb is formed on the back side.

ここで、表面成形ロール金型３と裏面成形ロール金型４、搬送ローラ対７、搬送ローラ対８は、それぞれの対が水平方向に対向配置されるとともに、順次鉛直方向に並べられている。またこれらの周速度はすべて一定速度で駆動されている。   Here, the front surface forming roll mold 3 and the back surface forming roll mold 4, the conveying roller pair 7, and the conveying roller pair 8 are arranged so as to face each other in the horizontal direction and are sequentially arranged in the vertical direction. These peripheral speeds are all driven at a constant speed.

表面成形ロール金型３と裏面成形ロール金型４とは、形成開始前にその間隔、金型同士の縦方向（周方向）、横方向（軸方向）の位置を正確に調整される。この調整によって、表裏に形成される光学素子がずれることなく形成できる。   The surface forming roll mold 3 and the back surface forming roll mold 4 are accurately adjusted in the interval, the vertical direction (circumferential direction), and the horizontal direction (axial direction) between the molds before the start of formation. By this adjustment, the optical elements formed on the front and back sides can be formed without shifting.

図１において、搬送ローラ対７、８、および搬送ローラ対９のスペーサーシートと反対側のローラは、光学素子には接触せず光学素子の間の部分に接触するローラが良い。図３はこのようなローラを示すもので、図３（ａ）は、周方向に溝が形成され光学素子形成部分が溝に入る構造の溝付きローラを、図３（ｂ）は、光学素子形成部分に対応した窪みが周面にマトリックス状に形成された窪み付きローラを示している。図１において、二重丸で示している搬送ローラは、この溝付きローラまたは窪み付きローラを採用する部分である。   In FIG. 1, the rollers on the side opposite to the spacer sheet of the conveying roller pairs 7 and 8 and the conveying roller pair 9 are preferably rollers that do not contact the optical element but contact the portion between the optical elements. FIG. 3 shows such a roller. FIG. 3A shows a grooved roller having a structure in which a groove is formed in the circumferential direction and an optical element forming portion enters the groove. FIG. 3B shows an optical element. The hollow with a hollow in which the hollow corresponding to the formation part was formed in the matrix form in the surrounding surface is shown. In FIG. 1, a conveyance roller indicated by a double circle is a portion that employs the grooved roller or the recessed roller.

このように光学素子には接触せず光学素子の間の部分に接触する搬送ローラ対を用いて光学素子シートを挟み込み、鉛直方向に搬送することにより、ベースフィルムＦ上で徐々に硬化する光学素子シートはその重みと搬送ローラ対の搬送力による張力がかかるので反りは発生することなく硬化させることができる。   An optical element that gradually cures on the base film F by sandwiching the optical element sheet using a pair of conveyance rollers that do not contact the optical element but contacts a portion between the optical elements and conveying the sheet in the vertical direction. Since the sheet is tensioned by the weight and the conveying force of the conveying roller pair, the sheet can be cured without warping.

表面成形ロール金型３と裏面成形ロール金型４から搬送ローラ対８までの鉛直方向の距離は、樹脂が完全に硬化するまでの距離以上とする。この距離は、使用する樹脂材料や形成する光学素子の大きさなどに依存するが、おおむね３ｍ以上である。   The distance in the vertical direction from the surface forming roll mold 3 and the back forming roll mold 4 to the conveying roller pair 8 is set to be equal to or longer than the distance until the resin is completely cured. Although this distance depends on the resin material used and the size of the optical element to be formed, it is generally 3 m or more.

なお、上記の説明では、ロール金型は精密に作製され、軸の偏心やロール形状の偏りは無いものとしているが、これら偏心、偏りをまったくゼロにすることは難しく、レンズと絞りや両面にレンズを形成する場合などのように、表面と裏面の光学素子の偏心が問題になるものにおいては、これらの影響は大きくなる。この場合、事前に両ロール金型の軸偏心とロール形状を計測し、計測値を記憶しておいて、両ロール金型の速度を記憶された偏心計測値およびロール形状計測値を用いて補正するようにすればよい。このとき、両ロール金型の回転位置情報が必要となるので、表面成形ロール金型３と裏面成形ロール金型４にマークを付けてこれを計測するか、あるいは、軸にロータリエンコーダを設けて回転位置情報を得るようにする。   In the above description, the roll mold is precisely manufactured, and it is assumed that there is no shaft eccentricity or roll shape deviation, but it is difficult to eliminate these eccentricity and deviation at all. In the case where the eccentricity of the optical elements on the front surface and the back surface becomes a problem, such as in the case of forming a lens, these influences become large. In this case, the shaft eccentricity and roll shape of both roll molds are measured in advance, the measured values are stored, and the speed of both roll molds is corrected using the stored eccentricity measured values and roll shape measured values. You just have to do it. At this time, since the rotational position information of both roll molds is required, the surface forming roll mold 3 and the back forming roll mold 4 are marked and measured, or a rotary encoder is provided on the shaft. Rotational position information is obtained.

以上説明した本発明の実施例では、光学素子を形成する材料として紫外線硬化樹脂を用いたが、紫外線硬化樹脂は、ウレタンアクリレート、エポキシアクリレート、不飽和酸ポリエステルなど光学素子の性能に合わせて適宜選択できる。また、紫外線硬化樹脂に替えて、可視光や電子線などのエネルギー線硬化樹脂や、ジエチレングリコールジアリルカーボネート、シロキサニルメタクリレートなどの熱硬化性樹脂を用いることもできる。   In the embodiments of the present invention described above, an ultraviolet curable resin is used as a material for forming the optical element. However, the ultraviolet curable resin is appropriately selected according to the performance of the optical element such as urethane acrylate, epoxy acrylate, or unsaturated acid polyester. it can. Further, instead of the ultraviolet curable resin, an energy ray curable resin such as visible light or an electron beam, or a thermosetting resin such as diethylene glycol diallyl carbonate or siloxanyl methacrylate may be used.

紫外線照射ランプとしては、高圧水銀ランプ、メタルハライドランプなどを用いることができ、さらに近年開発されたＬＥＤ方式の紫外線照射ランプを用いることもできる。   As the ultraviolet irradiation lamp, a high pressure mercury lamp, a metal halide lamp, or the like can be used, and an LED type ultraviolet irradiation lamp developed in recent years can also be used.

先に説明したように、本発明においては、光学素子としてレンズ以外にも種々の形態の光学素子を形成することができ、また、その形成方法も「成型」「成形」「印刷」を用いることができる。   As described above, in the present invention, optical elements of various forms can be formed as optical elements in addition to lenses, and the forming method is “molding”, “molding”, and “printing”. Can do.

上述の実施例は「成形」であるが、「成型」の場合は、樹脂を加熱して軟化させ、ロール金型に注入し、加熱及び加圧によって成型する。また、「印刷」の場合は、ロール金型を凹版とし、金型の凹部にインクを入れ、ベースフィルムに押圧して転写する。そして、このような形成方法を表面側と裏面側とで異なる方法を用いることができるのも勿論である。   The above-mentioned embodiment is “molding”, but in the case of “molding”, the resin is heated and softened, poured into a roll mold, and molded by heating and pressing. In the case of “printing”, the roll mold is an intaglio, and ink is put into the depressions of the mold and transferred to the base film by pressing. Of course, different methods can be used for the front side and the back side.

１ ベースフィルム供給ローラ
２、７、８、９ 搬送ローラ対
３ 表面成形ロール金型
４ 裏面成形ロール金型
５、６ 紫外線硬化樹脂供給部
１０ スペーサーシート供給ローラ
１１ 成形品ローラ
Ｆ ベースフィルム
Ｓ スペーサーシート
ＵＶ１〜ＵＶ８ 紫外線照射ランプ DESCRIPTION OF SYMBOLS 1 Base film supply roller 2, 7, 8, 9 Conveyance roller pair 3 Front surface forming roll metal mold 4 Back surface forming roll metal mold 5, 6 UV curable resin supply part 10 Spacer sheet supply roller 11 Molded product roller F Base film S Spacer sheet UV1-UV8 UV irradiation lamp

Claims (5)

第１ロール金型と第２ロール金型とを所定間隔を空けて水平方向に対向配置し、両ロール金型の間にベースフィルムを供給してそれぞれのロール金型により複数の光学素子を前記ベースフィルムの両面に同時に成型、成形もしくは印刷するとともに、両ロール金型で形成された光学素子シートを鉛直下方に搬送し、樹脂が完全に硬化するまでの距離以上の距離で鉛直方向の搬送を継続することを特徴とする光学素子シートの同時両面形成方法。   The first roll mold and the second roll mold are arranged to face each other at a predetermined interval in the horizontal direction, and a base film is supplied between the two roll molds so that a plurality of optical elements are provided by the respective roll molds. Simultaneously mold, mold or print on both sides of the base film, transport the optical element sheet formed by both roll molds vertically downward, and transport in the vertical direction at a distance longer than the distance until the resin is completely cured A method for simultaneously forming both sides of an optical element sheet, which is continued. 前記第１ロール金型または前記第２ロール金型による光学素子形成が、紫外線硬化型樹脂を前記第１ロール金型または前記第２ロール金型に供給し、該樹脂を紫外線で硬化させることにより行われることを特徴とする請求項１に記載の光学素子シートの同時両面形成方法。   Optical element formation by the first roll mold or the second roll mold is performed by supplying an ultraviolet curable resin to the first roll mold or the second roll mold and curing the resin with ultraviolet rays. The method for simultaneously forming both sides of an optical element sheet according to claim 1, wherein the method is performed. ベースフィルム供給部と、
所定間隔を空けて水平方向に対向配置され、前記ベースフィルム供給部から供給されるベースフィルムの両面に同時に光学素子を成型、成形もしくは印刷する第１ロール金型および第２ロール金型と、
前記第１ロール金型および前記第２ロール金型の鉛直方向下方に配置される少なくとも１対の搬送ローラ対とを有し、
前記第１ロール金型および前記第２ロール金型から前記搬送ローラ対までの距離を樹脂が完全に硬化するまでの距離以上としたことを特徴とする光学素子シート形成装置。 A base film supply unit;
A first roll mold and a second roll mold, which are arranged opposite to each other in a horizontal direction at a predetermined interval, and simultaneously mold, mold or print optical elements on both surfaces of the base film supplied from the base film supply unit;
And having at least one pair of transport rollers disposed vertically below the first roll mold and the second roll mold,
The optical element sheet forming apparatus, wherein a distance from the first roll mold and the second roll mold to the pair of conveying rollers is equal to or more than a distance until the resin is completely cured. 前記第１ロール金型または前記第２ロール金型による光学素子形成が、紫外線硬化型樹脂を前記第１ロール金型または前記第２ロール金型に供給し、該樹脂を紫外線で硬化させることにより行われることを特徴とする請求項３に記載の光学素子シート形成装置。   Optical element formation by the first roll mold or the second roll mold is performed by supplying an ultraviolet curable resin to the first roll mold or the second roll mold and curing the resin with ultraviolet rays. The optical element sheet forming apparatus according to claim 3, wherein the optical element sheet forming apparatus is performed. 前記搬送ローラ対が、光学素子形成部分に対応する周方向の溝を有する溝付きローラ、あるいは、光学素子形成部分に対応する窪みを有する窪み付きローラであることを特徴とする請求項３または４に記載の光学素子シート形成装置。   5. The conveying roller pair is a grooved roller having a circumferential groove corresponding to the optical element forming portion or a hollow roller having a recess corresponding to the optical element forming portion. 2. An optical element sheet forming apparatus according to 1.
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