WO2009151171A1

WO2009151171A1 - Apparatus and method for manufacturing an optical sheet

Info

Publication number: WO2009151171A1
Application number: PCT/KR2008/003363
Authority: WO
Inventors: Jong Wook Huh; Dong Ryoul Kim
Original assignee: Miraenanotech Co., Ltd.
Priority date: 2008-06-13
Filing date: 2008-06-13
Publication date: 2009-12-17

Abstract

An apparatus for manufacturing an optical sheet includes a first roll around which a base film is wound, a second roll around which the base film on which a coating solution is applied is wound, two or more guide rolls disposed between the first and second rolls and conveying the base film, a coating solution injection unit for injecting the coating solution in the base film, and a pattern molding unit engaged with one of the guide rolls and applying the coating solution injected from the coating solution injection unit on the base film in a predetermined pattern. The pattern molding unit includes a forming mold provided with a predetermined pattern, a master roll depressing the injected coating solution on the forming mold, at least one pattern guide roll conveying the forming mold, and a pre-coating apparatus for filing the coating solution in the pattern of the forming mold.

Description

APPARATUS AND METHOD FOR MANUFACTURING AN

OPTICAL SHEET

Technical Field

[1] The present disclosure relates to an apparatus and method for manufacturing an optical sheet. More particularly, the present disclosure relates to an apparatus and method that can consecutively mass-produce optical members each having a micro- scale or nano-scale pattern and used for a display or an optical device and improve a yield in producing the optical members. Background Art

[2] Recently, the use of liquid crystal display (LCD) devices among a variety of flat display panels is on the rise. The LCD device displays information using an electrical/ optical property of liquid crystal injected in an LCD panel. The LCD device is a non- emissive display that displays an image using a light source such as a lamp.

[3] That is, unlike a cathode ray tube, the LCD device absolutely needs a backlight assembly that can emit light since the liquid crystal material injected between a thin film transistor (TFT) substrate and a color filter substrate is not a light emissive material that is self-emissive material but a passive type material that displays an image by adjusting an amount of light from an external side.

[4] The backlight assembly includes a mold frame defining a receiving space, a reflective sheet installed on a base surface of the receiving space and reflecting the light toward the LCD panel, a light guide plate that is installed above the reflective sheet to guide the light, a lamp unit that is installed between the light guide plate and a sidewall of the receiving space to emit the light, a plurality of optical sheets that are stacked on the light guide plate to diffuse and collect the light, and a top chassis that is installed above the mold frame to cover a section arranging from a predetermined location of an edge of the LCD panel to a side surface of the mold frame.

[5] Here, the optical sheets include a diffuser sheet for diffusing light, a prism sheet that is formed on the diffuser sheet to collect the diffused light and transmit the collected light to the LCD panel, and a protective sheet for protecting the diffuser sheet and the prism sheet.

[6] Figs. 1 and 2 are respectively cross-sectional and perspective views of a prism sheet of the related art.

[7] Referring to Figs. 1 and 2, a prism sheet 10 in accordance with the related art includes a body 11 on which light diffused by a light guide plate and diffuser sheet is initially incident and a plurality of protrusions 12 that are formed in an isosceles triangular column shape to collimate the diffused light. The protrusions 12 are arranged in a stripe pattern on the body 11.

[8] The protrusions 12 are arranged to have a pitch ranging from several tens to several hundreds μm. A vertex angle α of the triangular column is 60-130°. As the vertex angle α of the triangular column is reduced, the luminance increases but the viewing angle is reduced.

[9] Therefore, in the related art prism sheet, it is difficult to expect that both of the luminance property and the viewing angle property are simultaneously improved.

[10] In order to solve this limitation, the applicant of the present application has been proposed an optical sheet having a micro-lens pattern in Korean Patent Application No. 10-2005-33262 (Laid-open Patent No. 10-2006-011090A). This is shown in Fig. 3.

[11] Fig. 3 is a perspective view of an optical sheet having a micro-lens pattern.

[12] In Fig. 3, there is shown an optical sheet 20 that can simultaneously improve both the luminance and viewing angle. The optical sheet 20 includes a body 21 and protrusions 22 (that are arranged in a micro-lens pattern).

[13] The light collection and diffusion are more effectively performed by the protrusions

22 formed on the optical sheet 20.

[14] Meanwhile, the applicant has disclosed an apparatus and method for manufacturing the optical sheet having the above-described features in Korean Patent No. KR10-605386 (entitled "OPTICAL MEMBER FABRICATING APPARATUS AND METHOD AND FORMING MOLD USED FOR THE SAME"). A variety of embodiments for overcoming and solving a variety of limitations that may be caused when the optical sheet shown in Fig. 3 is manufactured based on the invention disclosed in Korean Patent No. KR10-605386 will be described in detail in the following description. Disclosure of Invention Technical Problem

[15] Embodiments provide an apparatus and method for manufacturing an optical sheet, which can improve a yield in producing the optical sheets each having a predetermined pattern. Technical Solution

[16] In one embodiment, an apparatus for manufacturing an optical sheet includes a first roll around which a base film is wound, a second roll around which the base film on which a coating solution is applied is wound, two or more guide rolls disposed between the first and second rolls and conveying the base film, a coating solution injection unit for injecting the coating solution in the base film, and a pattern molding unit engaged with one of the guide rolls and applying the coating solution injected from the coating solution injection unit on the base film in a predetermined pattern. The pattern molding unit includes a forming mold provided with a predetermined pattern, a master roll depressing the injected coating solution on the forming mold, at least one pattern guide roll conveying the forming mold, and a pre-coating apparatus for filing the coating solution in the pattern of the forming mold.

[17] In another embodiment, an apparatus for manufacturing an optical sheet having a first pattern includes a first roll around which a base film is wound, a second roll around which the optical sheet is wound, two or more guide rolls disposed between the first and second rolls and conveying the base film or the base film, a pattern molding unit having a master roll engaged with one of the first and second guide rolls and at least one pattern guide roll for conveying a forming mold provided with a second pattern having an inverse image relative to the thirst pattern, a pre-coating apparatus formed between the pattern guide rolls and filling the coating solution in the pattern of the forming mold, and a coating solution injection unit for further filling the coating solution in the pattern of the forming mold filled with the coating solution by the pre- coating apparatus.

[18] In still another embodiment, a method for manufacturing an optical sheet on which a first pattern is formed includes conveying a base film for the optical sheet, primarily filling coating solution in a forming mold having a second pattern that is an inverse image to the first pattern, secondarily filling the coating solution in the forming mold by injecting the coating solution toward a region where the base film and the forming mold contact each other, hardening the coating solution to transfer the coating solution to the base film, and separating the forming mold from the base film to which the hardened coating solution is transferred.

Advantageous Effects

[19] According to the embodiments, when the optical sheets each having a fine pattern are produced, the yield can be improved and thus the manufacturing cost can be reduced.

Furthermore, a large-sized pattern can be easily formed. [20] In addition, a processing cost for making a master pattern can be reduced as a film type forming mold is used for forming the pattern.

Brief Description of Drawings

[21] Fig. 1 is a cross-sectional view of a prism sheet of the related art.

[22] Fig. 2 is a perspective view of a prism sheet of the related art.

[23] Fig. 3 is a perspective view of an optical sheet having a micro-lens pattern.

[24] Fig. 4 is a cross-sectional view of a forming mold according to an embodiment.

[25] Fig. 5 is a view illustrating a state where coating solution is not sufficiently filled in a pattern layer of a forming mold. [26] Fig. 6 is a schematic view of an apparatus for manufacturing an optical sheet according to an embodiment.

[27] Fig. 7 is an enlarged view of a portion of the apparatus of Fig. 6.

[28] Fig. 8 is an enlarged view of a portion of an apparatus for manufacturing an optical sheet according to another embodiment.

[29] Fig. 9 is a schematic view of a pre-coating roll according to an embodiment.

[30] Fig. 10 is a schematic view illustrating a state where a coating solution is primarily coated on a forming mold according to an embodiment. [31] Fig. 11 is a schematic view illustrating a state where a coating solution is secondarily coated on a forming mold according to an embodiment.

Best Mode for Carrying out the Invention [32] First, there is a need to refer to the disclosure of Korean Patent No. 10-605386

(hereinafter, referred to as "Related art invention") in connection with technical features of the present disclosure. [33] In the following description, a variety of limitations that may be caused when the optical sheet shown in Fig. 3 is manufactured will be described again and embodiments for solving and overcoming the limitations will be described in detail. However, it will be understood that embodiments can be applied not only the optical sheet having the micro-lens pattern as shown in Fig. 3 but also other types of optical sheets for diffusing or collecting light. [34] According to the related art invention, a forming mold shown in Fig. 4 is required to manufacture the optical sheet shown in Fig. 3. [35] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. In the drawings, each part is enlarged and exaggerated for clarity of illustration.

[36] Fig. 4 is a cross-sectional view of a forming mold according to an embodiment.

[37] Referring to Fig. 4, a forming mold 40 includes a pattern layer 42 having an inverse image relative to a pattern image of the optical sheet and a base layer 41 defining a body. [38] In connection with the related art invention, the optical sheet having an inverse image relative to the pattern image of the pattern layer 42 is manufactured by injecting a coating solution in the pattern layer 42, hardening the coating solution, and removing the pattern layer 42 from the hardened coating solution.

[39] The following will describe a manufacturing method of the forming mold.

[40] First, after a master formed of metal or a thin film is fixed, polymer resin for the mold is applied on the master. Subsequently, a base film for the forming mold is applied on the master on which the polymer resin is applied, after which a prede- termined pressure is uniformly applied on the base film by rolling a cylindrical roller.

[41] At this point, the applied polymer resin is filled in spaces of the pattern of the master and uniformly distributed with a predetermined thickness by the pressure applied by the roller. In this state, heat or ultraviolet rays are emitted to the resulting structure in a state where the resin is filled between the master and the base film to harden the resin, after which the base film is separated from the master.

[42] Here, the base film may be formed of polymer resin for mold or a film having a surface that is processed to have an adhesive property.

[43] Meanwhile, when a moving speed of the forming mold 40 increases to improve a yield in producing of the optical sheets, as shown in Fig. 5, a phenomenon where the coating solution 50 is not fully filled in the pattern layer 40 of the forming mold may occur.

[44]

[45] *That is, since grooves of the intaglio pattern of the pattern layer 42 of the forming mold 40 are formed in a several micrometer unit, an air layer may be formed in the grooves of the intaglio pattern of the pattern layer 42. In this case, the coating solution 50 injected toward the forming mold 40 may be fully filled in the grooves of the intaglio pattern.

[46] In this case, protrusions of the relief pattern of the optical sheet manufactured may be deformed. That is, a desired relief pattern cannot be obtained.

[47] Embodiments of the present disclosure can improve the yield of the optical sheets by preventing the above-described limitations.

[48] Fig. 6 is a schematic view of an apparatus for manufacturing an optical sheet according to an embodiment.

[49] Referring to Fig. 6, an optical sheet manufacturing apparatus in accordance with an embodiment includes a base film 110, a first roll 120, a second roll 150 around which an optical sheet 112 on which a pattern is formed is wound, and a plurality of guide rolls 130a, 130b, 130c, 130d, and 130e for conveying the base film 110 and the optical sheet 112 on which a pattern is formed.

[50] The guide rolls 130a, 130b, 130c, 130d, and 130e may be referred to as first, second, third, fourth, and fifth guide rolls 130a, 130b, 130c, 130d, and 130e in accordance with their positions, respectively. The number and positions of the guide rolls are not limited to this configuration.

[51] The optical sheet manufacturing apparatus in accordance with the embodiment further includes a pattern molding unit 140 applying the coating solution on the base film 110 with the pattern. The pattern molding unit 140 is provided between the third guide roll 130c and the fourth guide roll 130d. The pattern molding unit 140 functions as a pattern roll. This is also disclosed in the related invention. [52] However, the pattern molding unit 140 has a main coating region and a pre-coating region. Particularly, the pattern molding unit 140 injects the coating solution into the pattern layer of the forming mold through two steps. These technical features will be described in more detail with reference to the accompanying drawings.

[53] The pattern molding unit 140 includes a forming mold 142 having a pattern image, a master roll 144 for pressing the coating solution in the pattern formed on the forming mold 142 and transferring the pattern-formed coating solution to the base film 110, and pattern guide rolls 146a and 146b for conveying the forming mold 142.

[54] The forming mold 142 includes a base layer and a pattern layer provided with pattern. The forming mold 142 may be divided into two or more sections that are connected to each other in a belt type. Likewise the above-described pattern rolls, the forming mold 142 functions to pattern-form the coating solution.

[55] For reference, the forming mold shown in Fig. 6 is partly provided with the pattern layer. However, the pattern layer may be formed on an entire surface of the forming mold disposed on the belt that is conveyed by the pattern guide rolls 146a and 146b.

[56] The installation of the forming mold 142 may be performed by allowing the sections to enclose extending lines connecting the mater roll 144 to the pattern guide rolls 146a and 146b and connecting opposite ends of the adjacent sections of the forming mold 142.

[57] Particularly, there are provided pre-coating regions 200, 201, and 202 where the coating solution is primarily and partly injected in grooves of the intaglio pattern layer of the forming mold 142 as the forming mold 142 moves in an arrow direction in the pattern molding unit 140.

[58] That is, at the pre-coating regions 200, 210, and 202, the coating solution is primarily filled (or applied) in the forming mold 142 in the pattern mold unit 140. The forming mold that is primarily filled with the coating solution at the pre-coating regions 200, 201, and 202 are conveyed to the master roll 144. The forming mold 142 conveyed to the master roll 144 is secondarily filled with the coating solution supplied from the coating solution injection unit 160 provided near the master roll 144.

[59] Therefore, the injection of the coating solution into the forming mold 142 is done by the primary injection performed at the pre-coating regions and the secondary injection performed near the master roll 144.

[60] However, three pre-coating regions are provided in the embodiment. However, the present disclosure is not limited to the embodiment. For example, only one or more than three pre-coating regions may be set. For reference, the pre-coating region shown in Fig. 7 is the pre-coating region 200 formed between the first and second pattern guide rolls 146a and 146b.

[61] The optical sheet manufacturing device in accordance with the embodiment further includes a coating solution injection unit 160 for injecting the coating solution into a region where the base film 110 is introduced into the pattern molding unit 140 and a hardening unit for hardening the coating solution by emitting heat or ultraviolet rays.

[62] The following will describe an operation of the optical sheet manufacturing apparatus of the embodiment.

[63] First, the base film 110 wound around the first roll 120 is conveyed by the guide rolls

130a, 130b, 130c, 130d, and 130e. At this point, the forming mold 142 of the pattern molding unit 140 is also conveyed and rotated in a state where it is wound around the master roll 144 and the pattern guide rolls 146a and 146b.

[64] Since the master roll 144 is engaged with the third and fourth guide rolls 130c and

130d, the base film 110 contacts the forming mold 142 by the third guide roll 130c.

[65] Particularly, the third guide roll 130c functions to adjust a gap by which a thickness of the pattern layer of the optical sheet 112 that is manufactured by adjusting a thickness of the coating solution applied on the base film 110.

[66] In more detail, as a gap between the third guide roll 130c and the master roll 144 is reduced, the thickness of the pattern layer of the optical sheet increases. On the contrary, as the gap between the third guide roll 130c and the master roll 144 increases, the thickness of the pattern layer of the optical sheet is reduced. The thickness of the pattern layer of the optical sheet may be also adjusted by varying a viscosity of the coating solution, a patterning speed, and a tension of the base film.

[67] Meanwhile, the coating solution is injected by the coating solution injection unit 160 into a predetermined region where the third guide roll 130c and the master roll 144 are engaged with each other and the injected coating solution is filled in the groove of the pattern of the forming mold 142. Here, before the coating solution is filled in the grooves of the pattern of the forming mold by the coating solution injection unit 160, the coating solution stored in a coating solution container (this will be described later) is primarily filled in the grooves of the pattern of the forming mold at the pre-coating regions 200, 2001, and 202.

[68] The coating solution supplied from the coating solution injection unit 160 is uniformly distributed on the base film 110 by the pressure between the third guide roll 130c and the master roll 144, thereby realizing the pattern forming. In addition, the coating solution filled in the grooves of the pattern is hardened by the heat or ultraviolet rays emitted from the hardening unit 170.

[69] The base film 110 on which the patterned coating solution is applied and hardened is pulled by the fourth guide roll 130d, in the course of which the base film 110 is separated from the forming mold 142. The finished optical sheet 112 is conveyed by the fifth guide roll 130e and wound around the second roll 150.

[70] Here, the fourth guide roll 130d functions to separate the optical sheet 112 applied with the coating solution from the forming mold 142. That is, the fourth guide roll 13Od separates the optical sheet 112 provided with the pattern layer from the forming mold 142.

[71] In the above-described embodiment, the base film 110 and the optical sheet 112 are interconnected. That is, the base film 110 and the optical sheet 112 are discriminated in their names depending on whether the coating solution is applied thereon.

[72] That is, the base film 110 is a film before the pattern layer is formed and the optical sheet 112 is the base film on which the patterned coating solution is applied as the base film passes through the pattern molding unit 140. In addition, in Fig. 6, only a part of the pattern layer is formed on the optical sheet 112. However, the sheet wound around the second roll 150 is also formed with the pattern layer.

[73] The following will describe a pre-coating apparatus and method in accordance with an embodiment.

[74] Fig. 7 is an enlarged view of a portion of the apparatus of Fig. 6, Fig. 8 is an enlarged view of a portion of an apparatus for manufacturing an optical sheet according to another embodiment, Fig. 9 is a schematic view of a pre-coating roll according to an embodiment, Fig. 10 is a schematic view illustrating a state where a coating solution is primarily coated on a forming mold according to an embodiment, and Fig. 11 is a schematic view illustrating a state where a coating solution is secondarily coated on a forming mold according to an embodiment.

[75] Particularly, Fig. 7 illustrates an enlarged view of a structure of the pre-coating region in the optical sheet manufacturing apparatus. Fig. 6 illustrates an embodiment when the pre-coating region is formed between the first pattern guide roll 146a and the second pattern guide roll 146b.

[76] Referring to Fig. 7, the forming mold having an inverse image relative to the pattern image of the optical sheet that will be manufactured moves along the first pattern guide roll 146a, after which the forming mold is primarily coated with the coating solution at the pre-coating region 200 and moves along the second pattern guide roll 146a.

[77] Here, the forming mold includes the base layer and the pattern layer as described above. The pattern layer has an intaglio pattern that is the reverse image to the micro- lens pattern.

[78] First and second pre-coating rolls 211 and 212 for transferring the forming mold are provided at the pre-coating region 200. The second pre-coating roll 212 is dipped in the coating solution contained in a coating solution container 210 so that the coating solution can be injected in the forming mold by the second pre-coating roll 212.

[79] Therefore, as the second pre-coating roll 212 rotates, the coating solution contained in the coating solution container 210 is injected in the pattern layer of the forming mold conveyed from the first pre-coating roll 211 to the second pre-coating roll 212. [80] That is, the coating solution filled in the grooves of the intaglio pattern formed on the forming mold has a predetermined viscosity and thus the coating solution stored in the coating solution can contact the forming mold along a surface of the second pre- coating roll 212.

[81] Fig. 7 illustrates front portions of the first and second pre-coating rolls 211 and 212 and Fig. 9 illustrates side portions of the first and second pre-coating rolls 211 and 212.

[82] Meanwhile, as shown in Fig. 8, the coating solution container 210 is designed to have a size that can receive the second pre-coating roll 212 and other pre-coating rolls that are disposed besides the second pre-coating roll 212.

[83] Referring to Fig. 9, bearings 21 Ia and 212a are installed on the side portions of the pre-coating rolls 211 and 212 so that the pre-coating rolls 211 and 212 can smoothly rotate even by a relatively small force. The second pre-coating roll 212 is designed to fill the grooves of the intaglio pattern of the forming mold with the coating solution and the first pre-coating roll 211 is properly spaced apart from the second pre-coating roll 212 so that the forming mold can be tightened as it is being conveyed.

[84] Meanwhile, a cleaning unit for removing a remaining coating solution by generating friction on the surface of the second pre-coating roll 212 is further provided to prevent the remaining of the coating solution on the surface of the second pre-coating roll 212 after the coating solution is injected into the grooves of the intaglio pattern of the forming mold.

[85] Here, the first pre-coating roll 211, the second pre-coating roll 212, and the coating solution container 210 may be referred to as a pre-coating apparatus. In the embodiment, one or more pre-coating apparatuses may be provided. As the number of the pre-coating apparatuses increases, the generation of bubbles in the grooves of the intaglio pattern of the forming mold can be more effectively prevented and thus the production yield is not deteriorated even when the optical sheet is produced at a high speed.

[86] Further, the pre-coating apparatus may be installed at a variety of different locations in the pattern molding unit 140 illustrated in Fig. 6.

[87] The coating process of the forming mold by the pre-coating apparatus is illustrated in

Fig. 10. In Fig. 10, the coating solution 213 contained in the coating solution container 210 is primarily coated on the pattern layer 142b having the intaglio pattern of the forming mold 142.

[88] Here, the coating of the pattern layer 142b by the pre-coating apparatus is preformed for a predetermined portion of the intaglio pattern of the pattern layer 142b.

[89] Meanwhile, the forming mold that is primarily coated with the coating solution at the pre-coating region is conveyed to the master roll 144 of Fig. 6, after which the coating solution injected from the coating solution injection unit 160 is secondarily coated on the forming mold. [90] Fig. 11 illustrates a state where the coating solution 161 supplied from the coating solution injection unit 160 is filled in the grooves of the intaglio pattern of the forming mold. [91] The coating solution pattern that is formed by secondarily coating the coating solution on the forming mold using the mater roll 144 is transferred on the base film, thereby completing the optical sheet having the micro-lens pattern as shown in Fig. 3. [92] According to the embodiments, when the optical sheets each having a fine pattern are produced, the yield can be improved and thus the manufacturing cost can be reduced.

Furthermore, a large-sized pattern can be easily formed. [93] In addition, a processing cost for making a master pattern can be reduced as a film type forming mold is used for forming the pattern.

Claims

[1] An apparatus for manufacturing an optical sheet, comprising: a first roll around which a base film is wound; a second roll around which the base film on which a coating solution is applied is wound; two or more guide rolls disposed between the first and second rolls and conveying the base film; a coating solution injection unit for injecting the coating solution in the base film; and a pattern molding unit engaged with one of the guide rolls and applying the coating solution injected from the coating solution injection unit on the base film in a predetermined pattern, wherein the pattern molding unit comprises a forming mold provided with a predetermined pattern, a master roll depressing the injected coating solution on the forming mold, at least one pattern guide roll conveying the forming mold, and a pre-coating apparatus for filing the coating solution in the pattern of the forming mold.

[2] The apparatus according to claim 1, wherein the coating solution is primarily filled in the pattern of the forming mold by the pre-coating apparatus and secondarily filled in the pattern by the coating solution injection unit.

[3] The apparatus according to claim 1, wherein a plurality of the pre-coating apparatuses are provided in the pattern molding unit.

[4] The apparatus according to claim 1, wherein the pre-coating apparatus comprises a first pre-coating roll, a second pre-coating roll, and a coating solution container; the forming mold is conveyed by rotation of the first and second pre-coating rolls; and the coating solution stored in the coating solution container is filled in the pattern of the forming mold along a surface of the second pre-coating roll by the rotation of the second pre-coating roll.

[5] The apparatus according to claim 1, wherein the forming mold is located on an extending line connecting the mater roll to the pattern guide roll.

[6] The apparatus according to claim 1, wherein a thickness of the coating solution applied on the base film varies in accordance with a gap between the master roll and the guide roll engaged with the mater roll.

[7] An apparatus for manufacturing an optical sheet having a first pattern, comprising: a first roll around which a base film is wound; a second roll around which the optical sheet is wound; two or more guide rolls disposed between the first and second rolls and conveying the base film or the base film; a pattern molding unit having a master roll engaged with one of the first and second guide rolls and at least one pattern guide roll for conveying a forming mold provided with a second pattern having an inverse image relative to the thirst pattern; a pre-coating apparatus formed between the pattern guide rolls and filling the coating solution in the pattern of the forming mold; and a coating solution injection unit for further filling the coating solution in the pattern of the forming mold filled with the coating solution by the pre-coating apparatus. [8] The apparatus according to claim 7, wherein the pre-coating apparatus comprises first and second pre-coating rolls for conveying the forming mold and a coating solution container for storing the coating solution. [9] The apparatus according to claim 8, wherein a part of the second pre-coating roll is dipped in the coating solution contained in the coating solution container. [10] A method for manufacturing an optical sheet on which a first pattern is formed, the method comprising: conveying a base film for the optical sheet; primarily filling coating solution in a forming mold having a second pattern that is an inverse image to the first pattern; secondarily filling the coating solution in the forming mold by injecting the coating solution toward a region where the base film and the forming mold contact each other; hardening the coating solution to transfer the coating solution to the base film; and separating the forming mold from the base film to which the hardened coating solution is transferred. [11] The method according to claim 10, wherein the primarily filling the coating solution comprises dipping a part of the pre-coating roll in the coating solution contained in the coating solution container and rotating the pre-coating roll to filling the coating solution stored in the containing solution container into the second pattern. [12] The method according to claim 10, wherein the secondarily filling the coating solution comprises supplying the coating solution from a coating solution injection unit to the region when the base film and the forming mold contact each other and filling the coating solution into the second pattern of the forming mold.