Method and apparatus for manufacturing a lens sheet

Abstract

An apparatus for manufacturing a lens sheet comprises an application device, a substrate supply device, a pressing device and an irradiation device. The application device applies ionizing radiation curing type resin in the form of liquid on the upper surface of a forming die for a lens sheet to form an uncured resin body on the upper surface of the forming die. The substrate supply device places a substrate on the uncured resin body. The pressing device presses the substrate against the uncured resin body to flatten the uncured resin body, so as to form a uncured resin layer, while spreading the uncured resin body to an outside periphery of the forming die. The irradiation device irradiates ionizing radiation on the uncured resin layer through the substrate to cure the uncured resin layer.

1 . A method for manufacturing a lens sheet, comprising: 
 a resin-application step for applying ionizing radiation curing type resin in a form of liquid on an upper surface of a forming die to form an uncured resin body on the upper surface of said forming die;    a laminating step for placing a substrate on said uncured resin body and then pressing said substrate against said uncured resin body to flatten said uncured resin body, thereby forming a uncured resin layer, while spreading said uncured resin body to an outside periphery of said forming die;    a curing step for irradiating ionizing radiation on said uncured resin layer through said substrate to cure said uncured resin layer, thereby forming a cured resin layer; and    a removing step for removing said cured resin layer together with said substrate from said forming die.    
     
     
         2 . The method as claimed in  claim 1 , wherein: said resin-application step comprises a partial-surface application step for applying the ionizing radiation curing type resin on at least one part of the upper surface of the forming die to form a uncured resin pool thereon.  
     
     
         3 . The method as claimed in  claim 1 , wherein: said resin-application step comprises a full-surface application step for applying the ionizing radiation curing type resin on an entirety of the upper surface of said forming die to form a first uncured resin layer and a partial-surface application step for applying the ionizing radiation curing type resin on at least one part of said first uncured resin layer to form an uncured resin pool thereon.  
     
     
         4 . The method as claimed in claim  1 , wherein: the pressing of said laminating step comprises continuously pressing said substrate from said one side of the forming die to an other side thereof, said one side of the forming die serving as a pressing-starting side.  
     
     
         5 . The method as claimed in  claim 1 , wherein: the pressing of said laminating step comprises continuously pressing said substrate from a central portion of the forming die, said central portion of the forming die serving as a pressing-starting side.  
     
     
         6 . The method as claimed in  claim 4 , wherein: said partial application step comprising applying the ionizing radiation curing type resin on said pressing-starting side.  
     
     
         7 . The method as claimed in  claim 5 , wherein: said partial application step comprising applying the ionizing radiation curing type resin on said pressing-starting side.  
     
     
         8 . The method as claimed in  claim 1 , wherein: the pressing of said laminating step is carried out using a pressing roller.  
     
     
         9 . The method as claimed in  claim 4 , wherein: the pressing of said laminating step is carried out using a pressing roller.  
     
     
         10 . The method as claimed in  claim 5 , wherein: the pressing of said laminating step is carried out using a pressing roller.  
     
     
         11 . The method as claimed in  claim 1 , wherein: the pressing of said laminating step is carried out using a surface plate.  
     
     
         12 . The method as claimed in  claim 4 , wherein: the pressing of said laminating step is carried out using a surface plate.  
     
     
         13 . The method as claimed in  claim 5 , wherein: the pressing of said laminating step is carried out using a surface plate.  
     
     
         14 . The method as claimed in  claim 1 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         15 . The method as claimed in  claim 4 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         16 . The method as claimed in  claim 5 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         17 . The method as claimed in  claim 8 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         18 . The method as claimed in  claim 9 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         19 . The method as claimed in  claim 10 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         20 . The method as claimed in  claim 11 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         21 . The method as claimed in  claim 12 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         22 . The method as claimed in  claim 13 , further comprising: a die-temperature adjusting step for adjusting temperature of the forming die to a prescribed temperature, which is suitable to formation of a lens sheet, said die-temperature adjusting step being followed by said resin-application step.  
     
     
         23 . The method as claimed in  claim 14 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         24 . The method as claimed in  claim 15 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         25 . The method as claimed in  claim 16 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         26 . The method as claimed in  claim 17 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         27 . The method as claimed in  claim 18 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         28 . The method as claimed in  claim 19 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         29 . The method as claimed in  claim 20 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         30 . The method as claimed in  claim 21 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         31 . The method as claimed in  claim 22 , wherein: said resin-application step, said laminating step, said curing step and said removing step are carried out on a traveling passage of an endless conveying device for conveying the forming die, and said die-temperature adjusting step is carried out on a returning passage of said endless conveying device.  
     
     
         32 . The method as claimed in  claim 1 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         33 . The method as claimed in  claim 4 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         34 . The method as claimed in  claim 5 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         35 . The method as claimed in  claim 8 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         36 . The method as claimed in  claim 9 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         37 . The method as claimed in  claim 10 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         38 . The method as claimed in  claim 11 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         39 . The method as claimed in  claim 12 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         40 . The method as claimed in.  Claim 13 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         41 . The method as claimed in  claim 14 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         42 . The method as claimed in  claim 15 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         43 . The method as claimed in  claim 16 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         44 . The method as claimed in  claim 17 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         45 . The method as claimed in  claim 18 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         46 . The method as claimed in  claim 19 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         47 . The method as claimed in  claim 20 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         48 . The method as claimed in  claim 21 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         49 . The method as claimed in  claim 22 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         50 . The method as claimed in  claim 23 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         51 . The method as claimed in  claim 24 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         52 . The method as claimed in  claim 25 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         53 . The method as claimed in  claim 26 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         54 . The method as claimed in  claim 27 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         55 . The method as claimed in  claim 28 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         56 . The method as claimed in  claim 29 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         57 . The method as claimed in  claim 30 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.  
     
     
         58 . The method as claimed in  claim 31 , further comprising: a resin-temperature adjusting step for adjusting temperature of the ionizing radiation curing type resin to a prescribed temperature, which is suitable to formation of a lens sheet, said resin-temperature adjusting step being followed by said resin-application step.